Implementation of MCIS (c-MES) system at Russian enterprises of automobile industry

Implementation of MCIS (c-MES) system at Russian enterprises of automobile industry

World automobilization goes very intensively during last decades: starting from 1996 to 2005 automobile release rates almost twice exceeded an increase in a world population. An average car service period has increased. In the USA in 1980-1995 it has risen from 6,6 to 8,5 years. In 1997 Western Europe, USA and Japan covered 72% of automobile world manufacture, by 2000 their part decreased to 69%; by 2005 ─ to 62%. Today we face considerable growth of automobile production in the largest developing countries (China, South Korea, Mexico, Brazil, India). China managed to increase its share in a world automobile industry from 3% to 8%. Indian automobile industry today is the second most rapidly developing in the world. Annually it produces about 8 million cars. During 2005-2006 India became the 3rd automobile market in the countries of Asian-Pacific region. From 2005 till 2010 Indian motor industry received more than $5 billion dollars.

Today automobile industry is one of leading in Russian Federation which is proved by statistics. So, number of working people in the industry is 4,6% of all workers occupied in Russia and 13% –of workers in mechanical engineering. The motor industry gives 3,8% of all industrial output of Russia and 23% of mechanical engineering volumes. During the last years the capacity of Russian automobile technics market has grown essentially. According to ASM Holding data total vehicle production in Russia rose on 90.2% to 1,106,979 units in January-October 2010. Russian car output rose on 96.2% to 954,741 units in the period. Output of foreign-branded cars soared on 112.3% to 492,473 units. Companies operating under the «industrial assembly regime» produced 328,178 cars in the period (106.3%). Output of Russian-branded cars rose on 81.5% to 462,473 units. Truck output rose on 67.6% to 117,688 units. Foreign-branded trucks rose on 100.1% to 10,440 units. Bus output rose on 37.2% to 34,550 units (cleared from double counting of domestic truck chassis-mounted buses). Foreign brand bus output rose on 43.3% to 4,699 vehicles. By the current forecast of ASM analysts Russia’s annual vehicle production in 2010 was expected to reach 1.34 mln units including 1.16 mln passenger cars. In 2009, Russia’s vehicle output fell on 59.7% to 722,102 units according to statistics of ASM Holding (Avtoselhozmash-Holding, Russia). Today Russian cars are already successfully sold in Africa, Asia and Latin America. So it is quite obvious why Russian automobile industry decided to implement complex automation software such as c-MES (Collaborative Manufacturing, CM), i.e. MCIS (Motion Control Information System) by Siemens AG.

Siemens AG, Departments of Industry Automation and Drive Technologies, a leading global provider of integrated solutions and management systems for industrial and manufacturing enterprises and Avtodizel (Yaroslavl Motor Works) launched Russia’s largest project on implementation of a c-MES-system (MCIS) on November 22nd 2010. The MCIS project aims to improve optimization of production and reduce costs through better production processes management at Avtodizel (Yaroslavl Motor Works), Russia.

The agreement between the Parties provides implementation of MCIS (Motion Control Information System) developed by the concern Siemens AG as a corporate standard at Avtodizel (Yaroslavl Motor Works). MCIS is an integrated software that enables to automate production processes, improve product quality and productivity, reduce downtime, increase production efficiency.

Avtodizel (Yaroslavl Motor Works) opted on the solutions of Siemens c-MES Software (MCIS) after careful analysis and consideration of the leading players of the MES-solutions world market. SITEK Group, MES Dpt. is a certified Competence Center for implementation of c-MES-systems (Collaborative Manufacturing) for discrete production and its integration with ERP and PLM-systems in the production of the Customer was chosen. SITEK Group, MES Dt., provides adaptive operations execution software solutions for manufacturing organizations in Russia, CIS and Europe. It offers Siemens AG (MCIS) and Preactor International solutions, adaptive operations execution platforms and application suite that enable to control and adapt manufacturing operations in the enterprise, supply chain network, planning procedures. High level of service and reliability of the created systems were determining factors in choosing project partners.

Manufacturing Execution System (MES), i.e. MCIS (Motion Control Information System) solution by Siemens AG is a control system for managing and monitoring work-in-process on a factory floor. MES software keeps track of all manufacturing information in real time receiving up-to-the-minute data from machine monitors. Although manufacturing execution systems used to operate as self-contained systems they are increasingly being integrated with enterprise resource planning (ERP) software suites. The goal of MCIS is to improve productivity and reduce cycle-time, total time to produce an order. By integrating MES with ERP software, factory managers will be proactive about ensuring the delivery of quality products in a timely, cost-effective manner. According to the report of TechNavio Insights manufacture automation will get more intensive and qualitative character during 2009-2013 extending for more business branches and geographical zones.

