Notes

--- About Q CELLS--------- Mr. Kenner and Ms. Pfeiffer------------
Q cells joint venture with Hanwha (korea).
Products – Solar Cells, Solar modules, solar power plants..

---------------Motivation ------------ From career point of view-----

- I am already worked in Korea for over 4.5 years , i have gained very good insights about the customers in korea and asisan region. Having worked in different sectors of manufacturing like Solar, electronics, Oil and Energy, Automotives. At this point of time i want to leverage that experience and bring it back to Germany.

-As to motivation to work for QCells- Having already worked in the Solar sector with solarworld, I attained very good understanding of solar manufacturing process and the MES involved with it. Q Cells also being the same sector, based out of Europe seems a positive option. And this is where I want to pursue my career..in the Renewable sector.
With Majority of my experience in Manufacturing and MES specifically, this particular role is very similar to what I am looking for.
- Having studied and worked in Germany before, I feel very comfortable settling back in German work environment. I can also speak the language so it makes life a lot easier.

---- From a personal perspective -----
- Me and wife plan to stay in Germany for probably the rest of our lives, we have been married for over 3 years now and we plan to raise a family ..and we plan to do that in Europe - Also that my wife can speak German we she is also quite familiar with German working style and culture..





















-------------Key Role in MES in Industrial automation --- Mr. Kenner and Ms. Pfeiffer-

➢ I have over 10.5 years of work experience.. I majority of my experience in System Integration of IT Services in Manufacturing Industry and Industrial automation in sectors like Oil and Energy , solar, Electronics, Telecom and Automotive . Currently I am working as Sr. MES Consultant/ MES Project Manager with Samsung ,handling a 15 team members

➢ I act as the interface or SPOC between project stakeholders, partners and Project engineering teams. This means a lot of cross collaboration with diff team members In diff. time zones

➢ As a MES Consultant and Project Manager - I am responsible to for end-to-end lifecycle of the project. I am responsible to handle not just one project at a time but multiple projects. My RESPONSIBILITIES include - conceptualization to REQUIREMENT ELICITATION phase, prioritizing the requirements ; Designing the product ; developing the solution ( by my development team) ; under strict QA guidelines and then going through different Testing stages with a particular focus on acceptance testing ; creating Product licensing strategies; Finally staging the product and releasing/rollout and deploying this product to different customer locations worldwide. creating a project plan , project reporting to the higher management particularly at VP , EVP level,

- I have a MESA certification for MES/MOM methodologies – So I consult the production sites and line managers about the “Best practices for MES” according to MESA and ISA-95 standards. eg: master data management best practices, Enterprise application integration (EAI) – like Interface centric, Model Centric and Data Centric , Industry standards like ISA-95, MIMOSA, SCOR (supply chain operations reference model)

- Any change request that happen or conflicts that happen , resolving those conflicts and reporting them. I also act as their ESCALATION MANAGERWhich involved travelling to several customers sites across Europe and Asia and South America regions

- I provide the customers TECHNICAL CONSULTANTION, I have to think from the customers perspective and see how it benefits them and i understand their needs- Consulting customers particularly on MES project, Integrating MES with Business Layer, CRM, Logistics, SCM and PLM typically SAP integration, EAI (Enterprise application intergratoin eg: Tibco, highway101), BPM and BRM. CIM and EES (Equipment engineeringsystem) applications

- Together with clients and partners Analyze business process and then consult improvement in manufacturing process – Enhance their existing product and architecture

- CONCEPTULIZE how the MES solution can implemented. Architecture Consulting, Requirement elicitation from the our global and local sites and implementing those changes


- PORTFOLIO EXPANSION-
One my important roles is to expand the samsung portfolio for MES, by looking at new potential industries like Steel and Rolling Mills, Solar industry and leverage the MES expertise of Samsung and Miracom products. Typically in Vertical Integration and Production Optimization ( eg : SPC, APC, Predictive maintainence etc..)

