Glossary of Manufacturing Terms
One of the most widely used definitions of advanced manufacturing involves the use of technology to improve products and/or processes, with the relevant technology being described as “advanced,” “innovative,” or “cutting edge.” For example, one organisation defines advanced manufacturing as industries that “increasingly integrate new innovative technologies in both products and processes. Examples include processes within Medical Device and Aerospace manufacturing.
An Application Programming Interface is an interface that is used by one application program to communicate with programs of other systems. ERP vendors provide API’s for integrating other applications with their ERP systems.
ArchestrA is an Invensys Wonderware comprehensive automation and information software architecture designed to integrate systems by leveraging the latest, open industry standards and software technologies, this can also help and extend the life of legacy systems. ArchestrA ‘industrialises’ Microsoft .NET and other Microsoft technologies in order to provide an even more productive toolset for building critical operations management software solutions for manufacturing, production and facilities operations. The result exposes services needed by manufacturing and industrial infrastructure such as common name space, object management, industrial security, high availability and redundancy, plant connection, enterprise connection, client interface, web portal and systems management. Utilizing ArchestrA technology, applications can be rapidly assembled using software objects rather than being “programmed”. Templates can be created for almost any purpose then used to build new applications simply through the reassembly and slight modification of these templates – saving time and lowering development costs.
Is the quality management standard specifically written for the aerospace industry.The current version of AS9100 aligns the standard with ISO 9001:2008 and has extra requirements regarding Regulatory Compliance and aerospace-sector specific requirements.
Thousands of customers rely on batch management software solutions to perform repeatable and consistent execution of batching processes across all industries. This can be as electronic batch records (EBR) system in regulated industries, paperless operated production environments or automated recipe management for supervisory systems. Batch management usually complies with the ISA 88 (S88) standard.
BOM (Bills of Material)
A list of the materials and quantities that will be required to manufacture something, the term spans all industrial sectors and is an operational stage at the interface between ERP and MES.
‘Bolt-on’ is a colloquial term for a software application that performs specific tasks and that interfaces with an ERP system. Examples of bolt-on’s that interface between Internet solutions and ERP systems include Manufacturing Execution Systems and Warehouse Management Systems. (See “MES” and “WMS”.) A bolt-on implies that the software is modular and can be readily integrated to another core piece of software or more currently to a unified platform (one that has core functionality that underpins many modules or ‘bolt-ons’)
A Corrective & Preventative Action tracking software system is the crux of any quality system. It is a regulatory requirement that FDA / global regulatory inspectors and ISO auditors consider critical. When implemented properly, a Corrective Action (CAPA) software system improves product quality and safety, increases customer satisfaction, and more importantly, ensures FDA and ISO compliance.
Continuous improvement is an ongoing effort to improve products, services, or processes. These efforts can seek "incremental" improvement over time or "breakthrough" improvement all at once, it is recommended to plan incrementally as benefits from a first stage can fund subsequent stages. Processes are constantly evaluated and improved in the light of their efficiency, effectiveness and flexibility.
Continuous improvement is sometimes seen as part of the 'system' whereby feedback from the process and customer are evaluated against organisational goals. The fact that it can be called a management process does not mean that it needs to be executed by 'management'; but rather merely that it makes decisions about the implementation of the delivery process and the design of the delivery process itself.
Condition monitoring or condition-based maintenance is a combination of advanced technologies designed to increase the effectiveness of production assets with minimum costs by monitoring the condition of plant. CM utilises techniques such as vibration sensing, thermal imaging and oil analysis to detect faults and pinpoint potential failures before they cause unplanned downtime.
Modular software packages that track maintenance, prioritise tasks, assign work based on the availability of necessary parts and labour and analyse equipment failures in order to implement appropriate preventive maintenance measures. CMMS provides fully-featured document management capabilities that streamline maintenance and regulatory functions with sophisticated workflow capabilities that help organisations synchronise their entire operation.
An EmsPT work method which provides customers with an extensive range of services and products enabling them to reach their manufacturing performance goals. The Programme is made up of five stages: D – Discover
, R - Return on Investment
, I – Implementation
, V – Value
, E - Enable and Evaluate.
DRIVE starts with our initial visit and involves staying engaged until the customer sees beneficial value and is making sustainable gains in manufacturing performance. DRIVE is a field proven methodology that maximises the value of investments.
Enterprise Resource Planning represents the current evolution of manufacturing resources planning systems (see “MRP”). ERP is being positioned as the foundation and integration of enterprise-wide information systems. Such systems will link together all of a company’s operations including human resources, finance, manufacturing and distribution, as well as connect the organisation to its customers and suppliers.
