446

Request for

Information

Manufacturing

Execution System

RONAL AG

2

List of Content

1 Introduction .................................................................................................................................... 3

1.1 Company profile ...................................................................................................................... 3

1.2 Locations ................................................................................................................................. 3

1.3 Standard process step ............................................................................................................. 4

1.4 Specials .................................................................................................................................. 10

2 Project information ....................................................................................................................... 11

2.1 Motivation ............................................................................................................................. 11

2.2 Objectives.............................................................................................................................. 11

2.3 Project organization .............................................................................................................. 12

2.4 Project timing ........................................................................................................................ 12

3 Basic functionalities ...................................................................................................................... 14

3.1 APS module Requirements ................................................................................................... 15

3.2 Visualization and Monitoring ................................................................................................ 15

3.3 Report ................................................................................................................................... 16

3.4 Traceability-Requirements .................................................................................................... 17

3.5 Human Resource ................................................................................................................... 17

3.6 Energy Management ............................................................................................................. 17

4 System and Software Requirements ............................................................................................. 18

4.1 General MES Requirements .................................................................................................. 18

4.2 Supported Systems and approved Standards ....................................................................... 20

4.3 Business continuity / Emergency requirements ................................................................... 21

4.4 Definition of required Interfaces .......................................................................................... 22

4.5 System Architecture .............................................................................................................. 24

4.6 User/Account Management and Permissions concept ........................................................ 24

4.7 Customizing/Personalization Capabilities ............................................................................. 25

5 Implementation Concept .............................................................................................................. 26

3

1 Introduction

This document describes the functional specification of Ronal as a request for information.

1.1 Company profile

RONAL is a leading manufacturer of light alloy wheels and shower enclosures.

RONAL stands for cutting edge technology, creative design and uncompromising quality. Quality is

RONAL’s philosophy.

RONAL was founded in 1969 and soon became one of the pioneers in the global market for light alloy

wheels.

Besides its production of wheels, RONAL has been focused for the past 28 years on the production of

shower enclosures as well. RONAL's philosophy is centered around three principles; customer focus,

innovation and quality work. These principles are responsible for the continuous growth of the

company.

1.2 Locations

Due to RONAL's international manufacturing network, it is able to work with competitive cost

structures and it is able to serve its customers locally.

RONAL supplies and takes care of its customers directly from Germany, Spain, Czech Republic,

Poland, Italy, Mexico and the USA.

In order to safeguard the highest quality, RONAL manufactures its own production tools. The

production of the tools takes place in both Portugal - Cantanhede - and Switzerland - Härkingen.

Apart from the tooling department, Härkingen also accommodates the Research & Development

department and the headquarters of the group. This geographical and organizational structure

secures short development times at the highest quality and know-how levels.

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1.3 Standard process step

Process Melting

Input Output

Aluminum alloy AlSi7MG or AlSi11MG with

about 600 – 900kg

Aluminum chips from the production

Scrap wheels

Aluminum melt of both alloys AlSi7MG or

AlSi11MG

Processing Process in numbers

Pouring of the melt out of the oven to

transportation ladle

Preparation of melting cleaning with argon or

forming gas impeller purging

Process temperature about 750°C – 785°C

Energy demand about 110 – 1350 m3

gas/ton

Manpower 12 operators / 4 shift model

Process Casting

Input Output

Prepared melting AlSi7MG or AlSi11MG in the

ladle with about 850 – 1500 kg

Compressed air for feeding of the mold and

cooling of the air (8-16 cooling cycles)

Filter for the melting (“oxide brake”)

Raw cast wheel AlSi7MG or AlSi11MG

Wheel data via conveyer to the next process

step


Visual quality control

Eliminate the casting fin

Transportation via conveyer to the next

production step

Temperature of the melting in the casting

machine about 680°C – 715°C

Mold temperature about 485°C – 560°C

Cycle times about 250 – 380 sec/wheel

Raw cast weight about 9 – 35 kg

Manpower about 5 operators per shift per 12

casting machines / 4 shift model

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Process X-Ray

Input Output

Raw cast from the conveyer

Wheel data from the conveyer

X-Ray programs

Raw cast wheels X-rayed

- i.o. wheels to next process step

- n.i.o. wheels to scrap


Transportation with conveyer to the next

process step

Cycle time about 40 sec/wheel

High dynamic radio scope up to 30 pics/sec

Manpower about 4 operators / 4 shift model

Process Degating

Input Output

X-rayed wheel i.O.