A trend towards consolidation in the MES industry is clearly evident from the developments, acquisitions and outsourcing activities that have taken place in the past two years. This is characterized by the attempt of MES companies to fill out their product portfolios. For example, Siemens AG acquired Elan Software Systems to gain market share and industry expertise of pharmaceutical and biotechnology industries. Another example is SAP’s acquisition of Visiprise, which serves more than 60 industry-leading global customers including many existing SAP customers in discrete manufacturing industries (high tech, aerospace and defense, automotive, medical device, etc).

c-MES (Collaborative Manufacturing Execution System) is still new to a Russian industrial reality. Not too long ago, the goals for manufacturing were simply to optimize costs, produce high-quality products and effectively use assets. Now in order to fearlessly face global competition effective interaction between productions within an enterprise must be achieved. The decision of this problem is Collaborative MES or c-MES.

c-MES is the main part of an incorporated manufacture concept. Application of c-MES practices help enterprises to optimize an added value chain creation for maximum profit achievement. The main task of c-MES is to give all interested specialists an opportunity to work together in making final decisions on the basis of the data received in real time.

The c-MES (Collaborative Manufacturing) model includes components that implement eight basic functions and cooperate with other information systems and the personnel both within the company and outside. These are: 1) RAS (Resource Allocation and Status); 2) DPU (Dispatching Production Units); 3) DCA (Data Collection/Acquisition); 4) LUM (Labor/User Management); 5) QM (Quality Management); 6) PM (Process Management); 7) PTG (Product Tracking and Genealogy); 8) PA (Performance Analysis).

According to statistics c-MES provides 45% decrease in production cycle duration; 75% reduction of data input time; 24% decrease of incomplete production quantities; 61% decrease in volume of paper reports between working shifts; reduction of production cycle time on 27%; spoilage volume fall on 18%; a 56% cut in superfluous paper documentation.

At production and supply chain management (SCM) reliable information interchange between several systems is needed much more often than communications between several levels of one system. In the previous generation of MES-systems basic attention was given to operating personnel (dispatchers, operators or managers) information provision. If to talk about c-MES software it provides information on manufacture possibilities («what»), productivity («how much»), schedule («when») and quality («accessible level») (according to MESA International,

In present-day globally competitive and recessionary environment it is imperative that enterprises further eliminate waste, become leaner and more agile to respond to customer’s demand. The main way to realize a profit is to low production costs. Optimization of manufacturing processes reducing overhead costs associated with the need to keep in stock some supplies of raw materials might help. It is known that in western practice leaders of various levels are provided with reliable and operational information on the current state of affairs in order to optimize costs without risking to break the production process. The automated production collaborative management system (c-MES) solves these tasks which functions include operational planning, reduction of material balances, monitoring, recording and analysis of losses, calculation of reserves and work in progress as well as tracking the effectiveness of the equipment use monitoring its condition.

c-MES system MCIS (Motion Control Information System) by Siemens AG is a complex industrial executive system. Systems of such class solve synchronization problems, coordinate, analyze and optimize output within production processes. The main thing here is the possibility to make verified administrative decisions taking into account the information provided by MES-system in real time. Such systems are used by foreign automobile enterprises for a long time. Russian SITEK Group, MES Dpt. is the company-integrator of MCIS software by Siemens at Avtodizel (Yaroslavl Motor Works).

Avtodizel (Yaroslavl Motor Works) and SITEK Group accomplished preparatory project on Avtodizel process management automation in 2007. Collaborative MES system MCIS software by Siemens AG was chosen. It was decided to use Siemens concept TRANSLINE 2000 that was specially developed for automobile industry. Unification of hardware and program components of control systems was accomplished. As a basis the complete set that includes Sinumerik 840D with numerical program control and movement converters Simodrive 611 was chosen. Sinumerik 840D is a digital NC system for highly sophisticated tasks.

With the Sinumerik 840D the customer relies on its benefits: the highest possible degree of performance and flexibility (i.e. mainly for complex multi-axis systems); uniform system openness (i.e. from operation through to the NC kernel); integrated certified safety functions.

TRANSLINE 2000 is a human machine interface, runs on Siemens PC based standard operator panel. The screen forms are optimized for fast and simple setup procedures and tool change.

Main goals of MCIS implementation at Avtodizel (Yaroslavl Motor Works) are complete control of all production processes provision in order to trace work in progress, parameters of operating equipment and time expense. Such control will lead to production quality improvement, decrease in its prime cost. During MCIS project the following program modules are planned to implement: 1) TPM (Total Productive Maintenance), 2) TDI (Tool Data Information), 3) MDA (Machine Data Acquisition).

