MES Buyers Guide

May 26, 2016 | Author: tuvaoh | Category: Types, Presentations
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MES Buyers Guide...

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Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

MES 2011

A Buyer’s Guide

Manufacturing execution systems

A Report Prepared by: Managing Automation Media Research Services © 2010 Thomas Publishing Company, LLC

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

b u y e r ’ s g u i d e se c t i o n s

Category Introduction

AMR Research first used the term “manufacturing execution system” in 1992 as part of its threelayer MES model.

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MES is defined by the Manufacturing Enterprise Solutions Association (MESA) as a dynamic information system that drives effective execution of manufacturing operations: Using current and accurate data, MES guides, triggers, and reports on plant activities as events occur. The MES set of functions manages production operations from point of order release into manufacturing to point of product delivery into finished goods. MES provides mission critical information about production activities to others across the organization and supply chain via bi-directional communication.7 Despite a proliferation of articles and commentaries on MES, for many manufacturers it remains a confusing acronym. Although all systems are used to manage and monitor workin-progress on the factory floor, the software may vary significantly for each vertical industry and product line. In general, MES systems will allow users to specify when materials should be ordered and to schedule tasks against an organization’s total production capacity through advanced production scheduling (APS). This allows for visual representations of projected workloads, and offers some form of Overall Equipment Effectiveness (OEE) reporting to gauge real-time efficiency. MES can also guide workers or machines through the production process. Specialist functionality for particular process industries can include modules such

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he transformation of the traditional factory from a production facility into a modern service center has resulted in management problems for which many manufacturers are not yet prepared. The economic efficiency of modern value creation is not a property of the products but rather of the process that creates them. What this means is that the decisive potential of companies is found less in production capability and more in process capability.1 The requirement for process capability gives rise to the requirement that all value-adding processes be geared to the process result and thus to the customer. A necessary condition of process transparency is the ability to map the company’s value stream in real time, without the acquisition process involving major outlay—a capability beyond enterprise resource planning (ERP) technology, but perfectly suited to manufacturing execution systems (MES). 2 Manufacturing execution systems software is an increasingly critical component of modern manufacturing environments. MES collects and analyzes production data, tracks quality control, and is frequently integrated

with ERP systems to monitor manufacturing schedules and ensure delivery of orders. MES serves as the intermediary between a business system such as ERP and a manufacturer’s plant-floor control equipment; it creates an audit control for tracking, tracing, and compliance purposes, and delivers work instructions to plant-floor personnel.3,4 The origins of the MES concept are found in the data collection systems of the early 1980s. Various functional areas of corporate management (e.g., production planning, personnel, quality assurance) were furnished with dedicated data collection systems, which became part of the computer-integrated manufacturing (CIM) pyramid model.5 CIM focused on the hierarchy of the manufacturing enterprise. As new pressures transformed manufacturing (e.g., increasing globalization and customer focus), the need for a new model emerged, resulting in MES. AMR Research (now part of the research and analysis firm Gartner) first used the term “manufacturing execution system” in 1992 as part of its introduction of the three-layer MES model. This model reduced the manufacturing model to three functional areas—planning, execution, and control—and helped manufacturers by reducing the number of layers of software, and focusing on the need to link the planning process to the control process through the newly defined execution process.6

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

b u y e r ’ s g u i d e se c t i o n s

Category Introduction as ingredient expiration date monitoring and emergency shutdown systems.8

For manufacturers to thrive in the decades ahead, they will have to deploy MES across their enterprise.

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❏ Reduction of errors, and therefore a reduction of waste and rework ❏ Better understanding of the location and source of problems ❏ Reduction or elimination of manual entry time and costs ❏ Reduction of cycle time, resulting in increased yield and throughput ❏ More efficient use of equipment assets ❏ Improved planning and streamlined schedules ❏ Reduction of inventory ❏ Reduction of order-to-ship times ❏ Lower costs for regulatory compliance An MES system can either reside on a centralized server or be distributed across modular hardware and software units that provide “services” and communicate on a local area network. The distributed design allows a business to assemble modules from different vendors without the need for the placement of multiple copies of complex

Normally, MES would include the following basic functional modules: ❏ ❏ ❏ ❏ ❏ ❏

Detailed planning and control Material management Operating resources management Personnel management Data acquisition and processing Interface management

❏ Performance analysis ❏ Quality management ❏ Information management12 While the implementation of an MES system is always challenging, the rewards and return on investment are higher than they have ever been. ❑

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By providing operator support, production scheduling, tracking and tracing capabilities, and accurate, real-time visibility into production processes, MES may deliver the following benefits to a manufacturer:

and expensive computer systems in areas that will not use their full capacity.9 When the first MES setups hit the market in the 1990s, they were a good idea but ahead of their time. They promised great efficiency and significant quality improvements, but were too immature and expensive to make economic sense.10 Much has changed since then. Product lifecycles are shorter, profit margins are tighter, and regulatory environments are more severe. As these market dynamics continue shifting toward smaller production runs, greater emphasis on quality, and more complex market environments, only automated data collection and processing in a real-time, continuously available environment will provide manufacturers with the agility they need to survive. Therefore, it is widely accepted that for manufacturers to thrive in the decades ahead, they will have to deploy MES across their enterprise.11

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

The Technology Landscape

Process standardization helps manufacturers pool plant capacities across the extended enterprise.