Wheel data from the conveyer

Allocated tool

Raw cast wheel degated


Transportation with conveyer to the next

process step


Manpower about 4 operators per shift

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Process FlowForming (FF)

Input Output

X-rayed wheels i.O. degated

FlowForm tools

FlowForm programs

Flow formed wheels

- i.o. wheels to next process step



Transportation via palette/conveyer to the heat

treatment


Wheel temperature during the process about

340°C

Manpower 1 operator per shift

Process Heat treatment

Input Output

AlSi7MG wheels

- X-rayed i.o. degated

- FlowFormed i.o.

Wheels heat treated

Partly wheel data via barcode


Transportation with conveyer/palette to

machining

Cycle time solution heat treatment about 280

min with about 540°C

Quench hardening about 65°C

Cycle time artificial aging about 180 min with

about 155°C


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Process Machining

Input Output

Wheels AlSi7MG or AlSi11MG

- Heat treated and FF in AlSi7MG

- Wheels AlSi11MG x-rayed i.o.

degated

Wheel identification and machining programs

Machined wheels

- i.o. wheels (via drawing) (turned,

drilled, balanced and pre-deburred)




washing and leak test

lead time for the whole machining process

steps about 6min//wheel

Manpower 1 operators per shift per line

Process Balancing

Input Output

Machined wheels after washing and leak test

with helium

Programs for the balancing

Machined wheels

- i.o. wheels

- n.i.o. wheels leak tested/balanced to

scrap



deburring

Cycle time 30 sec/wheel

Manpower 1 operators per shift per line

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Process Brushing / Deburring

Input Output

i.o. wheels washed, leak tested, balanced

manpower

i.o. wheels brushed and deburred

n.i.o. wheels to scrap


Transportation with palette to surface finishing Cycle time manual deburring about 2-10

min/wheels (depends on design)

Cycle time brushing about 1 min/wheel

Manpower 1 operators per shift per work

station

Process Painting

Input Output

i.o. wheels deburred

Formulation for painting

Paint systems

Painted wheels

- i.o. wheels as customer specification

- n.i.o. for rework or stripping or scrap


Wheels direct via roller belt to finished goods

control

- to storage

- to next production step

Capacity about 500 wheels per hour

Paint layer intensity with 3-layer-paint about

150 – 180 my


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Process Storage/Shipping

Input Output

Wheels painted with quality control i.o.

Labels

Instruction for logistic

Packaging material and loading equipment

i.o. wheels painted to customer specification

packaged and prepared for shipping


Shipment to the customer Manpower about 8 operators per 4 shift

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1.4 Specials

Process Front Facing

Input Output

Wheels painted 2/3-layer-paint

Front Facing-programs (turning programs)

Mirror lathe

Front Faced i.o. wheels with basis 2/3-layer

paint


Transportation with palette to painting area for

transparent finishing

Manpower 1 operators per shift per machine

Process Multi Color Rim (MCR)

Input Output

Wheels painted 2-layer-base coat and contrast

paint

Front Facing-programs (turning programs)

Mirror lathe

Front Faced i.o. wheels with 2-layer-base

coat and contrast paint

Colored base coat appears at the Front

Faced surface


Transportation with palette to painting area for

transparent finishing

Manpower 1 operators per shift per machine

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2 Project information

2.1 Motivation

The motivation of the project is to have a standardized conception of functionalities to control the

production with each steps included.