- Vertical integration of MES with ERP(SAP R3), SCM, CRM and PLM which follows strict compliance and open standards eg: B2MML using XML etc.. Equipment integration with - File based equipment interfaces and protocol based equipment interfaces (OPC, XML, Modbus, profibus... )

- SUPPORT
Proving 1st, 2nd and 3rd level support to our customers and different sites (Both Application level and Hardware level) . Resolving their issues and problems, or any new change requests that happen.
- Verifying the MES solution in-house (different types of testing) and then final deployment and commissioning of software. - Giving Demo, hold workshops, brainstorming sessions, One on One interviews wth stakeholders and clients /Introduction of MES to different production sites – which involved Organizing and structuring the teams, training, creating user manuals, administration guides etc.

STANDARDIZATION
- Business process optimization and standardization ,- Standardization of process across different production plants , Samsung has 28 sites running legacy systems, so the challenge is to transition from legacy system to new generic MES (HQ)which controls all the production sites

- Since I also have a technical background I am also involved in - Training the IT team / , releasing documents to Development teams, training manuals, coaching the Maintenance managers in the production line.

- Collaborating with multi-cultural teams across geographic locations, different Subject Matter Experts of different for administrator and production line engineers ,departments like Production team , planning teams, supply chain team, logistics and packaging team, Sales team getting their requirements and prioritizing them.

- Creating one harmonized multi-site, multi-country MES template that uses a consistent approach to MES that can be used across plants by using Business Process Management and Business Rules Engine.

- Solution Architect for Creating a generic MES template to Integrate the MES across different sites by defining certain best practices for the process and taking them from one project to another. Mainly focusing on re-usability of modules (Trying to move MES to cloud based MES, using concepts of big-data for MES, real time analytic etc.. )

-Analysis of requests and demands according P&I process . Business requirements specification and translation business requirements into application specifications

- Bring out new initiatives and develop concepts to use new technology for MES , create BUSINESS PROPOSALS and give them to clients for the MES solutions for standardization of MES(Eg: Cloud based MES , Smart Manufacturing, Virtualization, thin clients , Big data, real time analytics, CEP , In memory data gird, Business process, ESB, etc .. ),

- Created Generic/modular MES covering Quality Management, Labor management , Process Management , Product Tracking and Tracing , Data acquisition , Resource Management/Planning (recipes) ,Quality Management Performance analysis, Work In progress (WIP) , Material management Handing Production management , Production planning , Dispatching , Analysis reports (BI)

- EAI tools - Miracom Highway 101, Tibco Rendezvous, Webspere, worked with several db - oracle, MS SQL, Open source (Mysql, postgresql.. ) , NanoTrack MES solution, nanoRTS (Real time dispatching solution ) , nanoDCS (decision control system) which uses Korean product InnoRules (Business rules system)

---------------- WORK WITH MES VENDORS --------

- I have worked with several MES vendors like - Rockwell, Siemens , GE, CamLine... , Miracom MESplus, .Created of the MES from the scratch


------------- Standardization benefits of MES ----------

lowers cost of maintaining the IT systems,
Improving quality control ,
Improving better visibility to shop floor activities(Real-time) ,
faster product development and delivery to market ,
improving OEE , Better collaboration , standarization of reporting, reduces Total cost of owernship (TCO) by connecting users, content and enterprise applications
eg: reduce cycle time and receipt of good in SCM , Optimize on-time-delivery


--------Integration mechanism --------
- Interface centric - using EAI tools use SOA and ESB together or Manufacturing service bus with MDM
- Data centric approach - using ETL model
- Model centric - Using Business Process Management using Business Rules Modelling
Here services are developed rather than adapters, tools consists of registry/repository, orchestration or workflow tools, security, monitoring and lifecycle management for services
- Application centric approach – code is generated to establish point-to-point transfer of data between applicaions
-------

------------------QUESTIONS for QCells-----------------
- So how many production sites does Q Cells have ?
- How Does Q Cells integrate MES with ERP layer ? What ERP does Q Cells use (SAP, Navison etc ?)
- How is Q Cells MES team placed in reference with MES vendor which provides MES to Q Cells ? ( As in what’s the Q Cells MES team role ? )

