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Grischa Götzke - IT Projects & Consulting

Terms

APS:

Advanced Planning System

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PDA:

Production Data Acquisition

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EAI:

Enterprise Application Integration

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ERP:

Enterprise Resource Planning

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PCC:

Production Control Centre more ...

MDC:

Mobile Data Capturing more ...

MDA:

Machine Data Acquisition more ...

MES:

Manufacturing Execution System

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PPC:

Production Planning and Control more ...

Staff Work Time Logging System:

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TMS:

Transport Management System more ...

WMS:

Warehouse Management System
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Access Control System:

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Please note:

The following very short explanations of the abbreviations and terms used in this website shall act for a better understanding of the content of this website only. These explanations do not represent official definitions and official definitions should not be replaced by these explanations. To not go beyond the scope of the website the explanations do not claim of being complete.

ERP: Enterprise Resource Planning

An ERP-system supports resource management and resource planning of enterprises. Thereby different business processes will be reproduced in different function groups like for instance Master Data, Sales, Purchasing, Materials Management, Production, Finance, Accounting, etc. A main task during an implementation of an ERP-system in a company is always to map the business processes of the company to their representation in the ERP-system. This will be done on one hand by adaptation of the business processes to the ERP-system and on the other hand by adaptation of the ERP-system to the business processes. The traditional ERP-systems are mainly focused on the company itself whereby new ERP II systems are more focused on additional support of cross-company processes. To these belong for instance modules like CRM (Customer Relationship Management), SCM (Supply Chain Management) or E-Procurement. The best technical bases for ERP II functionalities provide modern web-based service oriented architectures (SOA).

PPC: Production Planning and Control

Production Planning plans orders and material against available capacities / resources. Earliest and latest date for production order processing will be calculated and it will be checked if the needed capacities / resources will be available in time. The sequences how the production orders will be processed on the different resources (usually work stations or machines) will be calculated. The sequencing and scheduling can also be made often with better results by a PCC or an APS.

Production control releases the planned production orders to the production level and monitors quantities, dates and quality on processing. In case of deviations appropriate steps to ensure these parameters will be initiated. For monitoring the data which were delivered by PDA systems will be analyzed.

A PPC system is a software system supporting production planning and control often as a part of an ERP system.

APS: Advanced Planning System

Advanced planning systems (APS) support production planning in ERP-systems as per MRP II (Manufacturing Resources Planning) whereby traditional ERP-systems in general are planning standalone as per MRP (Material Requirement Planning). An APS does not consider one main resource as for instance the workstation only but it considers all required resources as for instance also materials, staff, tools, areas etc. The scheduling of the orders considers finite capacities whereby the scheduling of the orders as per MRP assumes infinite capacities. An APS has functionalities for simulations to be able to consider different boundary conditions. Another advantage of an APS, for instance in comparison to the detailed planning in a production control centre, is the fact that the planning will be processed on the data of the ERP system directly. So the results of the detailed planning are immediately available in the ERP system. The results can be represented in graphics similar to the representation in production control centres.

MES: Manufacturing Execution System

A MES is defined as an overall system which contains systems which are placed below an ERP system and which are directly connected to the production level. These are traditional systems for production control like for instance PDA-, MDA- or MDC but also for instance systems for quality assurance QA or process monitoring. Manufacturing execution systems have to meet special requirements regarding availability and performance due to the closeness to the production level. Which components are indeed included in a MES is different from supplier to supplier.

PCC: Production Control Centre

The key part of a production control centre is an electronic wall chart which will be displayed as a Gantt chart. The occupation of the resources (usually work stations) by scheduled activities (usually operations) will be displayed over the time axis. It is possible to schedule and reschedule the activities interactively using drag and drop operations on the electronic Gantt chart. But a production control centre provides also functionalities for automated scheduling whilst taking different disposition rules into account. There are different operations available in a production control centre to be able to resolve conflicts and to optimize processes. Such operations are for instance to split or to consolidate activities / operations. Beside of the detailed planning a production control centre supports monitoring and controlling of the running production. The production control centre receives to-be data from a higher-level production planning and control system (PPC) and confirms actual data back to the PPC system. The actual data will be captured within the production control centre directly or will be delivered by a lower-level PDA system.

PDA: Production Data Acquisition

Production Data Acquisition includes the collection of a wide range of production data like:

Order related data like

Conditions of orders, operations and activities

Actual data like times, duration and quantities

Order related quality data

Staff related data like

Attendance and absence times including reasons for absence

Data to calculate performance-linked payments

data for access control

Machine related data like

Actual data like running time and processed quantities

Interruptions and disturbances

Data for maintenance and repair

Consumptions and tool data

Process related data like

Process related quality data

Parameters and settings

During collection of the production data the data will be checked for plausibility and in case appropriate steps to ensure plausibility will be processed.