- Optimized planning and control of resources (machines, manpower) and processes

o Visualization of production monitoring for control

- Traceability of a wheel (whole lifecycle from Aluminum purchase till shipping to customer)

- Optimized visualization of information (reporting)

- Control with production orders based on feedback of the production

o Cycle times, lead times, scrap (on time during a production day)

- Planning of change overs during a production day

- Planning and documentation of manpower during a production day

- Visualization of the production (quantities) and process parameter

o Real time

o History

- Monitoring of the production, the quality and the process parameter

o Definition of borders – tolerances

o Warning function (signal/information/…) with overrun the borders

- Access control

- Reporting

o KPI’s

o Reports for production (monthly, daily)

o Energy consumption (Co2-bilance)

o Maintenance

- Documentation of down times, machines and tools

2.2 Objectives

The main goal is the increasing of the economics of scale with controlling the production based on

measured values.

Measured goals are defined:

- Traceability of the availability of machines

- Reducing of non-productive time

o Systematically change overs

o Increasing the OEE Productivity, Availability, Quality

o Management of production processes

o Accelerate of crucial production processes

o Harmonized manufacturing landscape

o Consolidation of applications

To achieve the goals we need to gather all production, process and quality related process parameter

in ONE consistent data base to visualize, control and trace.

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2.3 Project organization

Orderer of the project is the Chief Officer Operation Thomas Trampenau.

Project manager:

- Ulrike Buchholz (Operations)

Core Team consists of:

- Jacek Cyrwus (Plant manager)

- Holger Girmond (ERP - XPPS)

- Patrick Huber (IT Strategy)

- Rafal Karolewski (Support implementation in the 1st plant W06)

- Thomas May (Quality)

- Thomas Trampenau (COO)

- Manfred Wirth (Infrastructure)

2.4 Project timing

We defined different project phases with the timing for the first plant. In the following picture are shown the main steps including the time line.

The main steps are divided in sub steps

- Analyses and rough specification (phase 1)

o Definition of basic requests at MES

o Project draft --> request specification

o Long list based on „rough specification

o Reducing long list with defined criteria to short list – max. 3 supplier

- Clarify request (phase 2)

o Adjustment of requests with the system provider

o Consulting o provider based on conception and implementation

o Definition of necessary investments

o contract specification with implementation guide, costs, dates

o Choose of system provider

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- Detailed conception (phase 3)

o Evaluation of quotation and selection of supplier for phase 3

o Definition of detailed integration in existing IT-systems for data transfer of master data

o Definition of necessary configurations in the system (user admin, rights,…)

o Definition of surfaces and layouts, e.g. at gathering station

o Definition of basic conditions for corporate standards: standard inspection plans,

standard attribute

o Definition of evaluation

o Decision of the right system provider

- Developments of system supplier

- Test environment

o Define test environment – start and test in a small area

- Realization of "pilot" (for each department) and training

o Training of defined staff

o Installation of hard- and software for "pilot" (reduced request)

o Integration master data

o Checkout of test environment (production environment)

Automatically data collection

Manually data collection

o Adjustment and optimization of configuration, layouts, user surface, …

o Preparation of standard reports and analysis

- Implementation and active phase 1st plant

o Master data transfer

o Connection to existing systems for data collection

o Test planning

o Employee training

o Data collection

o Roll-out at plant

- Business operation

o Regular business

o Maintenance and system maintenance

- Review

- Roll-Out RONAL Group

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3 Basic functionalities

Different main functionalities are defined and combined to MES-modules.

One of the main integrated documents describes in detail the expected functions in form of a

checklist.

The Ronal MES is focused on the following main functionalities:

- APS

- Visualization and Monitoring

o Includes also History, Escalation, Documentation

- Reporting

- Traceability

- Human Resource

- Energy Management

The next chapters describe some of the functionalities in detail, the others are covered in the

checklist.

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3.1 APS module Requirements

Please note: The detailed requirements of the sub-functionalities can be found in the corresponding

checklist.

Ronal uses the ERP system Infor XPPS for the execution of all operational and economic aspects.