----------------------------------------JOB DESCRIPTION -----------------------

Guide you through the design, development and maintenance of applications and systems of Manufacturing Execution Systems (MES).
You are responsible for the operation of complex systems, ensure availability and coordinate escalations.
You are responsible for the Endanwenderbetreuung in 2nd level support for software requirements and system support.
You perform complex requirements and systems analysis.
They analyze malfunctions existing applications and identify and eliminate problem areas.
You define automated system monitoring, emergency scenarios and replacement processes and implement them.
They advise internal clients in defining new requirements and have experience in implementing active with a.
You define, perform and monitor projects through to their successful conclusion.
You agree to participate in the scheme 24x7 readiness.High service orientation
Cooperation in intercultural teams
Quick learner, in particular an understanding of customer needs and possible solutions

You have successfully completed your degree in computer science and have several years of professional experience in information technology or production automation technology.
They could gain experience in project management and project management as well as international experience.
You are familiar with production and automation methods.
A systematic, analytical way of thinking draws you also like decision-making and communication skills.
They excel in goal orientation and team skills.
They dominate. NET development environments that standard MS Office applications and have good knowledge of SQL.
Familiarity with Camstar MES or other system is an advantage.
Fluent in German and good English skills in written and complete your profile





So I while working for Fujistu-Siemens , i was exposed to working on Camline for their Mainboard and SMD production lines in Augsburg. Later to Siemens SImatic for the automotive manufacturing plant which was Siemens VDO

Cameron GmbH – Rockwell PMX solution and GE Proficy . RS-PMX Connect MES ( Provides Interface for ERP systems and other systems like Document Management System (DMS) and LIMS. And RS PMX equipment management system

With SolarWorld – developed new customized MES from the scratch, Tibco/rdv

Samsung – Also customized MES, and Miracom MESPLUS, HighWay 101 and NanoTrack – AIMS system


Collaboration with meyer Berger group, Berger Lichttechnik group, Beckhoff, Siemens etc..

-- Figure out whats the availabilty of MES - availability reporting for last 12m, Downtime (time to repair or service down time ?) , Incident detection time, incident repair time, incident root cause analysis..

-- Non stop production - How --> 1. data caching (label printing, agent caching), 2.smart clients, 3. Horizontal communication btw equipments

INTEGRATION STEPS -

Business Assessment - Here a process centric approach is required to assess if some standardization of process is required across all enterprises. Here we try to establish the possible opportunities that exists within a organization where improvements can be made in the existing system

Business case development - Once the opportunities for improvement exists , i set the priorities and make a business case for implmenting a staged integration. This priorotization is ofcourse different for different companies

Implementation planning

Execution







SMD Manufacturing Process

1. (Surface Mount device )SMD Assembly Line - for mainboards for servers and different electronics components

1st Screening machine which has stencil in it which is carved on the bare PCB board. sorter paste is applied with sorter paste printer
2nd Vision system to detect any errors
3rd Pick and place machine or Assembly Machine [Lowerside of PCB]- where each compnents are put on the board automatically- these components are resistors, diodes, or integrated circuits
4th Reflow soldering [ lower side of PCB]
5th pick and place machine [ Upper side of PCB]
again a pick and place machine
6th inspection (automatic optical inspection)
7th reflowSoldering oven - each board having its own individual thermal profile
8th Automated visual inspection - camera checks for missing components with a Master Image and checks if the board is assembled correctly or not.
9. Automated THT(Through Hole Technology) assembly - larger components like capacitors and coils are assembled by hand using through hole technology
10. wave soldering under nitrogen env.
11. Optical inspection
12.Electrical test
230000 components per hour - with this speed we produce circuit board every 30 secs




MIRACOM SUITE - MODULES of MESPLUS

Basic Modules-
2. WIP Module – WIP, BOM, Inventory
3. EDC – Engineering data collection – collection of data for LOT processing
4. QCM – Quality Control management
5. SPC
6.FMB – Factory Monitoring Board
8. ALM – Alarm management system
9. Web Reporting
10. RTD (Real Time Dispatch)
11. ERP/APS Interface







Reference metrics
1. Supply chain responsiveness
2. Average days total inventory
3. Average days WIP inventory
4. Manufacturing cycle time
5. Average hours of overtime per week
6. Reducing the inventory costs
7. Reduce the cycle time









OEE = Availability x performance x quality