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left manufacturers with limited options to choose from, which led many manufacturers to perform custom development as a de facto MES approach.15 According to Wildeman, this picture is steadily changing. Large manufacturers are increasingly recognizing the benefits of standardized production processes, and macro drivers are propelling this idea as a more common must-do approach in many cases. Process standardization helps manufacturers pool plant capacities across the extended enterprise, better enabling the pursuit of a “virtual factory” concept and providing more strategic flexibility to respond to demand changes.16 Consider, for example, an international contract manufacturer. As its processes are standardized globally and an MES shows excursions at any given factory (e.g., high yield fallout or another unusual trend), the company can track the excursion to its root cause, be it process steps, a bad batch of material, or a test or design issue. It can track all its material by lot, in case there is an issue with incoming components, and alert all the plants with parts from that lot of the potential issue before they use the parts. An older system of local data location would never be able to prevent other facilities from using the bad material, except by non-automated processes (e.g., SQE e-mails, phone calls). The MES solution has the poten-

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n many respects, MES deployments are similar to the ERP systems that preceded them. MES brings to manufacturing operations the efficiency and data analytics that ERP brought to financial systems. A key difference that is sometimes overlooked, though, is the difference in transaction time frames. ERP system transactions are measured on a time scale of months, weeks, and days. MES setups have much shorter transaction time frames, measured in hours, minutes, and seconds. This is why MES must be designed for continuous availability. Even a momentary outage can break critical record chains that determine whether a product can be sold or is written off as spoilage. MES solutions also support real-time strategic decision-making, which depends on uninterrupted data collection and processing.13 Today’s plants are difficult places to run an application. Typically, data is scattered across hundreds of disparate systems, many of which were developed decades ago. The cost to develop and run applications using legacy data is painfully high. It cripples application delivery efforts, limits the room for application upgrades and replacements, and encourages many users

to stick with manual processes (even though there’s a broad-scale understanding that such processes are anathema to efficiency). Corporate IT departments are seeking to standardize enterprise applications globally as a way to streamline, simplify, and overcome many of these challenges. Yet mergers and acquisitions, outsourcing, and contract manufacturing are trends that create barriers to the drive for standardization. Plants often have multiple instances of different applications across their sites and business units, and many have resorted to standalone solutions to avoid the complexity of extensive integration and coordinating with corporate systems. This drives the number of disparate applications in systems even higher. 14 In the late 1990s, when MES was first deployed as a means to bridge the gap between transaction-oriented business systems and real-time production operation decisions, there was a recognition that the challenge of fitting MES software into the shop floor was taking place in unique operating environments. “Each plant per industry, per production style, has unique operating characteristics,” says Roy C. Wildeman, senior analyst at Forrester Research. As a consequence, MES developed as a fragmented market, full of specialist vendors. The combination of specialized requirements and fragmented support

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

The Technology Landscape

tial of saving the company tens of millions of dollars alone in preventing bad material.17

❏ Automation code is more accessible ❏ Code versions can be controlled across decentralized architecture ❏ Dashboards can aggregate disparate data sources ❏ Shop-floor applications can be delivered centrally as a single instance ❏ Hosted and SaaS deployments are lowering upfront capital requirements18

The global economic collapse has forced some manufacturers to postpone or limit plans “Many of the controls vendors increasingly to upgrade or standardize their products around OPC specireplace their fications, making integration more cost effecexisting MES. tive and allowing IT to more easily abstract

Managing Automation Buyer’s Guide

equipment-specific parameters into the MES layer,” Wildeman says. Three years ago, AMR Research attempted to raise the technological bar for MES, coining one of 2007’s major buzzwords: “Manufacturing 2.0.” This referred to next-generation technologies such as blogs, wikis, instant messaging, and user-centric interfaces on the shop floor. It called for a manufacturing service-oriented architecture (SOA) that merged

supports Wildeman’s observations. Parker says that most MES setups handle scheduling processes very well, but for other functionality, it’s a mixed bag. He also contends that MES software has not added many truly new functions in recent years, with recent innovations focusing on visualization of the production process and analytics.20 ❑

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Technology advances are offering better support for multi-site MES deployment:

product data management (PDM), process development models, and event-based supply chain collaboration with support for mobile and sensor technologies. The concept was developed in response to a growing interest in mobility, SOA-enabled applications, cloud computing, and new paradigms for factory training. Manufacturing 2.0 was also touted as the solution to some of the problems of traditional MES systems: rigid architecture, inability to support new lean and Six Sigma initiatives, difficult and costly deployments, and trouble functioning in multiple manufacturing styles.19 But the global economic collapse has limited discussion of Manufacturing 2.0, as IT budgets have been slashed and some manufacturers have been forced to postpone or limit plans to upgrade or replace their existing MES infrastructure. Roughly half of the installed MES software was deployed in the last six years, a sign that manufacturers are finding that MES upgrades are not easy. As more manufacturers look to standardize their MES, many are opting to rip and replace the systems, rather than upgrade existing ones. “Integration is far easier with the new MES systems that are based on Microsoft.NET Web services technology,” says Robert Parker, an analyst at IDC Manufacturing Insights. This is making the drive to standardize across multiple plants easier, and

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

How to Evaluate Costs/ROI

A new MES can cost from $150,000 to $300,000 for the software license, plus one-and-ahalf to three times that amount for services.

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1. SaaS pricing is evolving toward true usage-based models. Most early SaaS pricing was on a fairly simplistic, per-user-per-month basis, sometimes with add-on costs for “extras” such as mobile, storage, or advanced modules; today, many buyers are seeking pricing options that more closely map to value, such as usage-based or transaction-based models. 2. Many SaaS vendors are providing transparency into pricing and contract terms. These vendors have typically had transparent pricing, often listed on their Websites or shared by user communities. One challenge for buyers who are stuck in a traditional, on-premises

purchasing mindset is that SaaS vendors typically have limited transparency into breakdown of pricing (i.e., splitting out software, hosting, and support). 3. “Freemium” remains common, but approaches vary widely. Many SaaS vendors continue to offer various types of free trials or free low-end editions to allow potential customers to try the product before buying, and to capitalize on the word-of-mouth that is quite common among SaaS users. 24 Typical project payback for MES investments comes in six to 24 months. Most MES projects are justified on cost-reduction measures: lower work in progress (WIP) and finished goods inventory (FGI); reduced waste, scrap, and materials; reduced cost of regulatory compliance; reduced rework; lower maintenance costs; reduced indirect labor costs; shorter cycle times; shorter lead times; improved quality; and reduced process and product variability. Process improvements also accrue to the ROI for MES investments: faster new product introduction (NPI) cycle, shorter time to innovation, improved adherence to customer audit requirements (traceability and genealogy), and promotion of flow manufacturing. Finally, overarching market improvements are supported by MES: better collaboration, improved supply chain visibility, and a platform for continuous improvement.25 ❑