This includes the following main modules and main processes (Not all modules and processes are

used in its entirety and there are also differences in the use of these between the individual plants):

EDI communication with customers and suppliers

Order processing for OE and AM customers

Warehouse and revolving inventory management

Material and (capacity) planning (MRPII)

Purchasing procurement

Production planning

Shop floor order handling

Data collecting and data feedback from the shop floor

The APS module should be positioned as a detailed planning system for the shop floor, which is

based on the higher level planning data (e.g. mid- and long term production plan) and on the shop

floor orders from the ERP system.

The main objective of the APS module should be the visualization of the ERP shop floor orders, the

ability to schedule (within certain limits and boundary conditions) the shop floor orders in a more

detailed matter, to visualize the production situation and to visualize the ongoing production results

and show the impact of them to the shop floor orders and the production situation.

3.2 Visualization and Monitoring


checklist.

Visualization

It is very important, that the system is flexible and able to modify. All interfaces should be possible to

change manually. Also important is to have some library with basic animations, graphs, charts and so

on.

There should be the possibility to show information not only on computer screens also on

dashboards, big screens located on production or even on tablets and Smartphones.

The visualization should be possible real-time and history.

History

There has to be the possibility to store/save historical data and have a constant access to them. Also

the system back up should be continuous.

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Monitoring

The system should be able to monitor process parameter of machine status and the production

process, also of the product quality.

Escalation

There should be the possibility to define warn limits and reactions for each warning ( sound

signalization, sending reports or work orders to declared employees) and also the kinds of reactions.

There should be the possibility to define the reaction of a warning – e.g. stopping a machine or

slowing down the process and so on.

Documentation This functionality should be able to administer programs, e.g. NC-programs.

3.3 Report

The solution provides data pools or cubes which come in a standard database format (e.g. SQL) and

can be analyzed.

Reporting uses the existing Ronal tools (EIS / EIP from aruba informatik GmbH).

To analyze it is very important to have statistic tools and history record. We need to be able to

analyze data in Excel as well.

One helpful tool could be value stream mapping. From the MES system we could get all the

information we need to make a value stream map and generate it for each part

There should be an easy way of generating and sending reports to different employees.

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3.4 Traceability-Requirements


checklist.

Definition: capability to trace a product from its origin through processing, delivery and receipt, to its

final location.

The MES system module “Traceability” enables RONAL to trace wheels in both directions, back and

forward, the minimum level of traceability is defined as lot traceability and where applicable on a piece

level.

A unique identifier (serial number) printed on the casted wheel will be used for identification and

allocation of data to each product during production process. The traceability system will link the serial

number to process and quality data including time stamp.

After entering a unique serial number it is possible, to identify the relevant process and quality data of

that product and by linked XPPS shipment information to identify which customer has been supplied

with this product.

It is possible to identify products by entering process or quality data or combinations of these (using

Boolean expressions) and to receive all relevant wheels that have been produced during these

conditions.

As production results and quality information are gathered in local time zones, the traceability

database needs to be using UTC time stamp.

3.5 Human Resource


checklist.

The system should support with the calculation of bonus for workers according quality and quantity.

The system should make one base for working schedule and one for work orders. For the

management it is also important to have all employees and their schedules in one data base.

The system should be able to generate reports, considering parameters, groups and individual

employees.

3.6 Energy Management


checklist.

The main functions are covered in the Ronal Energy Management System EMS, but partly functions

has to be covered be the MES.

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4 System and Software Requirements

4.1 General MES Requirements

Please note: for almost all of the described requirements the following paragraphs there is a

corresponding section in the detailed checklist that has to be completed as part of this RfI process.