Finite Capacity Scheduling
Finite Capacity Scheduling is a feature of automated scheduling software that takes into account that resources are not unlimited. Automated scheduling means that complex ‘what if’ scenarios can be modelled, assisting in continuous improvement and schedule adherence. Automated scheduling is usually also designed for integration with other software such as ERP, MES, Data collection, Forecasting, Demand Planning and OEE applications. In manufacturing, finite capacity scheduling is an approach to understanding how much work can be produced in a certain time period, taking limitations on different resources into consideration. The goal of finite capacity scheduling is to ensure that work proceeds at an even and efficient pace throughout the plant. Software applications for determining the best way to schedule work are called 'decision support tools.' Finite scheduling tools contrast with infinite capacity scheduling tools. Infinite scheduling tools, which are simpler, cannot account for limitations on systems that occur in real time.
Good Automated Manufacturing Practice (GAMP) is both a technical subcommittee of the International Society for Pharmaceutical Engineering (ISPE) and a set of guidelines for manufacturers and users of automated systems in the pharmaceutical industry. The Good Automated Manufacturing Practice (GAMP) Guide for Validation of Automated Systems in Pharmaceutical Manufacture describes a set of principles and procedures that help ensure that pharmaceutical products have the required quality. One of the core principles of GAMP is that quality cannot be tested into a batch of product but must be built into each stage of the manufacturing process. As a result, GAMP covers all aspects of production; from the raw materials, facility and equipment to the training and hygiene of staff. Standard operating procedures (SOPs) are essential for processes that can affect the quality of the finished product. See also Batch Management
A term used alternatively for traceability, this is frequently confused with tracking. The requirement for manufacturing traceability is driven both by regulation and by business risk strategies. Genealogy (or traceability) is a record of what, who, when etc that is accrued preferably automatically during a manufacturing process (usually by batches). The record can be accessed quickly (immediately in some cases) and allow ‘internal recalls’ to be implemented e.g. when an incorrect mix has taken place, or some form of contamination has been detected. If an external recall is experienced then genealogy/ traceability records will identify the lowest possible safe recall, mainly owing to its fine resolution data.
ANSI/ISA-95, or ISA-95 as it is more commonly referred, is an international standard for developing an automated interface between enterprise and control systems. This standard has been developed for global manufacturers. It was developed to be applied in all industries, and in all sorts of processes, such as batch processes (see S88), continuous and repetitive processes. The objectives of ISA-95 are to provide consistent terminology that is a foundation for supplier and manufacturer communications provide consistent information models, and to provide consistent operations models which is a foundation for clarifying application functionality and how information is to be used.
S88, shorthand for ANSI/ISA-88, is a standard addressing batch process control. It is a design philosophy for describing equipment, and procedures. It is not just a standard for software, it is equally applicable to manual processes. It was approved by the ISA in 1995 and updated in 2010. S88 provides a consistent set of standards and terminology for batch control and defines the physical model, procedures, and recipes. The standard addresses the following challenges: lack of a universal model for batch control, difficulty in communicating user requirement, integration among batch automation suppliers, difficulty in batch control configuration
Lean is an improvement technique that has been broadly adopted by manufacturing and non-manufacturing businesses. Care must be taken in projecting long term sustainable benefits if a manufacturing organisation is reliant upon manual data collection and spreadsheet data processing. Beyond a certain point automatic data acquisition, automatic data processing and reporting will be not only beneficial but critical to ongoing sustained improvement.
Legacy systems are existing systems and technology, which often represent a considerable investment which may also be entrenched in the organisation; they are often critical systems which are unsupportable and hardware dependent. ‘legacy’ implies that they have been superseded by more efficient and supportable technology. Some systems have been in place for many years; some are considered old or inadequate technology; many are host based with terminal emulation. Customers may be trying to replace or merely update legacy systems. There are many techniques to overcome this from new hardware that has legacy characteristics, virtualisation and following investigation with demonstrable ROI a complete root and branch replacement.
Manufacturing Execution Systems use network computing to automate production control and process automation. By downloading “recipes” and work schedules and uploading production results, MES bridge the gap between business and plant-floor or process control systems.
Manufacturing Operational Excellence
defines the "Rules of the Road" that can help you cut costs, increase cash flow and become more responsive to changing market conditions. Each of these "rules" can be accomplished with the implementation of an IT system for manufacturing operations excellence, commonly referred to as a Manufacturing Operations Management, or "MOM" system. This IT investment can be accomplished in phases to bring a quick return on investment, putting you in the fast lane for improved manufacturing operational excellence. See DRIVE
Maintenance, repair and operations are responsible within the manufacturing enterprise for maintaining and repairing plant. Traditionally seen as a cost centre to be targeted for budget cuts, modern predictive maintenance techniques such as condition monitoring (see “CM”) now mean MRO is increasingly viewed as an opportunity to maximise availability of production systems and so increase RONA.
Materials Requirements Planning covers the phases in the development of computerised methods for planning the use of company resources, including scheduling raw materials, vendors, production equipment and processes.