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ompanies should analyze the capabilities of state-of-the-art MES to estimate what an MES deployment should cost. what would be a reasonable price? Historically, MES setups were “big bang” implementations, where functionality needed to be delivered immediately. These created large projects and long time lines that frequently failed to deliver an adequate business return and often were not aligned to the current business problems upon project completion. SAP’s introduction of xApp Manufacturing Integration and Intelligence (SAP xMII), which it bills as the world’s first manufacturing intelligence portal, is another example of technology advances offering better support for MES deployment. Like ERP systems, MES solutions have historically had two basic pricing models: user-based and usage- or module-based. The former entails one license fee per user, which includes access to all modules of the system. The latter means functionality is purchased on an a la carte basis, plus an additional per-user fee.21 According to Simon Jacobson, a research director at AMR, a new MES can cost anywhere from $150,000 to $300,000 for the software license, plus one-and-a-half to three times

that amount for services, depending on the complexity and number of sites installed.22 Hosted and software-as-a-service (SaaS) deployments are also emerging as means to minimize capital requirements. CFOs can balk at a large capital outlay for enterprise software if it doesn’t translate into immediate ROI, but some SaaS vendors, such as Plexus Systems, are helping clients overcome this challenge by offering MES functionality as a subscription service over the Web.23 SaaS pricing models are in flux, though. At Forrester Research’s recent IT forum, a roundtable was undertaken with several leading software and services firms around the topic of SaaS pricing trends. Key takeaways:

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

Any supplier not able to integrate a staff worktime function and a performance-based remuneration function can be ruled out.

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t is a daunting task to identify criteria for selecting an MES solution and, by extension, an MES vendor. The more you understand about the matter, the harder it becomes to keep an overview perspective. Where should you start, and where should you stop? Once you’ve looked at multiple system presentations, it may be difficult to see where they differ; after a while, all user interfaces can look the same. MES setups are complex IT installations that, depending on the form they take, can affect a large number of functional areas in a manufacturing concern. Systems may be used for anything from straightforward feedback regarding quality assurance and personnel management to complex detailed schedulingcontrol systems. Once objectives have been defined, a better assessment can be made of the scope of services offered by different systems and suppliers. For example, if you want to start with machine data collection but know that in a

year or two the company will be looking at incentive wages, you can immediately establish knockout criteria. Any potential supplier not able to integrate a staff work-time function and a performance-based remuneration function can be ruled out immediately. Consider the possible objectives that can be met by the introduction of MES. This usually means that quantifiable approaches can be found, which then form the basis for calculating an ROI. Such a procedure is more efficient and involves less work; further, the level to which objectives have been achieved can be better assessed for the purpose of controlling subsequent investments. The following checklist should provide some assistance in designing and selecting MES solutions: 26 General Criteria 1. Does the MES have fully integrated production, personnel, and quality management? 2. Does it support paperless production? 3. Does it include all necessary standard products? 4. Does the system offer escalation management and workflow functions? 5. What references and knowledge of the industry does the supplier have? 6. How easy is it to adapt the MES setup’s functionalities to the

customer’s processes? 7. Does the MES manufacturer have a clear standard product and release strategy? System Concept 1. Is the complete MES functionality provided in a single system? 2. Can the individual components be used as modules? 3. Can the functions be configured? 4. Does the MES have an enterprise services architecture-oriented (ESA) structure? 5. Does the system orient itself by common industry standard products? 6. Does the system support the necessary platforms? 7. Does it support the necessary interfaces? 8. How easily can it adapt interfaces to the requirements of the customer? 9. What possibilities does the system offer for the customer’s own developments? 10. Can these adaptations be made just as easily at a later time? 11. What tools are available for preparing one’s own analyses? 12. Can the existing analyses in various levels of data aggregation be adjusted for all corporate levels?





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How to Evaluate Vendors

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

How to Evaluate Vendors

Managing Automation Buyer’s Guide

Production 1. Are there integrated functions that offer a view of all resources involved in production? 2. Are there overviews that allow evaluation of the current manufacturing situation? 3. Are the detailed planning functions based on current data? 4. Does detailed planning manage primary and secondary resources? 5. Is there a load planning function for different kinds of secondary resources? 6. Can you model different possibilities of technological relationships? 7. Is inter-order networking possible? 8. Can the types of capacity be varied? 9. Are different planning strategies supported? 10. Can detailed planning instances be evaluated by means of flexible and combinable key data? 11. Can alternative planning variants be simulated?

12. Can different optimization strategies be implemented? 13. Does the MES support different production structures (multiple machine work, multiple operator work, etc.)? 14. Is material tracking possible (e.g., in batches and buffer storage)?

2. Can working hours and payments models be configured simply for personnel time management? 3. Is there a workflow for processing of applications and approvals? 4. Is there a straightforward method to adapt calculation of incentive wages to collective bargaining agreements? 5. Is there a short-term manpower planning function with direct coupling to production loading? 6. Is there a short-term manpower planning function that assigns employees to work centers at which orders have been scheduled?

Quality 1. Can quality inspections be incorporated like work operations in the overall order structure? 2. Is there a dynamic configuration function to monitor testing and inspection equipment? 3. Is non-conformance management work Data Acquisition flow supported? 1. Does the MES permit gapless automated 4. Is gapless traceability of the production data acquisition and processing? process possible? 2. Are standard interfaces provided to 5. Does production planning have access machines and automatically controlled to quality data? machines? 6. Can process measurement data also be 3. Can all data acquisition functions be used as quality characteristics? configured for better ergonomics and 7. Is there support for automatic transfer thus greater acceptance? of measured data via standard interfaces? 4. Are standard data acquisition interfaces such as OPC supported? Personnel 5. Are the data acquisition functions 1. Is staff work-time logging with available on different platforms, such information and intelligence functions as RFID, bar-code readers, and label available at the terminal? printers? 27

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13. Is there an interface with leading ERP and PPS systems? 14. Does the modular architecture of the MES permit a gradual expansion to include further functions? 15. Is the system architecture open?