IT Strategic Directions (Excerpt)

• IT as Business Enabler

• overcome the “cost only” notion

• push/emphasize the strategic value/benefits

• demonstrate and deliver on promises

• Unify and Simplify

• Standardize and consolidate

• Reduce complexity

• Optimization and Globalization

• “Global first”: whenever meaningful, global solutions and globalized systems will

replace locally implemented solutions

• “Shared services”: instead of providing the same IT service multiple times per

plant/country but in slightly different flavors, we will see more global IT services

provided by one location for the whole group

• Globalize IT Team and processes (e.g. support based on ITIL)

System Maintainability

Ronal aim at “least effort” maintainability. This means that the ongoing efforts to keep the system

secure, stable, bug-free and current has to be minimal. In order to achieve this the maintenance

process has to be highly automated, the software update cycle has to be structured and needs to

follow a clearly defined schedule. System updates must not impact existing/already implemented

configuration adaptations and customizations.

Maintenance & Support

The support processes are clearly and transparently defined and aligned with Ronal company

structure and needs. Different support scenarios and cases are clearly defined and have transparent

SLA’s.

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Volumes/Quantities for Server and Database Sizing

Based on the process parameter documentation Ronal works with about 1023 process parameters in

total. The breakdown of the total is as follows:

Priority 1 (unimportant): 25

Priority 2 (important):114

Priority 3 (very important): 884

Taking prio2 and 3 together leads to rounded 1000 parameters multiplied by estimated 18 million

produced wheels per year results in 18 billion records a year given that MES is in a fully deployed and

productive status! Assuming one record is 10 kB (kilobyte) in size will give us an estimated yearly

data volume of 180 TB (terabyte = 1012

Byte = 1.000.000.000.000 byte).

Integration into existing IT Landscape

The solution has to integrate seamlessly into the existing IT landscape. The required integration is

twofold: on one hand it is the office network with the superordinate ERP/PPS (primarily Infor’s XPPS)

layer, on the other hand it is the production network with the subordinate machine and automation

layer with its machine control (PLC).

Technology-wise this translates into Wintel and IBM iSeries hardware on the ERP/PPS side and full

variety of PLCs (Siemens, Fanuc, Danobat, Deawoo, Omron, Hitachi etc.) on the machine and

automation side.

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4.2 Supported Systems and approved Standards

Databases and data formats

Due to data integrity reasons data records have to be stored in Unicode format.

Supported database standards are: Priority 1: MS SQL (2008 and higher); optionally Oracle (10.x and

higher) or DB2 on IBM/OS400.

Distributed databases (e.g. master-slave concept) have to be available and supported.

Hardware/OS

Server: Priority 1: HP Intel with Windows Server 2008 R2; optionally IBM iSeries with OS/400.

Client: Windows 7; required is an out-of-the-box integration with MS Office 2010 and Exchange 2010

(e.g. for notification service).

Network

LAN: All locations have Ethernet TCP/IP based LANs, using MS Active Directory as the central

objects directory/repository. Some locations additionally have special purpose WLANs (e.g. providing

Internet access for non-Ronal visitors or wireless access points in production facilities). Usually the

office and production networks are physically and/or logically separated for example by means of

VLANs. Historically there are still a few legacy protocols in use in some areas of some production

networks.

WAN: The Ronal locations are connected thru LAN-to-LAN VPN connections (over the Internet).

Bandwidths vary from 2 Mbps up to 100 Mbps. Connection types involve xDSL, FC, Ethernet and

MPLS. Most of the locations have a backup line in place however those capacities are minimal. All

locations are shielded from the Internet by firewalls.

System Security Concept

The MES solution will be another system within the Ronal corporate network boundaries; as for all

other already existing internal systems the same “usual” concepts, rules and policies will be applied.

The various components which are part of this concept can be expected to be there and available.

The only requirement - as far as the MES solution is concerned – is that it doesn’t interfere with the

existing system security concept and its applications.

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Data Security Concept

Data security is critical for the MES solution and comprises basically protecting a database from

destructive forces and the unwanted actions of unauthorized users. In addition to what one can

expect in this context on the facilities, hardware, OS and database level as means of addressing the

potential issues (such as encryption or strong user authentication) we expect additional application

based approaches to protect the MES database from data security breaches.

As an accompanying feature we expect a full audit trail which keep track of all actions and activities

that involve any MES application and data object. With his all modifications can be traced back.

