Process Industry

A Manufacturing Execution System (MES) is software designed for real-time management and monitoring of production processes. In process manufacturing, MES facilitates precise tracking of production parameters, control over quality and compliance with Bills of Materials (BOM), recipe management, and route modeling. These features are crucial for maintaining process continuity, adhering with specifications, and meeting regulatory requirements.

Advanced Planning and Scheduling (APS) is a system designed to optimize resource utilization and streamline even the most complex production processes. In process manufacturing, APS helps arrange production schedules in a logical, fluent and efficient sequence. What is more, in case of unforeseen circumstances, APS helps minimize downtimes and improve production performance. It also supports batch-based production planning, considering the capacity of containers, mixing tanks, and reactors.

Integrating MES and APS allows for complete synchronization between manufacturing operations and optimized scheduling.  This integration enhances responsiveness to changes, process optimization, waste reduction, and compliance with quality and regulatory standards.

MES solutions ensure real-time monitoring of manufacturing operations, with mechanisms like Statistical Process Control (SPC) and digital Control Cards to quickly identify deviations from quality standards. This allows for swift corrections, preventing the production of defective batches and ensuring compliance with quality requirements that are often incredibly strict.

Yes, APS systems support sustainability by creating optimal schedules. For example, careful task arrangement can reduce the number of cleanings, minimizing the use of water and chemicals. Moreover, the most energy-intensive tasks can be planned during periods of highest renewable energy availability. Additionally, APS promotes paperless operation, eliminating paper plans and schedules. These features help minimize the negative impact of manufacturing on the environment, aiding companies in achieving sustainability goals while optimizing their processes with APS solutions.

MES solutions ensure detailed documentation of every production stage, which is critical for auditing and regulatory compliance. For example, pharmaceutical production requires validation to confirm that each stage of production leads to obtaining a final product of the intended quality. Also, industries like pharmaceuticals, cosmetics, and food must follow Good Manufacturing Practices (GMP), which cover not only manufacturing but also product testing. Other regulations, such as the American Code of Federal Regulations for Food and Drugs (FDA 21 CFR), govern the production and distribution of food, drugs, cosmetics, and medical products. Through comprehensive and detailed planning, APS also supports process manufacturers in meeting these requirements.

MES and APS systems help tackle challenges such as maintaining process continuity, optimizing raw material use, quality control, managing process complexity, and meeting regulatory standards. With the help of these systems, companies can improve efficiency, safety, and quality management in process manufacturing.

Implementing MES and APS can be challenging, especially in complex manufacturing environments. It requires careful process analysis, collaboration with experienced implementation partners, and a well-structured implementation plan. However, the long-term benefits of implementation outweigh the initial challenges.

The key factors in successful digitalization of process manufacturing include proper team preparation, clear definition of business objectives, thorough analysis of production processes, and close cooperation with experienced implementation specialists. Active involvement from all stakeholders and continuous progress monitoring are also essential for the success of this endeavor.