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

Vendor Profiles

About Managing Automation Research Services

A good selection process starts with the creation of a crossfunctional team.

Managing Automation Buyer’s Guide

These questions open the door to the standard set of vendor evaluation criteria that any manufacturing company would use to conduct due diligence for a significant purchase such as an MES. The de facto questions include number of years the vendor has been in business; how long the MES product has been on the market; functionality for the type of business considering the purchase; vendor stability and reputation; ability to service and support the software; and, of course, making sure the vendor has a roadmap for the future of the product. A good selection process starts with the creation of a cross-functional team tasked with developing business requirements that will be used to evaluate alternatives. These requirements will be matched with specific features of the product under consideration. Specific requirements are more helpful in the selection process than general ones, which may be met to some degree by all the contenders, making it difficult to choose among them. 28 Throughout the selection process, conclude each step with the consensus of all members of the selection committee, including end users, to gather enterprise-wide acceptance for the MES package. ❑

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How to Evaluate Vendors

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Vendor Name

Product Names

Functional Range

Industries Served

Apriso

FlexNet

Managing and executing production, warehouse, quality, maintenance, and labor activities

Automotive, aerospace and defense, clean-tech, consumer goods, industrial equipment, life sciences, packaging, electronics

Aspen Technologies

aspenONE

Camstar Systems

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Includes data collection and Chemicals, polymers, oil and gas, Small, storage, performance analysis, pharma, CPG, food and beverage midsize, production dispatching, producand large tion resource management, production definition management, production execution

Camstar Enterprise Includes early collaborative Platform manufacturing process development, capacity and capability analysis, integrated engineering change process, product/ WIP traceability, genealogy, audit trail, quality data collection and process limits, global change enforcement and audit trail CDC Factory

Size of Business Served Large

Real-time finite production scheduling, real-time performance mgt., quality control, continuous improvement, business analytics, agile maintenance response, enterprise asset management, safety

Vendor Profiles

About Managing Automation Research Services

Databases Supported

Platforms Supported

Delivery Mode

Microsoft SQL Server, Oracle

Has built-in Microsoft. NET with SOA; BPM

On-premises, virtual environment

Microsoft SQL Server, Oracle

Microsoft Windows 2000, Windows XP, Windows Vista

On-premises

Medical devices, biotech, solar, semiconductor, electronics

Midsize and large

Microsoft SQL Server, Oracle

Microsoft

On-premises, SaaS

Process mfg. and discrete mfg.

Midsize and large

Microsoft SQL Server, Oracle

Microsoft .NET, Windows 64

On-premises

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CDC Software

Product Comparison Tables

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Vendor Name

Product Names

Functional Range

Industries Served

De Clercq Solutions

Objective MES

Dispatch work orders from ERP, production scheduling, manufacturing process mgt., non-conformance and corrective action, quality documentation, statistical analysis techniques, production reporting, supervisory control

Food and beverage, plastics, industrial parts and equipment, semiconductor, wholesale and distribution

Production operations, invenEmerson Syncade Smart tory mgt., quality mgt., mainteProcess Operations nance mgt., integration Management Management Suite, AMS Suite (asset performance management)

Product Comparison Tables Size of Business Served Midsize and large

Databases Supported

Vendor Profiles

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Platforms Supported

Delivery Mode

HP/UX, IBM AIX, Sun Solaris/Sun OS, Linux, Microsoft Windows CE, Windows NT/2000/XP, Windows Server 2003, Windows Vista

On-premises

Chemicals, food and beverage, life sciences, metals and mining, oil and gas, and others

Small, Microsoft SQL Microsoft Windows midsize, Server 2005, 2008 Server 2003 and 2008, and large Windows XP, Windows 7, Windows Mobile, Palm OS, Android

On-premises

IBM DB/400, Microsoft SQL Server, Oracle, MySQL

eyelit MES

Asset mgt., costing, shop floor control, reporting

Solar, semiconductor, MEMS, aerospace and defense, automotive, electronics

Midsize and large

Microsoft SQL Server, Oracle

Microsoft Windows, Unix, Linux, and others

Clients deploy using Java WebStart

GE Intelligent Platforms

Proficy Plant Applications

Includes order completion status, interactive schedule planning, automatic set-point loading, material delivery mgt.

Aerospace, automotive, chemicals, electronics, oil and gas, textile, constructions, CPG, and others

Small, midsize, and large

Microsoft SQL Server

Microsoft

On-premises

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Eyelit

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Names

Functional Range

Industries Served

HighJump Software

HighJump Manufacturing Advantage

Work order import, prioritization and dispatch; material picks and delivery to work cells; work queue; instruction and documentation review at work cells; material replenishments; real-time production review and adjustment, performance analysis; scrap reporting; machine utilization; labor productivity  

Industrial mfg., automotive, aerospace, food and beverage

Honeywell Process Solutions

Business FLEX, Matrikon, OptiVision, Uniformance

Includes planning and scheduling, supply chain mgt., operations mgt., data warehousing, integration and communications

Refining, oil and gas, power, chemicals, life sciences, and more

iBASEt

Solumina

Process planning, MES/MOM, quality management systems, supplier quality assurance, MRO

Intercim

Pertinence Suite powered by Velocity

Includes simplified process planning, advanced predictive analysis, process execution, quality mgt.

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Size of Business Served Midsize and large

Databases Supported

Vendor Profiles

About Managing Automation Research Services

Platforms Supported

Delivery Mode

Microsoft SQL Server, Oracle

Microsoft Windows

On-premises, cloud

Small, midsize, and large

Microsoft SQL Server, Oracle

Any system from any vendor

On-premises

Aerospace, defense, nuclear products, shipbuilding, industrial equipment, industrial electronics, medical devices

Midsize and large

Microsoft SQL Server, Oracle

Microsoft Windows, Unix

On-premises

Aerospace, defense, discrete mfg., life sciences, high-tech, energy, and more

Small, midsize, and large

Microsoft SQL Server 2008 R2, Oracle 11g

Microsoft Windows Server 2008 (32/64bit), Windows XP Professional, Windows Vista Business, Windows 7 (32-bit)

On-premises

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Vendor Name

Product Comparison Tables

Category Introduction

Vendor Name Invensys

Technology Landscape

Product Names

How to Evaluate Costs/ROI

Functional Range

Manufacturing Includes electronic work orders, Execution Module BOM, product traceability, operations standard functionality, inventory control

How to Evaluate Vendors

Industries Served Hybrid, process, discrete mfg.