Production Data Acquisition can take place by entering the data for instance directly into a PPC system (Production Planning and Control system) or by capturing the data using a PDA subsystem.

If a PDA subsystem will be used this system ensures the plausibility of the data. Furthermore this system should ensure the ability of the terminals to work in offline mode too. In case of a failure of one or more components of the overall system (network, database, application server, etc) it should be still possible to capture the data on the terminals. The captured data will be (normally multi-stage) buffered in this case and if all components of the overall system are up and running again the buffered data will be transferred to the higher level system automatically.

The captured data will be preprocessed by the PDA system and then transferred to one or more higher level system or systems.

In the recent years more and more industrial PC’s with software terminals are taking over the functions of the traditional hardware terminals. As a result of this a lot of new functionalities are possible on the front ends as for instance the display of drawings and pictures related to the current operation or the comfortable display of the operation schedule. Hereby the related data will be distributed by the PDA system to the front ends.

MDC: Mobile Data Capturing

Mobile data capturing is part of production data acquisition, whereby the data will be captured using mobile devices. The mobile devices can be connected to the PDA system via WLAN online or via docking stations.

MDA: Machine Data Acquisition

Machine data acquisition captures machine related data. For that often the machines are directly connected to the MDA system for instance via encoders on the machines and I/O cards or via PLC (programmable logic controller). Data regarding condition and status of the machines like for instance stoppages and malfunctions as well as production data like for instance produced quantity per time will be captured. By making the relation of the machine data to the related order it is possible to automate the collection of order related actual data.

Staff Work Time Logging System

Systems for staff work time logging capture attendance and absence times. For absence times the reasons for absence will be captured too. Captured arrive and leave events will be processed by a so called staff work time calculation. The staff work time calculation calculates among others different acquisition types and accounts for example for working time, vacation, overtime or flexitime. The staff work time calculation will be processed by the staff work time logging system itself or by a higher level ERP system. For the calculation it is necessary to collect and manage personal master data. Furthermore the calculation has to be able to work flexible with different working time models. The so calculated data can among others also be a basis for payroll and salary accounting. By combination of the personal data and the production order data of a PDA system also data for efficiency pay accounting can be calculated.

Access Control System

Access control systems control access authorization for persons in space and time. The identification of the person takes place on an access terminal for instance using a contactless badge. The identification can be optional completed by PIN entry or a biometric access control like for instance fingerprint, iris-scan or biometric facial recognition. Access will be enabled if the person is identified and according to the stored access authorization data for this person the person is allowed to enter the controlled room at the given time.

There are different additional methods to improve security like for example monitoring how long doors are open or four eyes access, meaning only two persons together can enable the access.

On the other hand it is often required to define periods of time where an access has always to be enabled (so called door-open-profiles).

WMS: Warehouse Management System

The core functionalities of a WMS control and monitor operational processes in warehouses and distribution centres. Main functions are for instance

Master data maintenance for instance for
locations, location areas, gates, workstations and printers, SKUs, product groups, packing configurations, packing materials and load carriers, addresses, suppliers, customers, ...

Inbound
Receiving, receiving inspection, storage under consideration of different put away rules, ...

Inventory management
Inventory movements, inventory adjustments, permanent inventory and cyclic stocktaking, ...

Outbound
Allocation of inventory according to existing outbound orders (FIFO), shipment consolidation, picking, packing or repacking, printing of shipping documents and labels, loading, shipping, …

In addition to the main functions further functions will be supported in different WMS with varying severity like for instance move task optimization, fixed and dynamic pick faces with replenishment, ABC classification, batch and lot management, expiry date monitoring, serial number capturing and serial number maintenance, KPI reporting, reporting, yard management and dock management.

MWS can work stand alone but in many cases WMS are connected with an ERP system on one side and with a TMS or directly with the carrier systems on the other side. The integration will be often implemented via an EAI system.

TMS: Transport Management System

A TMS provides among others different functionalities to support the following processes

Transport planning

Consolidation of deliveries and calculation of required transport capacities

Determining the transport mode (e.g. road, sea, air / parcel, indirect or direct delivery)

Carrier selection

Calculation and optimization of transport routes

Traceability

Capturing of the different statuses of transports, shipments and deliveries

Providing status information of the deliveries to the customer

Accounting

Carrier accounting

Monitoring of quality figures and KPI reporting

Integration

EDI with ERP and/or WMS as well as the systems of the carriers

EAI: Enterprise Application Integration

EAI-systems control as middleware the communication and so the integration of different, separate enterprise applications. EAI-systems control and monitor the data transmission between the systems, convert the data into the expected formats of each of the connected systems and react on events. Due to their flexibility often also parts of the business logic will be implemented in the EAI-systems to adapt the business processes without adapting the related enterprise systems.