May 2007
By John Dudenas, MES project manager, SCA Tissue North America
SCA Tissue North America is in the process of implementing a proprietary manufacturing software solution in all of its facilities. This software is called the Mill Execution System (MES) and was originally designed for use in the Barton, AL, facility, but has since expanded to a total of five SCA sites.
Prior to the implementation of MES, many of the SCA sites had individual methods and systems for tracking production and inventories. The MES is an attempt to standardize on one system that manages our production, integrates our automation and manages all of our inventories -- wastepaper, raw materials and finished goods.
While SCA had implemented an SAP enterprise resource planning (ERP) system, other functionality was required. Additionally, we needed shop-floor software that could interface with both the ERP system and the many automated systems within the facilities. SCA chose to develop the proprietary MES software with a scope ranging from raw materials through papermaking and converting to warehousing and distribution. SCA has partnered with Boxworks Technologies to develop and implement the solution.
Far-reaching functionality
All MES sites are equipped with a wireless network that provides access to the MES. All materials handling units, paper machines and converting machines are equipped with wireless computers and scanners. The IT architecture is primarily composed of the SAP ERP system and our proprietary MES, while the hardware is comprised of Intel servers running LINUX.
The following are some specific functions of the MES:
Trailer tracking: The tractors that move trailers internally and the SCA guard locations are equipped with wireless equipment to run the MES software. The MES tracks all incoming and outgoing trailers at the facilities. The system can also provide information about trailer location, contents, condition and duration of stay.
Waste paper: The MES tracks all waste paper from receipt through consumption.
Paper machine: The MES is used in the papermaking process to track quality parameters against design specifications. It also tracks production and manages inventory.
Warehouse management: All materials handling units are equipped with wireless computers that operate the MES software. All inventory is now managed in one system. The system provides standard procedures for managing warehouse locations, delivering materials to machines and cycle counting inventory.
Converting: Each converting machine is equipped with a computer that runs the MES software to track production, record quality and downtime information and issue materials.
Shipping and receiving: The system provides a consistent method to ship and receive paper and finished goods between SCA sites and to our customers. All work can be completed directly from the materials handling unit. Drivers are directed where to store and retrieve inventory throughout the shipping and receiving processes.
Materials tracking: The system provides the ability to track paper and vital supplies throughout the manufacturing process and ultimately to the customer.
Automation interfaces: The SCA sites are equipped with varying levels of automation. In some facilities, MES acts as the central application linking palletizers, conveyors, automatic guided vehicles and automatic storage and retrieval systems.
System benefits and beyond
Currently installed at five facilities, the MES has proven to be a highly configurable system that is uniform across all sites yet flexible enough to meet the unique needs of each facility. Some of its benefits are:
- More accurate inventory because transactions happen in real time with wireless technology and bar code technology
- Real time paperless production reports for issue logging, quality adherence, better efficiency and downtime information
- Trackability and recall ability of all components from receiving through shipping
- Improved warehouse driver utilization through system generated work lists
- One warehouse management solution for waste paper, vital supplies, paper and finished goods
- Quality tracking systems to support paper and finished goods
- Improved correspondence between work groups
- Visibility of all trailers and associated inventory at all sites
The MES will be installed at two more sites this summer and at the four remaining sites in 2008.
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