MPDV Mikrolab GmbH

HYDRA

Production data collection, shop floor scheduling, material and production logistics, machine data collection, tool management/DNC, quality assurance, process data collection, time and attendance, personnel scheduling, incentive pay, access control

Parsec Automation

TrakSYS

Includes data/information inte- Pharma, medical devices, food gration management, process and beverage, consumer health and asset/infrastructure model- products, automotive, chemicals, and others ing, production planning and dispatching, resource allocation, data acquisition, process and operation mgt.

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Performix xRecipe, Includes electronic work orders, Performix xMES, multi-language support, OSI PI Performix xBatch integration, material tracking, resource tracking, plant supervisory functions

Size of Business Served Small, midsize, and large

Plastics, metal, automotive, Midsize and large food and beverage, plant and mechanical engineering, furniture, wood products, printing and packaging, precision mechanics and optics, electrical engineering and electronics

Chemicals, consumer products, food and beverage, pharma

Vendor Profiles

Databases Supported

Platforms Supported

Delivery Mode

Microsoft SQL Server 2005, 2008; Oracle

Microsoft SQL Server 2008, Windows Vista (64-bit)

On-premises

HP/UX, Sun Solaris/ Microsoft Access, Microsoft SQL Sun OS, Linux, Microsoft NT/2000/XP, Windows Server, Oracle, Vista, Windows SQL MySQL, Informix, Server 2003, Windows ASCII text CE, Palm OS file-based

Midsize OLE-DB-compliant and large

Midsize and large

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Microsoft SQL Server

On-premises

Microsoft Windows, Linux, Unix

Browser technology/Webbased

Microsoft Windows 2000, 2003, 2008, XP, Vista, and 7; Linux

On-premises

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Performix

Product Comparison Tables

Category Introduction

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Vendor Name

Product Names

Functional Range

Industries Served

Plex Systems

Plex Online

Includes production scheduling, finite scheduling, lean tools, shop floor control, bar-code labeling, traceability, labor/time tracking, SPCs

Automotive, medical devices, industrial mfg., food and beverage, life sciences, aerospace

Oracle

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Vendor Profiles

Size of Databases Business Supported Served Small and SaaS/cloud-based midsize

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Platforms Supported

Delivery Mode

SaaS/cloud-based

SaaS

Execute, record, and monitor Aerospace and defense, industrial Midsize Oracle shop-floor activities in real time mfg., high-tech, CPG, life sciand large Manufacturing ences, oil and gas, and more Execution System for Process Manufacturing, Oracle Manufacturing Execution System for Discrete Manufacturing

Oracle Solaris x86-64 (64-bit)

Linux x86, Linux x86-64, HP-UX Itanium, HP-UX PA-RISC (64-bit), IBM AIX on Power Systems (64-bit), Microsoft Windows Server (32-bit), Oracle Solaris SPARC (64-bit)

On-premises, on-demand, or hybrid

FactoryTalk Scheduling, order mgt., quality Pharma, biotech, medical devicProductionCentre control and mgt., material track- es, CPG, food and beverage, automotive ing and mgt., WIP/Inventory, workflow and performance mgt.

Oracle 10, 11; Microsoft SQL Server 2005, 2008; Windows 2003, 2008, including 64-bit; Linux; Solaris Enterprise

Oracle 10, 11; Microsoft SQL Server 2005, 2008; Windows 2003, 2008, including 64-bit; Linux; Solaris Enterprise

On-premises, SaaS

Midsize and large

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Rockwell Automation

Product Comparison Tables

Category Introduction

Vendor Name SAP AG

Technology Landscape

How to Evaluate Costs/ROI

How to Evaluate Vendors

Product Comparison Tables

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Size of Databases Business Platforms Supported Supported Served SAP Manufacturing Traceability, non-conformance High-tech, industrial machinery Small, Microsoft SQL Microsoft Windows Editor’smgt., Note: This select list of ERP suppliers is based on market reports,Server, analyst reports,Server, and company information. Execution production transfer, ERP and components, aerospace andresearch midsize, Oracle HP-UX, Solaris, integration, return and repair, defense, automotive, medical and large Linux, AIX labor tracking, engineering devices change mgt., production metrics, globalization Product Names

Functional Range

Industries Served

Ampla

Siemens MES

SIMATIC IT

Includes quality control, traceability, process efficiency, production mgt., collaboration

Electronics, automotive, assembly, food and beverage, and others

Werum Software & Systems

PAS-X

Master batch records, finite scheduling, weighing and dispensing, electronic batch recording, equipment mgt., material track-and-trace, warehouse mgt., process quality control, corrective and preventive actions, operator training records, manufacturing intelligence

Pharma, biotech

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On-premises

Microsoft SQL Server, Oracle, OPC DA, OPC HDA, InSQL, major SCADA and historian systems

Microsoft, Java

CD

Midsize and large

Microsoft SQL Server, Oracle

Microsoft Windows XP, Windows 7

On-premises, Web-based

Midsize and large

Oracle

Flexible

On-premises

Metrics, production, downtime, Mining, food and beverage, CPG, Midsize quality, inventory, energy, water/wastewater and large planning, cost, knowledge, maintenance

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Schneider Electric

Delivery Mode

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Vendor Profiles Selected Suppliers of Manufacturing Execution Systems (In alphabetical order)

