mes implementation in a defense industry company con8390 01.10.2014
TRANSCRIPT
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