For instance, Total Productive Maintenance (1) TPM module) refers to a management system for optimizing the productivity of manufacturing equipment through systematic equipment maintenance involving employees at all levels. Under TPM everyone is involved in keeping the equipment in good working order to minimize production losses from equipment repairs, assists, set-ups. Under TPM operators no longer limit themselves to simply using the machine and calling the technician when a breakdown occurs. Operators can inspect, clean, adjust and even perform simple calibrations on their respective equipment. This frees the technical workforce for higher-level preventive maintenance activities that require more of their technical expertise. Management should also show interest in data concerning equipment uptime, utilization and efficiency. In short everyone understands that zero breakdowns, maximum productivity and zero defects are goals to be shared by everyone under TPM. TPM eliminates 6 big losses: 1) Breakdowns which can result in long, expensive repairs; 2) Set-ups, conversions and changeovers; 3) Idling and minor stoppages; 4) Reduced equipment speed; 5) Defects and Rework; 6) Start-up Losses.

2) TDI module: Tool data management is one of the most important CNC manufacturing tasks. Smooth sequences in the fields of tool handling, cost control and saving are required. The Motion Control Information System Tool Data Information (MCIS TDI) has been designed for this purpose. It makes these rationalization potentials transparent and provides functions which help users to benefit from the detected savings potential. MCIS TDI provides the necessary connection concepts and functions for a comprehensive overview of the used tools.

3) MDA module: The MDA (Machine Data Acquisition) production data management module logs machine data and processes it for workshop management, detailed dispatching and reporting.

A list of licensed control system components together with the project book, data transmission MDA-interface were developed during conjoint team work at Avtodizel. A working group for the project realization was assembled: Siemens (Germany), Siemens (Moscow) and SITEK Group (Moscow). The concept of the control system construction and the basic requirements for equipment manufacturers were worked up according to Nikolay Teterin, Avtodizel MCIS implementation Project Manager. During the project realization MCIS software will be adjusted according to Avtodizel technical requirements.

Production scheduling will give an opportunity to receive the information on condition of production targets in real time, sequences of its performance on the basis of priorities defined for each industrial object. By means of MCIS automation of a new in-line engine JAMZ-530 production will be performed not only on existing industrial territories but also on platforms constructed today. On termination of the project MCIS will allow to provide transparency of production processes, control and service of production equipment, time decrease of manufacture tool preparation.

Victor Kadylkin, CEO of the Yaroslavl Motor Works commented: “We are creating an entirely new production: a fundamentally new engine, new engineering building, new approach to the engine development and production process taking into account modern standards of quality, new methods of production management. We are striving to achieve European quality of work and any mistake in production costs more than ever before. Thanks to MCIS solution we expect to have rapid, reliable and accurate information at hands on the status of each machine at each site and here we rely on SITEK Group and Siemens competence and experience”.

Pavel Klepinin, CIO at Yaroslavl Motor Works added: “All machinery for a new engine production at Yaroslavl Motor Works is equipped with Siemens control equipment. Р� new uniform standard to control the equipment from the chip to a set of commands was agreed to draft with Siemens three years ago. All our machines are designed to meet this standard. It is obvious that MCIS will bring this standard to the level of production management tools and services. The use of machines and tools at our enterprise will become truly centralized, transparent and manageable”.

Avtodizel (Yaroslavl Motor Works) is one of the largest Russian enterprises that specializes on diesel engines of a universal purpose manufacture, couplings and transmissions. The Yaroslavl engines are established on commercial cars, buses, main lorry convoys, career dump-body trucks, air field tractors, combine harvesters, timber carrying vessels, dredges, etc. In 2001 Avtodizel became part of RusPromAvto company transformed later into GAZ Group (parent company).

Siemens AG (Berlin and Munich) is a world leader in electronics and electrical engineering. The concern operates in areas such as industry and energy, as well as in healthcare. Moreover Siemens is the world’s largest supplier of environmentally safe technologies. More than 405 000 employees develop and manufacture products, design and build equipment and systems offering tailored solutions for specific customers. More than 160 years Siemens stands for technical progress, innovation, quality, reliability and international cooperation.

SITEK Group is a certified Competence Center of c-MES-systems in mechanical engineering of Siemens and represents its interests in the CIS countries since 2008. SITEK Group supports global improvement by delivering control and visibility in manufacturing. SITEK Group serves 100+ customers in Russia, Europe and CIS delivering hi-tech automation c-MES-software. Its customers include AVTOVAZ, Zawolzhsky Motorny Zawod (ZMZ), Belarusian Autoworks (BELAZ), Minsk Tractor Works, Yaroslavl Motor Works and other. For more information, please, go to (MES or c-MES).

For the additional information contact Vera Leonik, Chief Marketing Officer (CMO) of MES Dpt., SITEK Group, MES Dpt., Tel. in Minsk (Republic of Belarus): + 375 17-217 00 15, E-mail: [email protected], (section: Manufacturing Execution System) (MES)