Notes

Zentral fuer New Technology. software company established for the last 30 yrs or so..
• Into Manufacturing
• ERP Intergration ( SAP netweavear)
• Travel
Services into –
• Factory Automation
• SAP services
• Software Development
• Training
Also partners with MES vendors like – Camstar, Miracom, CmNavigo,.
Znt- Industries – Automotive, Medical devices, solar, semiconductor,
znt self products - ZAC (znt automation components, zXitap for equipment integration , zspc )
znt works with 3 korean vendors - Miracom, Bistel and CSPI (scheduling, dispatching and forecasting.. )

---------------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. At this point of time i want to leverage that experience and bring it back to Germany

- Europe has big MES market also most companies want to expand to Asia. So I can bring a lot to the table for with my work experience of working in different cultures and work envirornment and especially in the MES sector for manufacturing.

- I had the chance to talk to with Mr.mayer already twice and after talking to him , I got a very positive feeling of the work and the company, After also looking to the znt portfolio via the website, I think znt has a very good standing as it shows that you have partnership and collaboration with several industry wide MES solution providers, Equipment integration providers.

- 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. Hans Mayer -------------
CEO : Jae Chool Lee Managing director : Mr.Min

- I have over 10.5 years of work experience with almost 80% of experience in the Manufacturing Industry and Industrial automation. In different sectors like Solar with Solarworld AG, Automotive , Electronics, Oil and Energy and bit of it Semiconductors- But mainly in discrete manufacturing.Majority exp in MES but also in Equipment integration and business layer intergration

- Currently I work as Sr. MES consultant / MES project manager and System Integrator with Samsung... I handle a team of 15 people ( its a group of multicultural people , distributed in diff geographic
locations..)

- 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. At times about SEMI standards SEMI-E54 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)

- My roles is , I am the project manager and Sr. Consultant for our MES system and any new requirements that come are implement by Software Dev Team. and then I am responsible for commissioning our MES throughout the global sites across the world. creating a project plan , project reporting to the higher management particularly at VP , EVP level, developing the project and then marshaling and handling the resource in my team, distributing the work
Any change request that happen or conflicts that happen , resolving those conflicts and reporting them. – Which involved travelling to several customers sites across Europe and Asia and South America regions
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 (Eg: Cloud based MES , Smart Manufacturing, Virtualization, thin clients , Big data, real time analytics, CEP , In memory data gird, Business process, ESB, etc .. ),

- I typically represent the customers , I have to think from the customers prespective 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 to improve the efficiency at the shop floor.

- CONCEPTULIZE how the MES solution can implemented. Architecture Consulting, Requirement elicitation from the our global and local sites and implementing those changes
- Interface or the SPOC between the customers and the Software Engineering teams and Partners. I also resolve their problems and conflicts, by understanding what they want to then routing these problems to the right department

- 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..)

- Consult manufacturing sites on Process control ( directed at monitoring, controlling, stabilizing and pursuing ways to improve the process) , Metrics ( )
- 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... )

- 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.

- 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

- 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.. )


---------------- 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 maintaning 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 recipet of good in SCM , Optimize on-time-dilevery


--------Integration mechanism --------
- Interface centeric - 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
-------
SPC - statistical Process control - infrastructure tool for Production control quality in
Semiconductor industry.
SPC allows you to predict tool trends like - when the machine is due for maintanence , tools wear

------------------QUESTIONS for ZNT-RICHTER -----------------
- Whats the business model with your partners like - camstar, bistel,miracom, cmnavigo etc...
and in which market ?

- Now that miracom is bought over by Samsung, how do you partner with miracom ?

- What the structure of team and company, who will be utilized?
- Does znt-richter has some training programs for different MES vendors

- How does Znt collaborate with its partners in delivering MES projects ?

- Whats the business model for ZNT ?

- What level of support is provided by ZNT 1st, 2nd or 3rd ?

- So here the thing, I am quite enthusiastic to join znt, looking at the vast profile you have..and very honestly I got a very positive feeling after talking couple of times with Mr.Mayer… So yes I would like to join as soon as possible , as I have to inform about my decision to Samsung by the end maximum 2nd week of August.. So lets say I would like to join by mid September.

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

You work for an IT consulting company and advise customers in the electronics, semiconductor, solar, medical and manufacturing industries, with the introduction of MES solutions (Manufacturing Execution System)

They are the "face to the customer", that is technical and commercial contacts

They act as an interface between internal software development and customer

Together with the client to analyze the business and manufacturing processes and develop a
concept for the implementation of an MES solution

The MES system is then implemented technically by your colleagues from the software development

Project management in the conceptual phase

Travel activities and presentations for customers in German and English

Further development of the company's "best practices" for MES


A degree / training or equivalent practical experience
Several years of professional experience as a consultant or project manager in MES, ERP, PLM or similar projects
Industry experience in the manufacturing industry
IT background and knowledge in the Manufacturing / Production / Manufacturing
Programming knowledge is not required
Willingness to travel nationally and internationally (Asia, USA)
High service orientation
Cooperation in intercultural teams
Quick learner, in particular an understanding of customer needs and possible solutions



http://www.madehow.com/Volume-1/Washing-Machine.html

http://www.ehow.com/how-does_5314525_television-manufacturing-process.html

http://www.ais-automation.com/eng/index.php?haupt=loesungen&klasse=1&klasseb=7&font=12&statum=

http://program-plc.blogspot.kr/2012/01/difference-between-opc-and-modbus.html

Read about Advanced process control
MES integration with ERP and Equipments

http://www.google.com/imgres?imgurl=http://www.chinup.com.tw/images/index/standard-solar-module-manufacturing-process.jpg&imgrefurl=http://www.chinup.com.tw/products/crystalline-silicon-solar-cells.htm&h=387&w=500&sz=49&tbnid=nZbWU9qJ14lHxM:&tbnh=90&tbnw

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 (NanoTrack MES, NanoDSP(decision support system)-dispatching solution, nanoRTS - real time scheduler


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

http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/oem-ap059_-en-p.pdf

Virtualization -- Read this --> http://www.ab.com/onecontact/process/whitepaper/get/PROCES-WP007A-EN-P.pdf

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 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

1. Basic Module -
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.

QUESTIONS from work perspective
- Is ZNT into Process manufacturing as well?
- So I understand if I’m in Munich the travel is about 50% and if in Dresden then its 40%. So its not a substantial decrease in travelling.
- If its okay to ask who all are your clients ?
- So how do you differentiate which
- So Mr. Mayer told me that for over 20% there is provision for company car, so what’s the expected distance which employees travel with car ? like from Munich to Augsburg etc. ?

Questions for Financial Perspective
1. Salary 70 K
2. Relocation package – 2 Flight tickets and Moving cost (3000 E)
3. Is there any provision which ZNT can providing some temporary accommodation to for 7-8 days so that I can find a house hunting



Consulting customers on Hardware datacenter where MES solution is hosted.
Which includes SLA negotiation , finding the right hardware resources, Availability MTBF