oracle mestec brochure

8/8/2019 Oracle Mestec Brochure

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M e s t e c & OracleManufacturing plant-floor efficiency -

Unlocking the next level of lean



Plant-floor efficiency - Unlocking the next

level of lean

Enterprise resource planning (ERP) software brought about a

revolution in manufacturing efficiency. But in manual-

intensive operations, the plant-floor is still fraught with

inefficient practices that waste time and money and slow

down productivity.

With globalised competition and narrowing profit margins,

discrete and batch-process manufacturers need to widen the

application of lean principles within the plant-floor operation

itself to maintain competitive advantage and meet increased

demand for complex make-to-order items.

Plant-floors are still plagued with

inefficiency

ERP has reformed many areas of manufacturing operations,

including order management, inventory management, works

scheduling, materials planning, cost control and reporting.

However, in many manual-intensive manufacturing

organisations, vital production data held within ERP systems

is inaccessible to plant operators. At the same time, the vast

amounts of data generated on the plant-floor are managed

separately from the main ERP system, often being collected

and distributed via mountains of paper and standalone

applications such as spreadsheets.

Disconnected back-office and plant-floor

operations waste time and money

The lack of a common data management platform to manage

all plant-floor related processes causes a business-critical

disconnect. Information about production schedules and

engineering changes is often communicated slowly and

ineffectively to operators, resulting in delays and wasteful

errors. Meanwhile, data from paper forms must be collated

and re-keyed into the ERP system and spreadsheets must be

manually updated. This creates unnecessary administrative

work and leads to clerical errors. These kinds of problems

are exacerbated by the fact that managers have poor visibility

of what is happening on the plant-floor, making it difficultto react quickly to changing conditions or to identify

potential problems.

Replacing paper and spreadsheet-based processes with a single

software application to manage plant-floor activities speeds up

cycle times. It enables engineering changes and one-off items

to be made faster; reduces unnecessary paperwork; eliminates

unnecessary costs and creates a single source of

data for reporting, analysis and auditing. Linking this

application to back-office ERP means that everyone is

working efficiently from the same data for a faster, more

streamlined manufacturing operation.

Streamline back office and plant-floor with

Oracle and Mestec

Oracle and Mestec have come together to create a total lean

manufacturing solution for manual-intensive discrete and

batch-process manufacturing organisations. The joint solution

features easy, out-of-the-box integration between Oracle

Manufacturing Applications - which are fully integrated with

Oracle’s E-Business Suite of enterprise applications - and

Mestec’s plant-floor data management solution.

Oracle provides a comprehensive suite of discrete, flow and

process manufacturing management applications as an integral

part of Oracle E-Business Suite, which also includes

applications for the entire range of ERP functions from

financial accounting to human resources, customer

relationship management and supply chain management.

Oracle offers packaged, highly configurable applications for

manufacturing organisations, allowing customers to manage

the entire product lifecycle from initial design and engineering

through work-in-process to cost and quality management.

Mestec provides a manufacturing execution system (MES),

plant-floor data management system, and ERP plant-floor

interface in one integrated solution suite. Its highly

configurable system is suited to all discrete and batch-process

manual-intensive manufacturing organisations. Mestec’s award

winning MES manages and controls the entire plant-floor

manufacturing process and all its integral activities.

The combination of Oracle and Mestec ensures a seamlesstwo-way data flow between the plant-floor and the rest of the

organisation. Work schedules and engineering changes flow

from Oracle to Mestec in real time, enabling even the most

complex production requirements to be carried out quickly

and efficiently. The Mestec solution, meanwhile, gathers a

wealth of plant-floor data, from batch completions to quality

information and test results, and feeds relevant information

directly into Oracle E-Business Suite for accurate and efficient

updating, reporting, auditing and analysis.

A single source of manufacturing data

The joint solution relies on one central Oracle database,

providing a “single source of truth” for both ERP and

plant-floor data. Working from a single data source, managers

and operators can access up-to-the-minute operational data,

speeding up production times and allowing problems to be

identified and addressed as soon as they arise.

Mestec and Oracle - Manufacturing plant-floor efficiency - Unlocking the next level of lean



Why Oracle and Mestec?

Oracle and Mestec together bring the principles and benefits

of lean manufacturing to manual-intensive operations,

replacing disparate, incompatible systems and “islands of

information” with a single solution for lean, efficient and

demand-driven operations management. Particular benefits

include:

• One underlying Oracle database providing a “single source

of truth” for all operational data

• Real-time flow of data to the plant-floor including works

orders and engineering changes

• Automatic collection and entry into the Oracle ERP system

of plant-floor data including WIP moves, completions,

actual times, scrap, materials consumption and quality

• Simple touch-screen and barcode interface for

plant-floor operators

• Highly configurable solution modules for rapid

implementation with no expensive integration work

or customisations

• Rapid, proven return on investment

Core Oracle E-Business Suite functions are shown at the top

together with Oracle’s Discrete and Flow Manufacturing.

• The red boxes below show sub-modules with a

plant-floor relevance

• The corresponding and complementary Mestec MES

functions are shown in connected white boxes

directly underneath

• A second row of MES functions provide some examples

of non-ERP related plant-floor functionality. These are

also provided through the Mestec touch-screen

operator interface

• To complete the total manufacturing solution, supporting

‘back-office’ MES functions are shown in the bottom row

• Examples of specific data types that are exchanged between

the systems are shown within the two large arrows

The above diagram shows how Oracle E-Business and Mestec work together to create a total lean manufacturing

solution for manual-intensive organisations.