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Apriso traces its roots to 1992, when Teledyne Industries spun off its software business to Apriso’s predecessor organization, CIM Vision International. The company recognized the need for an adaptive MES. As a result, in 2002, FlexNet was launched as a modular and easily integrated application suited to fill the critical gaps between business and process control applications. The FlexNet platform is a unified suite of manufacturing software applications that can coordinate all manufacturing operations within a plant, between plants, and across the supply chain and enterprise. Functionalities include managing and executing production, warehouse, quality, maintenance, and labor activities. In addition, extended quality capabilities enable advanced SPC calculations to be embedded directly within any process, as well as the ability to perform quality planning or quality containment management, should an out-of-spec event occur. FlexNet replicates processes across multiple locations, enabling global KPI reporting with actionable capabilities to instantly remedy an out-of-tolerance event. Apriso’s CEO is Jim Henderson. Aspen Technologies Aspen Technologies, led by President and

CEO Mark Fusco, is a supplier of software that optimizes process manufacturing in a number of industries. Established in 1981, AspenTech’s annual revenue last year was $166 million. More than 75,000 users at over 1,500 companies rely on AspenTech products. AspenTech’s MES product, aspenONE, provides functionality consistent with S-95 production operations management models to help customers increase profitability, achieve better asset utilization, and drive continuous improvement efforts. The AspenTech MES product aggregates process, production, and business information into a context for understanding and improving performance. Camstar Systems Camstar is a privately held company led by President and CEO Scott Toney. The company provides manufacturing execution, process planning, enterprise quality management, and supply chain intelligence products. Since 1984, Camstar has served hundreds of customers worldwide, the majority of which are tier-one companies. Camstar’s MES product supports a broad diversity of manufacturing industries and processes. The highly configurable platform adapts to a user’s business without custom code, and its open SOA architecture was designed for ease of integration to enterprise

applications and shop-floor automation. The manufacturing model provides revisioncontrolled, auditable, structured definition of the product definition and associated manufacturing processes. It includes workflows with approved alternate paths, step-by-step operator procedures, parametric data collection with limits and out-of-spec actions, electronic signature requirements, and detailed bills of materials. By enforcing adherence to processing rules, this model is the basis for the manufacturing audit trail. CDC Software Founded in 2002, CDC Software’s MES product is CDC Factory, a packaged manufacturing operations management system that transforms manufacturing performance by letting people make real-time, actionable decisions. CDC Factory integrates the functionality of shopfloor data capture, packaged metrics such as Overall Equipment Effectiveness, analytics and scorecards, continuous improvement capabilities, and paperless quality management. The technology is combined with a change method that focuses on developing a structure of daily performance reviews to drive better performance. The process develops operator skills so operators are able to drive their own improvements; the product is typically deployed in less than six weeks per factory.

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Apriso

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De Clercq Solutions De Clercq Solutions has more than 10 years of experience with the implementation and integration of MES setups. The company’s MES offering, Objective MES, starts with detailed planning; it optimally controls operators and machines, and analyzes performance and quality. The product dispatches work orders efficiently, taking into account the real capacity and capacity utilization. Objective MES also helps optimize resources. It monitors production and reacts to problems. The system also supports maintenance activities and quality management. Koen De Clercq is the CEO of the company. Emerson Process Management Emerson Electric is a global leader in bringing together technology and engineering to provide solutions to industrial, commercial, and consumer markets through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. The company’s sales in fiscal 2009

were $20.9 billion. Emerson’s CEO is David Farr. Emerson Process Management, an Emerson business, is a leader in helping businesses automate their production, processing, and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences, and other industries. Emerson Process Management offers two MES products, Syncade and AMS Suite, to the industries it serves. Eyelit Eyelit, founded in 1997, delivers a broad set of manufacturing solutions, including eyelit MES. The software provides insight into production process efficiency, performance/ equipment efficiency, inventory control, and resource management, along with the ability to automatically react to conditions in any factory system. Led by CEO Salil Jain, Eyelit has designed its MES product for use in the aerospace/ defense, electronics, semiconductor, and solar industries. GE Intelligent Platforms GE Intelligent Platforms, headed by CEO Maryrose Sylvester, is a global provider of software, hardware, services, and expertise in automation and embedded computing. The company serves industry segments such as energy, water, consumer packaged goods, government

and defense, and telecommunications. GE Intelligent Platforms offers a number of products with MES functionality, including Proficy Plant Applications and a number of other products that fulfill the Proficy Platform. HighJump Software HighJump Software is a global provider of supply chain management software that streamlines the flow of inventory and information from supplier to store shelf. Founded in 1983, HighJump has more than 3,500 customers worldwide. The company’s CEO is Russell Fleischer. For discrete manufacturers, HighJump provides an MES product called HighJump Manufacturing Advantage. It bridges the disconnect between MES and warehouse management systems (WMS), enabling optimal inventory flow throughout the shop floor. The HighJump manufacturing execution system also provides a flexible and adaptable system architecture. Honeywell Process Solutions Honeywell Process Solutions is a unit of Honeywell International’s Automation and Control Solutions business. The CEO of the unit is Norm Gilsdorf. With offices in more than 100 countries, HPS serves a range of industries, including refining, oil and gas, pulp, paper and printing, power generation, chemicals and petrochemicals, life sciences, metals, minerals,

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CDC had 2009 revenues of $204 million, and is headed by CEO Peter Yip. The company delivers industry-specific solutions to 10,000 customers worldwide in the manufacturing, food and beverage, business services, distribution, transportation, retail, government, real estate, financial services, healthcare, and notfor-profit industries.

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iBASEt iBASEt has been a leading provider of hightech software products and services since 1986. iBASEt’s MES product is called Solumina. The software is an Operations Process Management suite that manages work and quality processes for the manufacturing and maintenance, repair, and overhaul of highly engineered products. Solumina functional modules include process planning, MES and operations management, quality management, and supplier quality assurance in one integrated system. The company’s CEO is Ladeira Poonian. Intercim Founded in 1983, Intercim, headed by CEO John Todd, supports more than 100,000 users worldwide in a number of fields, mainly advanced and highly regulated industries. In 2009, Dassault Systèmes took a minority position in Intercim. Both companies believe

in real-time information exchange and collaboration between engineering, manufacturing, and the supply network. As a result of the combination, Intercim’s MES software product, Pertinence Suite powered by Velocity, bridges the gap between product design and the supply chain. Pertinence Suite supports Lean, Six Sigma, and other process initiatives. From simplified process planning and advanced predictive analysis to best-in-industry process execution and quality management, Pertinence Suite is designed to help manufacturers reach their operational goals.

