Wrong open means let MES to become "the emperor's new clothes"



To paraphrase "siege" classic: "marriage is a castle, outside of people want to go in, and the men of the city to come out" to describe the status quo of the current MES application - "people want to have used MES, using a person give up", there is a saying: 10 MES, 7 failure, 1 neither dead nor alive, a pseudo is successful, the last one still need to work hard, in the current digital manufacturing enterprise, information technology, intelligent upgrade, in the tide of MES popular but in succession to stumble, for reasons worth discussing,

Import the reasons for the failure of MES

Cause of MES implementation failure has a lot of, the so-called "successful MES is the same, the cause of the failure of MES each have each", many enterprises will not to a technology supplier, actually MES technology is relatively mature, the key lies in a variety of mature technology integration system and the enterprise current situation and demand match, not simply boil down to the manufacturer's reason, says companies and manufacturers have problems objectively,

Summary of the current enterprise of MES, have no condition to MES on nothing but the following factors:



1) in order to meet the requirements of customers on the quality control,

2) enterprise in response to national policy and intelligent manufacturing for government subsidies

3) comparison between the enterprise and enterprise, and others have MES I also want to have,

4) group, the leading development force subsidiaries on MES,

5) solve the cohesion between, management, manufacturing process is not free, need information technology power,



In front of the four kinds of motive, is the wrong way, project failure should be a big probability event, the MES should be automation workshop, workshop management, the coordination between government departments at a certain stage of development after the natural demand of the original workshop management, coordination between government departments methods cannot satisfy the requirement of enterprise development, the need to increase the use of information technology deepened control workshop data, information, processes and synergy,

China's manufacturing enterprises and the enterprises in developed countries in management development there is a certain gap, established manufacturing nation has experienced from the scientific management to the system management to modern management (information technology) the process of gradual development, many management foundation is not only the managers of the cognitive and staff's common sense, and China's manufacturing enterprises since the reform and opening up gradually contact with western management science, are widespread in the preliminary stage level, scientific management system, management level is not high, and the universal existence of weak foundation for modern management, the management has the sixth steamed stuffed bun say, when you see the German factory MES system did a good job, will think I also do a MES can achieve the same management level, actually otherwise, the first five at the bottom of the steamed stuffed bun didn't eat, eat directly the sixth to eat steamed stuffed bun, won't make the enterprises; Belly empty, enterprise psychological gap is big, the failure is inevitable, then again, what are you looking at when feeling good is really good?

Usually enterprise starting from the preparation of MES system is very seriously, set up a team of personnel responsible for, looking for more suppliers communication, visit to the related factories, round round communication, but often just then planted the seeds of failure,

First enterprise has very high expectation to the MES, want to run into the industrial 4.0, the vendors in order to cater to, it will give all kinds of tall solution, regardless of the actual factory already, also regardless of technical maturity, what is about to see and hear what, a vendor, another manufacturer so, the enterprise will think that this should be the goal of the enterprise, but those who can provide solutions according to the actual circumstance of enterprise ability of supplier is considered to lack, is eliminated, the earliest

Second enterprise itself, inadequate internal argument is not enough, each department stand in their own perspective to carry all kinds of demand, leading to the final demand range is too large, enterprise determine a tall goal after all, is to do the bidding work, not bidding of suspicious, the result is often low price bidding, and low-cost bidder, regardless of ability, actual case, Jonathan first, for businesses, feels very good also, take money to buy a jetta bought a Mercedes! Into implementation, suppliers will lower the goals and expectations greatly, this cannot be done, that not realistic, finally found that businesses get only a xiali, ideal how plump, reality is cruel!



Have to say, "to use
"
Why do you say MES status into "the emperor's new clothes"? It remains to be imported from the start, the motives of MES,

Generally the size of the factory on a MES system at least level of millions or even tens of millions of yuan, after several times for system finally launched, the first enterprise project director they must "good," said system is the main development, bad is the denial of their own ability; In front of the customer must also say "good" to show the production quality control, access to new orders; In front of the competent central government must also say "good", to show response to the government called for the business and to get subsidies policy incentives; Before your group leader must say "good", suggesting that the factory is executive force, given a blue-chip company of the end of the assessment, next year can get promotion, raise manufacturers more won't say "bad", everybody tacitly, together to maintain MES market false prosperity,

Huge development system can not need not, also is bad, how to do? Enterprise is the ingenious methods, there are a lot of helpless,



For one: normal production can need not at ordinary times, some people see or check the system temporary open up, after all, these people are tour, don't see doorways, very easy to deceive,

Not coup two: the whole production line is in use or not, you can also choose often representative, is often to visit and inspect the production line to use, after all, a limited number of production line with difficulty and maintenance costs are much lower,

For all three: read data directly from the equipment PLC statistical result is not logical, visitors can also be artificial modification according to the background or inspectors,

Coup 4: the whole function cannot be used up, can also use the function of the part, whatever it takes to make a huge sum of money to develop a system in which play a bit role,



Don't assume that all CanGuanRen check people don't see on MES use of suspicious, view you, take care of each other face and mood, MES have effect? Grassroots users most say, only production monitor, director, production planner, material planner say good is really good (objective said that as long as it is a good system change the way the original employees will always be some people produce conflicting emotions),



The right way to MES open

Current situation is a bit worrying, but there is no lack of MES successful application cases of enterprise, summarizes the successful case has the following several characteristics:

