MES Implementation in a Defense Industry Company CON8390

01.10.2014

MES Implementation in Roketsan

Ferruh Emre AytacMES Project ManagerUnit HeadProduction Planning Dept.

Table of Content

1. About Roketsan

2. Oracle Footprint at Roketsan

3. Purpose and Scope of MES Project

4. Challenges in Implementation

5. Developed Applications

6. Project Calendar

7. Project Facts

8. Achievements

3

General Information

• Founded in 1988

• One of the Leading Defense Industry Firms in Turkey

• Specialized in Designing and Producing Rockets and Missiles

• 1850 Employees including 950 Engineers

• Two facilities:

– 5,700,000 m2 Open Area

– 80,000 m2 Closed Area

About Roketsan

4

Milestones

Oracle Footprint at Roketsan

5

• Oracle EBS 11.0.3 Implementation Project (May 2000 – Mar 2001)

• 11.5.9 Upgrade Project (Sep 2004 – Dec 2004)

• R12 Implementation Project (Aug 2012 – Dec 2012)

• MES – Paperless Production Implementation Project (Dec at 2012 –

Feb 2014)

Modules

Oracle Footprint at Roketsan

6

• Discrete Manufacturing

• Quality

• ASCP

• Financials

• Purchasing

• Engineering

• Human Resources Man.

• Enterprise Asset Man.

• Project Management

• Primavera

• Hyperion

• MES

Purpose of the Project

Purpose and Scope of the Project

7

• Redesigning all Production Processes

• Adaptation of all Production Processes to ERP

• Monitoring Production Instantaneously

• Collection of Manufacturing and Quality Data

• Using Statistical Process Control Methods

• Standardization of Reports

• Minimizing Human Faults

Scope of the Project

Purpose and Scope of the Project

8

• All (58) Shop Floors in Roketsan

• All (1442) Stakeholders in Production System

• All Projects Carried Out in Roketsan

• All Production Documents and Processes

• Configuration and Change Management

Challenges In Implementation

9

• First Implementation in Turkey

• 25 years corporate culture

• Process Variety

• Product and Project Variety

• Project Scope

• Size of the Project Team

• Energetic Area

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

10

After

• Monitoring Production Online Using

MES

• Online Data about Employee and

Equipment Utilization

• Easy to Reach Genealogy Reports

on the System

Before

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

11

• Monitoring Production Online

Using MES

• Online Data about Employee and

Equipment Utilization

• Easy to Reach Genealogy Reports

on the System

Before After

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

12

• Monitoring Production Online Using

MES

• Online Data about Employee and

Equipment Utilization

• Easy to Reach Genealogy Reports

on the System

Before After

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

13

• Monitoring Production Online Using

MES

• Online Data about Employee and

Equipment Utilization

• Easy to Reach Genealogy Reports

on the System

Before After

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

14

Before

• Monitoring Production Online Using

MES

• Online Data about Employee and

Equipment Utilization

• Easy to Reach Genealogy Reports

on the System

After

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

15

• Monitoring Production Online Using

MES

• Online Data about Employee and

Equipment Utilization

• Easy to Reach Genealogy Reports

on the System

Before After

Developed Applications

16

• 20 new screens and extensions

• Using Oracle Forms, OAF, ADF, WCC and WorkflowPersonalizations & Extensions Routings ECO Collection Plans MES Operator MES Supervisor ...

New Screens Technician’s Cockpit Document Management Conformity Assesment MES Live Broadcast XML Reports with QR Code ...

Change Management for Routings

Personalizations & Extensions

17

Integration of Routings with WCC for document attachment

Personalized MES Operator Screen

Personalizations & Extensions

18

Fields hidden, reordered and added

Extended Backflush Components Screen

Personalizations & Extensions

19

Various validations added into buttons

Technician’s Cockpit

New Screens

20

Document Management - Before

New Screens

21

Discrepancy Report Before MES

Document Management - After

New Screens

22

Discrepancy Report After MES

MES Live Broadcast - MESSI

New Screens

23

Project Calendar

24

Project Facts

25

• 20 new screens and extensions

• 9 new XML Reports

• 70 Project Members

• 1450 Project Stakeholders

• 37 Training Sessions

• 20,000 man-hour direct labor (Roketsan)

• 101 day consultancy

Achievements

26

• Biggest IT Project in Roketsan

• ERP usage capability for technicians

• Additional 2.1 million ERP

transactions/year (520% increase)

• 7/24 Serving IT Infrastructure

• Multiple Database

• Redesign and Simplification of Production

Processes

• Instantaneous Traceability

• Easily Accessible and Analyzable Data

• Standard Reports for Various Level of

Management

• 2.8% Decrease in Production Labor Cost

MES Workstation

27

Questions and Answers

28

Thank you for listening