Foxboro, IMServ, InFusion, SimSci-Esscor, Skelta, Triconex, and Wonderware. Manufacturing Execution Module is the latest MES release. The software is offered in two levels of functionality. Operations -- Standard provides basic MES functionality such as electronic work orders, specifications, bills of material (BOM), product traceability, and genealogy. Operations-- Premium provides all of the Operations Standard functionality plus inventory control, certifications, steps/procedures, and labor tracking. A new addition to Operations and Performance Software 4.0 is the MES Client, an ArchestrA Toolkit-based front end.

Invensys Invensys PLC formed Invensys Operations Management in 2009, when it merged six long-standing branded product groups into a single unit focused on meeting the manufacturing industry’s need for comprehensive, real-time operations management solutions. Today, Invensys Operations Management, led by President and CEO Sudipta Bhattacharya, is a provider of automation and information technology, systems, software solutions, services, and consulting to the global manufacturing and infrastructure industries. The company’s products are used by more than 40,000 clients around the world in more than 200,000 plants and facilities. Invensys Operations Management’s offerings are delivered under several prominent industry brands, including Avantis, Eurotherm,

MPDV Mikrolab GmbH MPDV is a leading software provider specializing in recording and processing company data in the areas of production, human resources, and quality management. MPDV’s core MES product is HYDRA. Through HYDRA, MPDV provides a method for increasing economic efficiency in manufacturing plants. MPDV also produces the xMES product family, which provides SAP users or those using its tools with a wide range of MES functionality based directly on SAP AG’s Composite Application MII. The xMES line offers machine interfaces, collection functions, and modules for shop-floor data collection, machine data collection, and process data collection, as well as information systems and information portals. The company’s CEO is Jürgen Kletti.

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and mining. The company employs more than 10,000 people and has installed over 28,000 systems at more than 7,500 sites since 1974. Honeywell’s portfolio of collaborative MES products offers critical real-time performance, business processes, and operations management for process manufacturing industries. The products support virtualization environments to improve total cost of ownership and offer improved business process modeling capabilities.

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Vendor Profiles Parsec Automation Parsec Automation, led by President and CEO Eddy Azad, is focused on helping companies rapidly improve the productivity of their factories. Parsec does this by providing TrakSYS, an advanced and scalable manufacturingproductivity management software application suite. TrakSYS is an extensible MES application that is designed to aid lean, Six Sigma, TPM, and operational excellence efforts for companies in many industries, including automotive, chemicals, consumer products, construction materials, electronics, food and beverage, metals, mining, packaging, pharmaceuticals, paper products, textiles, utilities/energy, and wood products. Performix Performix, founded in 2005, develops products for the batch process manufacturing industry. Sham Afzalpurkar is Performix’s CEO. The company’s suite of composite software applications, Performix xMES, is designed to leverage SAP technology and manufacturing system infrastructure. Performix serves the chemical, consumer products, food and beverage, and pharmaceutical industries. Performix’ xMES Suite is used by Dow Corning and several leading pharmaceutical companies.

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Plex Systems Since 1995, Plex has been a provider of online software for the manufacturing enterprise and

is the developer of Plex Online, an SaaS-based product. Its integrated, on-demand software has resulted in a near 100% customer retention and solution implementation success rate. Plex Systems serves a global cross-section of manufacturing industries (OEMs and suppliers), particularly automotive, medicaldevice, food and beverage, and aerospace and defense companies. Plex Online offers features for virtually every department within a manufacturing company, including manufacturing operations management and quality management systems for the shop floor, customer relationship management for sales and marketing, supply chain management for procurement, and enterprise resource planning for finance and management. Plex Online’s integrated model delivers a “shop floor to top floor” view of a manufacturer’s operations. Plex Systems, headed by CEO Mark Symonds, is a privately held company. In 2009, recurring revenue grew 31% over 2008, and total revenue grew 14%. Oracle Oracle’s MES offerings are modular, open, and integrated solutions that provide a structured and standards-based shop-floor execution toolset. They include the capabilities needed to execute, record, and monitor shop-floor activities in a highly efficient and effective real-time basis. Oracle serves 370,000 customers globally

across a wide range of industries, including aerospace and defense, communications, engineering and construction, financial services, health sciences, insurance, oil and gas, retail, tax, and utilities. Founded in 1977, Oracle’s annual revenue for fiscal year 2010 was $26.8 billion. Oracle’s CEO is Lawrence J. Ellison. Rockwell Automation Rockwell Automation, headed by CEO Keith Nosbusch, is a $4.3 billion company with 19,000 employees and an extensive partner network. FactoryTalk ProductionCentre is Rockwell Automation’s MES offering. FactoryTalk integrates quality management and business analytics with paperless shop floor and repair execution. This integrated product improves operational efficiencies while ensuring regulatory compliance and the highest levels of quality. SAP AG Headquartered in Walldorf, Germany, SAP is the world’s largest business software company. Founded in 1972, SAP’s 2009 revenues were more than €10.6 billion. The company has more than 95,000 customers in over 120 countries. Bill McDermott and Jim Hagemann Snabe are co-CEOs. SAP Manufacturing Execution (SAP ME) is an enterprise-level, scalable manufacturing business product that enables global manufacturers to manage and control manufactur-

