(Manufacturing Execution System)
An execution system for production
MATE-MES is a solution that specializes in manufacturing execution systems. Created through the accumulated knowledge and experience of Computermate Co., Ltd., MATE-MES is a production site support and on-site management system that can systematically carry out plans and utilize execution information based on reality and the real state of the manufacturing industry.
An MES implementation solution developed by Computermate, MATE-MES provides support for each series of instructions and management in order to optimize the production activities that happen at production sites. As an MES solution that has been packaged to fit domestic small and medium-sized companies as well as manufacturing companies based on the 11 MES functions defined by MESA in the USA, MATE-MES also functions as a management support system that enables rapid response to the situations that occur on manufacturing sites.
The Need for MES
What kind of businesses need MES?
- Current information systems are under-utilized and generally cannot be used properly.
- It is difficult to manage information on production performance, and it is difficult to grasp how production is going.
- It is difficult and cumbersome to register defects, and production history management cannot be done. This makes it difficult to immediately respond to quality issues.
- Various data such as the measurement values of beginning/middle/final products are recorded manually or data management in the production process is insufficient.
- It is difficult to monitor a workshop at a glance.
Corporate Self-Assessment Checklist
- Insufficient knowledge-based information systems for the management of manufacturing sites
- Lack of integration functions in production sites
- Lack of information sharing between factories/departments/processes/work processes
- Difficulty in understanding each stage of the production progress
- Inconsistency in kind between raw material parts input
- Limitations on information provision and information collection necessary for production site work
- Limitations on flexibility for instantaneous changes in manufacturing sites
- Difficult to clearly comprehend the site and respond immediately
- Need for establishment of a system that allows one to identify the site at a glance and make decisions
- Limitations on responding to the difference between ERP's production infrastructure requirement planning system and performance
- Managers spending 25-35% of their time on checking and correcting on-site data
Defines management elements such as equipment, materials, and workers for each unit process
Manages tracking of all materials according to predefined specifications
Computerizes detailed execution results for each process and measurement details for each process
Manages all resources in the factory
Has an interface for linking with other systems
MES is an integrated production management system.
MES works in conjunction with the existing ERP (enterprise resource planning) systems, etc. to manage material warehousing and outgoing management with barcodes, etc. By clarifying things such as receipts and disbursements for raw/subsidiary materials and processing work orders, process management, production performance registration, etc. from the production planning stage, quality control is made possible through production history management. This is a system that helps workers and managers make quick decisions by clarifying data processing through job automation and collecting/analyzing on-site information using wired/wireless scanners or PDA, etc. in product arrival/delivery management.
MES is a solution that helps quality control and decision-making.
MES is a system that manages all production activities from the initiation of product orders to quality inspection of finished products. It functions as an integrated information system and collects and aggregates/analyzes/monitors various information on the production site such as production results, worker activities, facility operation, product quality information, etc. in real time while also controlling the production process, giving production sites a high-quality, profit-oriented production system.
In other words, it's a system that improves productivity, allows companies to accurately identify and manage their on-site production statuses in real time to respond to customers’ increasing demands for better-quality products, and reflects the specific aspects of the work sites of companies in all sorts of fields while taking into account all necessities from the management level.
MATE-MES Work Flow Chart
MES provides integrated management for all information that can be generated at production sites such as process progress information monitoring and control, facility control and monitoring, quality information tracking and control, performance information aggregation, warehouse operation management, work-in-process management, material input management, manpower management, facility management, etc.
The optimal MES system package with field analyses and interviews, customization that incorporates field characteristics and requirements, and additional development/function specialization
An MES solution system optimized for HTML5-based web environments that strengthens a company’s competitiveness through introducing new technology trends, improving open-source usability, and improving user convenience and accessibility
The Sencha-based mobile app platform MATE-MES Mobile provides a mobile operation environment for MATE-MES
MATE-MES enables the collection and optimal management of the production activity statuses of the ‘4 Ms’ that exist on production sites in real time through the information system. The term ‘4 Ms’ refers to the operator (manpower), production method (method), materials (materials), and production facility (machines).
Improves quality through systematic production management
Increases factory operation efficiency through the standardization of information within the factory
Identifies the exact cause of problematic losses and enables rapid responses
Reduces cycle times and lead times
Reduces paperwork between shifts
Reduces product defect rate
Reduces ‘works in progress’
Real-time data collection and statistical process management through automation
Consistent management of workers, managers, and upper management by boosting information visibility
Available real-time facility performance monitoring
Automobile parts industry
All parts and manufacturing businesses related to rubber molding, compounding rubber, painting, plating, sewing, electronics, wiring, injection molding, welding, casting/forging, heat treatment, and soldering
MATE-MES Implementation Examples
Example 1 - A case involving the new introduction of MES and linking to the previous ERP
S, a company that works with domestic automobile parts manufacturer H, was having difficulties coping with quality problems due to the lack of production history management and Initial/In-process/Final-stage management. With the introduction of MES, however, lot traceability was secured through accurate production history management in the manufacturing process, thereby laying the foundation for quality control. As a result, S is now able to immediately respond to customers’ quality-related requirements through the computerized management of measured valuesfor early/middle/final-stage products, which is something they had previously been managing manually.
The management screen for
MES Initial/In-process/Final products introduced into S company
Example 2 - MES Implementation in an Outdated POP System
H company, a mid-sized domestic auto parts manufacturer, was having difficulty in the integrated management of quality problems and logistics management and were unable to determine basic information for the establishment of a management policy due to their POP system being outdated. Through the introduction of MES, H company became able to implement a fool-proof system and link their facility environment and process logistics. This created an environment that allowed the company to respond to the quality requirements of customers (5STAR-certified).
||Before establishment (POP)
||After establishment (MES)
|Facility information monitoring
||Real-time facility information monitoring compared to work standards
|Logistics management between processes
||Management of only outsourcing information
||Lot tracking made possible via the movement barcodes between processes
|Job condition tracking
||Tracking via handwritten records
||Tracking of facility working conditions by production lot possible
|Computerization of various documents
||Hard-copy storage and scanning management
||Computerization of task check sheets, equipment checklists, and task standards for each process
|Material input management
||Input history management by product
||BOM reference material input, input history management possible
||Standard information management and history management for jigs
|Andon system (administrator calling)
||Use of two-way radios, pagers
||The manager of an extrusion operator can be called
A comparison showing the states before and after the introduction of MES by H
MATE-MES Implementation Display
Production Performance Management
Inspection Inventory Registration
Mass Production Mold Registration
SPC Data Collection
Defect Status by Item
Facility Operation Rate Analysis