Mean time between failures (MTBF) is the predicted elapsed time between inherent failures of a system during operation. The MTBF is typically part of a model that assumes the failed system is immediately repaired (MTTR), as a part of a renewal process. This is in contrast to the mean time to failure (MTTF), which measures average time to failures with the modelling assumption that the failed system is not repaired (infinite repair rate). MTBF should be considered as a projection of likely failure, useful for component selection, but MTTR will directly affect downtime recovery (see OEE Availability). Terminal Services is frequently sold on the basis of reduced MTTR.
Open Database Connectivity is Microsoft’s strategy for open database interface. Part of the Windows Open Services Architecture (WOSA), ODBC makes it possible to access both relational and non-relational database management systems (DBMS) in a diverse PC environment where minicomputers are linked to a mainframe. Defined by the SQL Group, a standards group made up of database vendors.
Is the internationally recognised standard for occupational health and safety management systems. It gives you a framework to identify, control and reduce the risks associated with health and safety in your workplace.
On Time Delivery in Full, a key goal for customer satisfaction and one that is facilitated by integrating scheduling functions with shop floor manufacturing processes. High OEE will assist this, but schedule adherence will be critical.
Overall Equipment Effectiveness
is a single measure showing how much of a product has actually been produced as a percentage of how much could have been produced.It combines all the standard performance measures - including availability, performance and quality. It should be thought of as the top measure in a cascade of measures. 85% is thought to be world class (according to definition). OEE is a harsh measure so do not aim too high, better to use it as a measure of improvement rather than an absolute numerical goal. The OEE Calculation
= Availability% x Performance% x Quality%
The immediate availability of data to an information system as a transaction or event occurs. Typical examples are SCADA, HMI, Historians and associated reports, some SQC packages also run in real time.
SC21 (21st Century Supply Chains)
SC21 is a change programme designed by ADS (Aerospace, Defence and Space Group) to accelerate the competitiveness of the aerospace & defence industry by raising the performance of its supply chains. International competition, together with the challenges posed by the defence industrial strategy, necessitates rapid improvement in the effectiveness of our supply chains. At the same time, industry must ensure that it delivers competitive solutions for customers whilst maintaining profitable business growth. For more information please visit http://www.adsgroup.org.uk/
Supervisory Control and Data Acquisition is often blurred with HMI (Human Machine Interface). SCADA operates usually above the machine level, such as a line controller, and provides visualisation of the process through graphical displays and trend graphs, with alarm and event lists. SCADA is often augmented with an historian to provide time series compressed data storage for high fidelity recall, for example to assist in line commissioning and optimisation and to diagnose root fault cause.
Schedule Adherence is a key measure that is directly linked to customer satisfaction. Schedule adherence can be improved by integrating scheduling with the shop floor ‘reality’ making adherence achievable and schedules realistic.
Serialisation is to mark each product with its own unique identity, ideally this being scanned at a point or sale or a point of use. The scanned data typically being fed back to cloud-based solutions to verify that the product that has been sold (in particular been dispensed) is a legitimate product and not counterfeit.
A stock-keeping unit or SKU is a number or code used to identify each unique product or item for sale in a store or earlier in the supply chain. An SKU is a unique identifier for each distinct product and service that can be purchased. The usage of SKU is rooted in data management, enabling the company to systematically track its inventory or product availability, such as in warehouses and retail outlets. They are often assigned and serialized at the merchant level. Each SKU is attached to an item, variant, product line, bundle, service, fee, or attachment.
Successful inventory management systems assign a unique SKU for each product and also for its variants, such as different versions or models of product or different bundled packages including a number of related products.
Statistical process control (SPC) is the application of statistical methods to the monitoring and control of a process to ensure that it operates at its full potential to produce conforming product. Under SPC, a process behaves predictably to produce as much conforming product as possible with the least possible waste. While SPC has been applied most frequently to controlling manufacturing lines, it applies equally well to any process with a measurable output. Key tools in SPC are control charts, a focus on continuous improvement and designed experiments. Integration of a test laboratory with operations through SPC produces a very effective solution to conformant product with least waste. SPC and SQC are frequently interchangeably used. Purely speaking SPC is more about the process; SQC is more about product quality.
The use of information technology to give automated intelligence to a network of vendors, suppliers, manufacturers, distributors, retailers and a host of other trading partners. The goal is for each player in the supply chain to conduct business with the latest and best information from everyone else in the chain, guiding supply and demand into a more perfect balance. Effective management of the supply chain enables a company to move product from the point of origin to that of consumption in the least amount of time at the smallest cost.
Work In Progress is usually referred to as a negative as it implies inefficient use of cash. Reduction of WIP is a frequent goal for continuous improvement and lean manufacturing.
Warehouse Management Systems comprise software that integrates mechanical and human activities with an information system to effectively manage warehouse business processes and direct warehouse activities. These systems automate receiving, put away, picking and shipping in warehouses, and can prompt workers to carry out inventory cycle counts. Most support radio-frequency communications, allowing real-time data transfer between the system and warehouse personnel. Not to be confused with WCS (Warehouse Control Systems) which concern the automation systems within a warehouse.