Backup/Restore Concept

The MES data will not be treated differently than any other business application data if it comes to

backup/restore. What we expect here is that the MES solution a) does work with any professional

Backup software and b) the MES solution adds features that optimize the backup and restore

process, e.g. time-wise.

4.3 Business continuity / Emergency requirements

High availability

The solution is expected to support high availability solutions (application and database/ data storage

layer).

Data history, archiving and reorganization

The solution has functionalities for archiving, data history creation and keeping as well as data

reorganization.

Archived data is separated from productive („live“) data but still accessible by the solution.

Centralized master data management

Master data records (e.g. for parts, suppliers, customers) are centrally manageable within a tenant as

well as cross-tenant (across the group).

Defined data ranges and/or data fields (within a data range) can be administered on a per plant basis.

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4.4 Definition of required Interfaces

Data interfaces

The solution comes with a variety of out-of-the-box interface options. XML, CSV, Text (ASCII), ODBC

und LDAP have to be supported as a minimum.

Data import and export have to happen in a manual and automatic way (batch and sequential

recurring).

Data Entry Interfaces

The solution provides interfaces with which manual data feedback from various other systems (e.g.

final goods inspection etc.) can be integrated into the MES or with which these systems can directly

be connected to the appropriate MES functionality (e.g. final goods inspection: Touchscreens are

directly linked to a MES module).

Office Integration

The solution offers out of the box MS Office 2010 integration. This means for example MS Office 2010

applications can be directly launched from within the MES solution, MS Office 2010 file formats can

be handled by the MES solution and data can be imported and exported from/to MS Office 2010 and

the MES solution.

Interface to ERP

The solution can work with a bi-directional interface to the ERP system. The system can work with all

parameters from the ERP system which are related to planning and scheduling of production orders,

so that this data does not have to be captured into two systems. Data which is not provided by the

ERP system can be maintained as master data in the system and has to be linked to the data from

the ERP automatically.

The interface from the ERP system (ERP to MES) should handle following data:

- Parts master

- Tooling and additional equipment master

- Machine and work center master

- Production orders header

- Work cycles

- Material information (BOM)

- Machines and work centers

- Tools and necessary equipment

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The interface to the ERP system (MES to ERP) should handle following data:

- Actual production cycle times

- Actual production rates (i.O. rates, rework rates, scrap rates)

- Planning results (start date, end date, machines etc.)

Interface to Maintenance system

The solution provides an interface to Ronal’s maintenance system EAN. Information which is send to

the maintenance system is for example (detailed data requirements have to be defined in a workshop

phase):

- Machine status (setup, production, inspection, maintenance)

- Actual production numbers per machine, mold or any other tool

Interface to Energy Consumption

The solution provides an interface to Ronal’s Energy Consumption System EMS.

Interface to Resource/Shift planning

The solution provides interfaces systems and is able to work with the shift model systems which are

maintained in the HR-Systems and is able to work with the daily time attendance and absence

records.

Staff and shift master data should be used from the existing systems wherever the necessary data is

maintained in these systems (HR and Time attendance systems).

CAQ/QA/QM Interfaces

The CAQ interfaces are covered in the RFI of the CAQ-project.

Machine (Controls) Interfaces

The solution should be able to handle and work directly with data from machine controls, OPC’s, other

interfaces (e.g. RS232) and other data capturing devices.

User Interface

The user interface has to be available as a „fat client“ (local installation) as well as a web client (web

browser) with identical sets of functionality and feature.

The web client muss has to run on Internet Explorer 9 and higher.

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4.5 System Architecture

System structure and landscape

Concerning “Installation topology” the solution offers both: one centralized installation (all locations

work on this single infrastructure) and the option to work with decentralized installations; in production

one or the other topology approach will be deployed.

Application architecture

The application architecture offers a 3 layer (data, logic, presentation) concept in a distributed system

landscape. The layers are logically separated from each other.