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ing and shop floor operations. It provides a multi-faceted set of functions that integrate business systems to the shop floor, allowing for complete component and material-level visibility for single and global installations. SAP ME collects data from multiple sources, integrating data systems with shop-floor activities to create one comprehensive production record. The result is an aggregate record of the entire product history, stored and available for effective key decision-making and for meeting compliance requirements. SAP ME was added to the SAP Product Portfolio for Manufacturing with the acquisition of Visiprise in 2008. Since the acquisition, SAP continues to invest in technology and functional enhancements adhering to SAP Product Standards, including the introduction of SAP xMII, which it bills as the world’s first Manufacturing Intelligence Portal. Schneider Electric As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers a variety of power management and automation products in sectors such as energy and infrastructure, industrial processes, building automation, and data centers/networks, as well as a broad presence in residential applications. Focused on making energy safe, reliable, and efficient, the company’s 100,000-plus employees achieved sales of more than $22 billion in 2009. Schneider Electric’s MES software, Ampla,

empowers businesses to reduce costs and improve production efficiency, performance, and profitability. Ampla’s energy module supports the identification and tracking of energy overconsumption based upon production context. Ampla is used to identify bottlenecks, analyze production downtime causes, calculate key performance indicators, manage WIP inventory, track the real costs of production, and manage other important operational performance issues. Ampla supports continuous improvement projects to achieve operational excellence. Siemens MES Siemens, founded in 1847, is a global leader in electronics and electrical engineering, and operates in the industry, energy, and healthcare sectors. With 405,000 employees in 190 countries, Siemens reported worldwide revenue of $104.3 billion in fiscal 2009. Siemens in the USA reported sales of $21.3 billion in the U.S. and employs more than 60,000 people throughout all 50 states and Puerto Rico. SIMATIC IT, Siemens’ MES product, allows companies to implement a cross-plant technological solution for enforcing value-driven strategies on the one hand and performance measures on the other. SIMATIC IT, with its open architecture, offers the collaboration and integration technologies that allow manufacturers to couple disparate systems, support distributed manufacturing operations, and connect manufacturing operations

with the rest of the enterprise. Werum Software & Systems Werum is a leading supplier of MES for the pharmaceutical and biopharmaceutical industries. Founded in 1969, the company employs more than 400 people at its headquarters in Lüneburg, Germany, and at eight other locations in Germany, France, the U.S., Japan, and Singapore. Hartmut Krome is President of Werum America Inc., and Chairman of the Executive Board of Werum Software & Systems. Werum’s MES software product is called PAS-X. It is installed at 16 of the world’s top 30 pharmaceutical and biotech companies, and runs in more than 500 installations around the globe. Werum provides integrated and ready-to-be-validated MES packages. ❑

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Footnotes Manufacturing Execution Systems Buyer’s Guide 1. Löhn, Johann. “Government Commissioner for Technology Transfer, Baden-Wurtemberg, Germany,” in the Foreword to Manufacturing Execution System—MES. Jürgen Kletti, Springer Publishing, Inc., June 27, 2007.

15. Ibid, slide 3.

2. ibid, VI.

16. ibid, slide 4.

3. Cole, Brenda. “Interest in Manufacturing 2.0 MES Software Persists Despite Recession,” SearchManufacturingERP.com, May 27, 2010.

17. Stratus Technologies. ibid, p. 4.

4. Managing Automation. http://www.managingautomation.com/enterprise-software/manufacturing-executionsystems.

19. Cole, Brenda. ibid.

6. Unger, Keith. “Manufacturers’ Needs Not Changing but Acronyms Are,” InTech, Oct. 3, 2001.

18. Wildeman, Roy C. ibid, slide 5.

20. Bassert, Edward, “Evaluating Your Need for an MES Upgrade,” SearchManufacturingERP.com, April 8, 2010. 21. ERP software blog. http://www.erpsoftwareblog. com/2010/06/4-questions-to-ask-to-lower-the-cost-ofaccounting-software-user-licenses. 22. Bassert, Edward. ibid.

7. Flakol, Rita. “MES vs. ERP: Is It All in the Jargon?” Manufacturing & Logistics IT, Nov. 28, 2008. 8. ibid. 9. Khosrow-Puor, Mehdi. Emerging Trends and Challenges in Information Technology Management. Idea Group, Inc., 2006, p. 865. 10. Stratus Technologies. “Manufacturing IT Infrastructure: Ready or Not for MES?” White Paper, October 2006, p. 3.

23. Wildeman, Roy C. ibid, slide 7. 24. Herbert, Liz. “Liz Herbert’s Blog for Sourcing and Vendor Management Professionals,” Forrester.com, June 7, 2010. 25. Global CyberSoft. “Effective Manufacturing With Integrated ERP and MES Solutions,” May 14, 2008. 26. Kletti, Jürgen. ibid, p. 259. 27. ibid, p. 260-262.

11. ibid. 12. The Association of German Engineers (VDI), VDI Guideline 5600.

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13. Stratus Technologies, ibid, p. 4. 14. Wildeman, Roy C. “Manufacturing Execution Systems

28. Knight, Jason and Lamb, Susan. “Selecting and Using a Manufacturing Execution System,” MDDI, October 2006.

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5. Kletti, Jürgen. Manufacturing Execution System—MES. Springer Publishing, Inc., June 27, 2007, p. 13.

(MES) Strategy Update: Must-Know Trends,” SearchManufacturingERP.com Webcast, April 26, 2010, slide 2.

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Managing Automation Media Research Services (MAM Research Services) is the market and buyer research arm of Managing Automation Media, which publishes Managing Automation, Manufacturing Executive, and the TechMatch technology product database, and produces the Manufacturing Leadership Summit conference. Managing Automation Media is a unit of Thomas Publishing Company, LLC of New York. MAM Research Services specializes in a variety of custom research and publishing products, including custom publishing supplements, manufacturing market surveys, and buyer’s guides.

Important Note Concerning This Buyer’s Guide This Buyer’s Guide is solely intended to provide information to help buyers in their understanding and navigation of the purchase process associated with particular technologies. Publisher makes no claim and does not warrant that the Buyer’s Guide is fully inclusive or comprehensive in its discussion of market trends, purchase process factors, or in the selected representation of vendors and their products, nor does the Publisher claim or warrant that use of the Buyer’s Guide will result in a successful purchase process outcome. Publisher advises users of this Buyer’s Guide to conduct their own due diligence process in the selection of any technology, and to use or engage other sources of information or counsel in that process where appropriate.

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