What is Manufacturing Process Management?
Manufacturing Process Management (MPM) is an ideal application for paperless systems, especially in industries like complex discrete manufacturing. MPM can also be referred to as Electronic Procedure Management.
Digital MPM systems enable manufacturing engineers to model and assess the resource requirements of the product design, and then identify the production methods that will best meet cost, quality, and other goals. MPM also identifies and manages which suppliers and partners are needed, and covers myriad details such as defining scope of work, procurement needs, BOM management, compliance, and traceability.
Electronic Procedure Systems: Vital to Paperless Manufacturing
Paperless systems open up new ways to make money in manufacturing, and electronic procedure systems for process management are a key step in going paperless. As the bridge between design and physical production, it sets the stage for the paperless processes that follow. It ensures that manufacturing plans are viable and effective, and that everyone has the correct work instructions at all times and in all places.
With MPM, everyone is on the same page with a single version of the truth from the start of manufacturing onward. Further, MPM lays the foundation for all the paperless processes that follow in the Manufacturing Execution System in addition to applications like SQM and MRO.
Benefits of Manufacturing Process Management Systems
Standardization and Compliance
Standardize processes for better efficiency, quality and overall throughput, with ensured compliance. Manage tooling calibration, data input, technician certification, and electronic signatures
Continuous Improvement
Use shop floor data to inform and improve design and process engineering for continuous improvement of efficiency and quality.
Limit Discrepancies and Their Impact
Address vulnerabilities in design to prevent discrepancies downstream and react quickly to non-conformance issues
Reduce Unplanned Downtime
Create consistency within your definition and resource management processes to prevent situations that cause unplanned downtime. Coordinate resource management with maintenance and quality and ensure all equipment is available for assigned tasks.
Facilitate Production Ramp Up
Identify and correct flaws in the preliminary design before any production has taken place. Accelerate production launches while managing quality and costs.
Model and Optimize
Optimize production by comparing alternative methods. Evaluate impact of using different sources, plants, and personnel.
A Closer Look at Manufacturing Process Management
The purpose of MPM is to define the manufacturing process for a given design. It then distributes and manages specific process plans and work instructions to the various production teams. This includes all the activities associated with manufacturing, including internal resources, partners and suppliers, and ongoing change orders.
Because MPM involves so many people and functions, it has a significant impact on quality, productivity, and profits.
What is a manufacturing process definition?
The manufacturing process definition establishes the essential processes required to manufacture and sustain a product, from initial conception and design through lifecycle maintenance, repair and overhaul. It defines the overall characteristics of the processes to and the roles of suppliers, but specific details–such as which supplier or production technique should be used–are left to the process plan.
An important part of the process definition is the assignment of supplier roles. When integrated with Supplier Quality Management (SQM), businesses can use MPM to network with suppliers, rate their service, and perform automated tests and inspections.
What it does – Process Plans and Work Instructions
Once the manufacturing process has been defined, MPM manages the creation of process plans and work instructions which are then distributed to shop floors for execution. Digital process plans and work instructions manage change and enforce consistent results on the shop floor.
Among other things, the Manufacturing Process Management System:
- Manages definitions and changes
- Distributes revision-controlled work instructions to the shop floor
- Manages revision-controlled work instructions with all where-used data stored for traceability
Using a system updated in real-time means better collaboration between internal and external players. MPM ensures that all parties are always working with the correct process plans and work instructions, avoiding the delays and costs that occur when there is not a “single version of the truth.”
PLM or MES: Who Owns the BOM?
BOM management is crucial to refined manufacturing operations. A BOM originates with product design engineers as an engineering BOM (eBOM), and is usually created and stored within a Product Lifecycle Management (PLM) system. A separate manufacturing BOM, or mBOM, must be created to guide the specifics of sourcing and manufacturing/assembling. The eBOM and mBOM are distinct and each requires its own version of the truth.
While the mBOM can be created in other applications, it’s more seamless to maintain and execute manufacturing BOMs in the MES where it’s close to the activity on the shop floor and is in the best position to execute efficiently. That’s especially true when you consider there can be as-built, as-shipped, and as-maintained BOMs, all of which may vary considerably from the original eBOM.
MES is intended specifically to manage this kind of manufacturing complexity, and iBASEt solutions are designed to be easily integrated with both your PLM/Engineering tools and your ERP/production planning and procurement tools.
Integrated MES and MPM: A Powerful Combination
A Manufacturing Process Management System does not operate alone. It is closely linked to everything that happens on the shop floor. That’s why integrating MPM within a larger MES solution is so powerful. MES and MPM together create a synergy that multiplies the value of each application.
Improved Closed-loop Capability
Every manufacturing detail captured by MES is available to MPM, enabling a dynamic, real-time closed-loop between production and planning. Problems are easier to spot and faster to correct. With iBASEt, the loop can be extended all the way to maintenance with the Solumina MRO solution.
Efficient Change Management
In complex discrete manufacturing, Engineering Change Orders (ECOs) are a common occurrence. There are often many ECOs for a single product. With an integrated MPM/MES solution, you can implement an ECO in real-time during a production run to keep operations moving, avoiding the delays that are necessary with other approaches.
Model-Based Manufacturing
MPM and MES together provide the ability to do model-based manufacturing, using real historical data to inform the models. Because the MES covers all manufacturing activities, process engineers can explore alternative approaches in fine-grained detail and make decisions with confidence.
Digital MPM in Complex Discrete Manufacturing
Digital Manufacturing Process Management is especially valuable in complex discrete manufacturing, which by definition involves complexities that are difficult to manage with paper systems. These environments are all unique by nature, but they share similar challenges. Manufacturers in this space often deal with hundreds or thousands of parts, iterative testing and improvement, frequent change orders and customization, internal and regulatory standards, and multiple teams collaborating from different locations.
iBASEt specializes in highly engineered, complex discrete manufacturing environments. Our solutions are specifically designed to handle this complexity and provide the control needed to increase manufacturing efficiency, productivity, and profits. Contact us to learn more about how complex manufacturers can benefit from robust manufacturing process management software.
In the end, you are talking about operational change management. You need end-user involvement – those who are doing the work to be involved in the process – in order to have any lasting success.