Virtualization is supported. The main focus is on the data and logic layer (hence application and

database server). Preferred is ESX/VMware and optionally HyperV/MS.

Modular structure

The solution comes with a modular structure. Hence the individual modules can be licensed,

implemented, activated and used module by module.

Multi-tenancy

The solution supports a multi-tenancy concept. Within a tenant several plants/sites can be managed /

administered.

4.6 User/Account Management and Permissions concept

Active Directory Integration is required (Integrated Windows Authentication, IWA, and LDAP).

Application permissions can be granularly assigned and administered with a role-based concept.

Security requirements / Role and Profile Definition

Access to and permissions within the solution are controlled by a granular permissions concept and

model which supports multiple detailed access groups and levels down to field level. User credentials

(user ID and password) have to come from AD.

Access for external (i.e. non-Ronal) parties (such as e.g. suppliers, customers) has to be possible. As

for internals access (where) and permissions (what) can be granularly assigned by using groups

and/or roles.

Workflow functionalities

Availability of a flexible workflow engine that allows the dynamically define chains of activities for

routing, escalation and other workflow purposes is key in order to automate recurring work items.

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4.7 Customizing/Personalization Capabilities

The solution offers flexible and easy to use customization features. This comprises but is not limited

to:

Addition and deletion of predefined parameters, fields, views and filters and

functionality (e.g. escalation, interfaces to databases and other applications)

Changes per GUI or script and command line possible

Configurable toolbar and menu for end user

Dialog and functionality changes in application equally and automatically implemented

in web interface (i.e. fat and web client are identical)

System updates are without impact on content and implemented adaptations of

configuration

Offline capabilities

In case of network interrupts the solution has to continue to work in an “offline mode”.

Licensing

The solution offers flexible and creative licensing options which cover Ronal requirements. In

particular concurrent user licenses have to be supported.

Hotline

The supplier has a central hotline. Communication languages are German and English. Any of the

other mentioned Ronal languages is an asset. Operating hours have to be based on local time zones.

Languages

The solution supports the following languages:

German

English

Spanish

Portuguese

Italian

Czech

Polish

Simplified Chinese

Additional languages are provided by the supplier or can be implemented/made available by means of

simple translation tables or the like. The language versions of the user interface and the outputs (e.g.

printing) can be separately managed and administered (example: users work with German user

interface, the printouts are in English). The language can be selected on a per user basis.

Printouts for external parties (e.g. for suppliers or customers) are printed in the supplier or customer

language which is defined in the (supplier or customer) master data record.

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5 Implementation Concept

Phase 1 (“the pilot”) will comprise the implementation of MES core features in the new Ronal plant

W06 in Walbrzych/Poland which goes live on 1st April 2013. MES core functionality means those

functionalities that are mandatory and absolutely required to run the production in the new plant. This

set of functionality is referred to as priority A features

Functionality Prio. W06

Scheduling of production orders B

Visualization of manufacturing situation and progress (scheduling), within a production day B

Controlling of production orders based on real time feedback (e.g. cycle times and scrap rates), within a production day B

Scheduling of change over on shop floor within a production day C

Allocation of operators / staff within a production day C

Wheel traceability C

Visualization of process parameters (real-time and history) B

Monitoring process parameter of machine status, manufacturing process, B

Monitoring of product quality A

Possibility to define warn limits for the process parameters and notification B

Access to PLC (control) B

Performance counter per employee (e.g. wage calculation) B

Reporting KPIs, e.g. OEE B

Production Report (monthly report) C

Daily production report C

Flexible reporting creation C

Energy consumption, GHG emission C

Maintenance C

Downtime Machine C

Life cycle of tools C

Administration of NC-Programs B

After this initial start and “optimization phase” of approx. 6 months will follow to stabilize the initial

setup and to add additional (B and C) functionalities.

Once W06 is stable (and as such the pilot is completed) MES is going to be rolled out plant after

plant. The sequence and timing still has to be determined.

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Documents

software requirements

project information

aps module requirements

general mes requirements

system architecture

project organization

project timing

list of content