ComprehensiveAs-Processed

Database & Genealogy

Configurationof ExecutionEnvironment

(Screen Layouts, etc)

Plant Floor Integrationto Business Systems

(PDM, etc)

Plant FloorWorkflow

Management

Plant & ToolMaintenance

RealtimeVisualisation

& Event Management

Product LifecycleManagement

ProjectManagement

Advanced SupplyChain Planning

FinanceHuman Resources

ManagementEnterprise Asset

ManagementTransport Planning

& Management

BusinessIntelligence& Reporting

Discrete & Flow Manufacturing

Mestec ‘Workstation’ - Touch-Screen and Barcode Operator Interface

As built/ processed detail

WIP movesCompletionsActual times

ScrapMaterial consumption

Quality

Works Order detailSchedulesQuantitiesOperations

Planned timesRevisions & Levels

Configurations

Operator Skills& Certification

Validation

Rework &Repairs

Management

Data InputValidation

MessagingPlant DeviceInterfacing

KanbanReplenishment

Signals

EngineeringChange Alerts

AutomaticWIP DataCollection

Realtime Capture& Evaluation Of

Quality Data

Sequential WorkInstructions& ElectronicDocuments

Material TraceCapture (including

Serial Number)

WorkstationPriority

Management

Time & ActivityCapture

Kanban Control& Fulfilment

EngineeringChange

ManagementWIP Management

QualityManagement& Reporting

NPI ProcessControl

Material Planning& Control

Job Planning& Scheduling Cost Management



© 2005, Oracle. Oracle, JD Edwards, PeopleSoft and Retek are registered trademarks of Oracle Corporation and/or its affiliates.Other names may be trademarks of their respective owners.

About Oracle

Oracle (NASDAQ: ORCL) is the world’s largest enterprise software

company. Oracle’s business is information - how to manage it, use it, share

it, protect it. For nearly three decades, Oracle has provided the software and

services that let organisations get the most up-to-date and accurate

information from their business systems.

Today, Oracle is helping more organisations around the world to become

more information driven than any other vendor. For more information about

Oracle, please visit www.oracle.com.

Oracle is a registered trademark of Oracle Corporation and/or its affiliates.

Oracle Corporation UK Ltd, Thames Valley Park, Reading,

Berkshire RG6 1RA, United Kingdom

Tel: +44 (0) 870 553 2200

Email: [email protected]

Web: www.oracle.com/industries/indus_manu/index.html

About Mestec

Mestec provides the best manufacturing execution system (MES),

plant-floor data management system, shop-floor data collection system

(SFDC) and ERP works order execution system in one integrated

solution suite. Mestec’s highly configurable system is suited to all

discrete and batch-process manufacturing sectors.

Implementations are focused exclusively on the delivery of tangible

business value. Through smart and efficient data and process

management, together with the elimination of effort that does not add

value, ROI periods of 3 to 12 months can be expected. With decades of

experience with hundreds of manufacturing organisations, Mestec

understands the causes of operational ‘profit erosion’. Mestec can

quantify these through a value opportunity audit which will allow the

customer to understand and evaluate the exact size of the improvement

opportunity. Mestec will work with the customer to exploit their

operational potential.

Mestec provides end-to-end implementation, support and integration of

its MES system into existing software infrastructures. The Mestec system

is currently used by a number of global manufacturing sector leaders.

Tel: +44 (0) 1494 834600

Email: [email protected]

Web: www.mestec.co.uk


“The combination of Lean and MES has been immensely successful.

We have seen a 35% increase in productivity , improvements in on-

time, in-full delivery, and there’s still room for more. We have up to date

information going to and from the shop floor, and that’s helping us to be

more agile. And the simplicity of the interface means it’s been excellent at

engaging people on shop floor - it has helped them to become more

responsible for their information. In conjunction with lean,

we’re shortening the information steps between customer and the shop

floor - and that makes a big difference.”

Adrian Wakefield, Business Services Director,

James Walker & Co.

“Measuring ROI will be achievable. By providing a touch-screen

interface for operators and allowing them to speed up the required ERP

transactions, we expect an ROI of less than six months. And that’s

before we have even looked at other benefits that the system will offer us.”

Peter Hall, Finance Director, James Walker & Co.

“We will achieve payback against our initial investment in the system

in months rather than years. And MES complements our lean

strategy ; we have a continuous drive to reduce non value-add activities

in our organization whilst protecting stringent quality requirements and

the Mestec system does exactly that. In the future we plan to use the

Mestec system to replace older legacy systems that are currently utilised on

some of our more mature projects. Our plan is to have just one system

that will cover all our requirements as far as shopfloor information

management is concerned.”

Roy Woods, Operations Director, Thales Air Defence

“The Mestec system complements our Oracle ERP system. It extends

the footprint of our enterprise systems to address the very granular and

data-intensive plant-floor processes. It automates all the necessary ERP

transactions to support our costing system too. By managing all our plant

data electronically, we save the burden of having to manage to manually

manage all this plant-centric data. So the business case to roll-out the

system is very strong.”

Paul Tomlinson, Operations Director,

Thales Missile Electronics

Proven to Deliver Rapid Efficiency Gains and Cost Reductions

Oracle and Mestec together deliver proven and quantifiable efficiency gains, resulting in lower costs, fewer errors, better business

information and faster time to market. The combination of Oracle E-Business Suite and Mestec provides a total manufacturing

solution for discrete and batch-process manufacturers looking to increase efficiency, meet all customer demands and extend

competitive advantage.