Carding process specification management, enterprise without import MES, management has been the benchmark in the industry, the MES system can make the whole production management better, more efficient and precise, from another perspective, how the current enterprise management is not very desirable, to solve the problem of management by importing the MES, which itself is a fallacy, and managers to transfer responsibility, people sick went to the hospital to see a doctor, because the doctor is a professional, enterprise ill find MES, but the MES software development are professional developers, they don't know the production management, process, quality control, a computer program is rigid, is teaching him how to do it, developed based on a low level of management system must be low, and once on the software system, the equivalent of management to finalize the design, and to the future of management to improve and improve a set of chains, improved management must first improve the software program, and you can keep the team management is the use of software and software can't be change, thus lost the motive force of the improvement,

Before importing the MES, requires enterprises to carry out a lot of preparation work, such as the need to enterprise's own information flow and material flow, many companies are actually handed the job to the manufacturer, so the enterprise management should not be the first step is to import system, should be combed with lean thinking and methods to process, please use Excel, forms, kanban system turn up, then the process software, so the probability of success is high, the cost is the lowest,



Prepare budget sufficient, long-term investment, budget is not only the first development of MES contract amount, MES application is a sustained effort, include at least the following fees:

1. Due to demand changes in the development process, the developers must offer extra, enterprises have been riding a tiger, at this time the price how many companies didn't say forget it,

2. Each year to developers pay system maintenance costs, developers have different charging standard is different also, about 15-20% of total amount of the contract,

3. The cost of the equipment modification, some equipment need to increase the PLC, sensor, modify the program, etc.,

4. The new production line, the cost of the new project access MES,

MES import cost must be high, if the budget tens of thousands, hundreds of thousands of import MES that must be a reading of the students' work, thank you for your contributions to foster qualified talents for the future for the industry,



MES high cost because of the system requirements:



1, the MES is the optimization of the whole workshop manufacturing process, rather than a single solve a production bottleneck;

2, MES must provide the function of the real-time data collection process, and make corresponding analysis and processing,

3, MES need between planning layer and control layer for information interaction, through the enterprise continuous information flow to achieve information fully integrated enterprise,



So MES must is a complex, highly customized and depth of the hardware system, its development cost must be high, a company has as part of the production line imported MES, have been hesitant to give the rest of the production line is connected to the MES every access to spend tens of thousands of pieces, a production line to another company access MES costs more exaggerated, a production line access MES to spend tens of (these are big foreign companies, domestic companies can't simply for reference), but also ask: why the new production line has access to the MES cost is so high? Due to the type of equipment is different, different manufacturers, and even dominate the development of equipment of electrical personnel different lead to totally different interface and interaction, In the absence of unified planning and finished electrical system on the basis of production line can't simple plug-in access In MES,

Is the enterprise MES project director lack of ability to changing requirements? No, IT is the responsibility of enterprises usually not the MES, often concurrently, as his own project manager, production manager, IT manager or manager, IE has been very busy, the development of MES is extra workload, time is limited, even if he is a full-time, maybe he is not understand the production process, even if he knows the production process and could not understand software development at the same time, suppose, he can put the enterprise demand for MES proposed 90% is already very high (number), the manufacturer's product manager understand 90%, programmers 90% complete.

90% x 72.9% x 90%=90%

Ideal and the reality of deviation is a bit big, all the MES development must be constantly communication companies and manufacturers, the process of change, vendors offer process, increasing the atmosphere on the friendly cooperation is likely to be changed, enterprises do not understand is a small changes in the demand for him, why so high price, take building as an example, the planning is 10 floors, is a tier 11 to completion, cost more than one floor for builders, building foundation, framework does not necessarily can take more than a layer of floor,

Cultivate MES professional maintenance personnel, complicated system itself, MES is necessarily software, hardware, the combination of man, machine, material, method of all kinds of factors of production management integration of complex system, such a complicated system itself, it will be like in the workshop as a restive special equipment installation become a source of problem, in my original company developed the assembly line, for example, in order to prevent a variety of possible artificial operation error, quality problem, we have installed more than 150 various types of sensors on the assembly line, some of the other sensor error is detected with (some around here), has a perfect ideal, the reality is insane, insane is precisely these complex control system consisting of sensors, all kinds of false positives, failure, loose and there is no way to proceed in a row, leading to production after some effort result is that most of the sensor is tape blocked, the import of MES was meant to help enterprises solve the problem, but not all the enterprises realize the MES itself is also a problem, and once it is out of the question, such as the ability of enterprise itself cannot solve, please manufacturers bearer is a cost that, if a matter of time before, the main business is the production of the enterprise, sales, system can't service should be eliminated, which is mainly to design,

To adapt to the dynamic change production conditions, the change is the norm for the daily operation of the enterprise, personnel, technology, production, equipment... Are in change, the same is not normal, MES or any other system development must be fully considered to address conditions change, rather than development system based on the theory of static input condition, because when conditions change system cannot be used instead of blaming the production change too much would be a mistake, this even work in the enterprises in which the understanding is usually insufficient, even to realize single can foresee all changes, and puts forward the countermeasures is extremely difficult, so the import of MES is not a one-time deal, investment is continuing, the recent chat with friends, talk to his brother factory import of MES system in abnormal situation, there is no way to operate, in addition to no other way to bypass the MES, like this factory, MES, become a chicken ribs is



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