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High-Level Solution
Figure 1. Digitization of Assembly Process planning - Process flow steps
Case Study:
Productivity Improvement and Cost Reduction with 3D Illustrations
Project Overview: Cyient supported a 19-seater business jet program, managing activities from design and stress analysis to assembly process planning and quality assurance. One critical task was verifying sealant application for the wing structure before shipment to the final assembly line.
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Figure 3. Case study benefits in production line
Integration of Graphics – SAP-PP & MES Production Systems
The Manufacturing and Execution System(MES) is a customized tool designed for the detailed execution of production plans. It ensures that the work orders are completed on time, tracks production progress, and schedules/monitors operator activities effectively on the shop floor.
The integration of SAP-PP, 3D Via Composer, and MES tools ensures a comprehensive approach to managing assembly processes, enhancing efficiency, reducing costs, and ensuring quality compliance.
Figure 4. Integration of SAP-PP, 3D Via composer & MES system
About the Author
Sreenivas Katte
Sreenivas Katte is an experienced manufacturing engineer with over 24 years of expertise specializing in manufacturing & assembly process planning within the aerospace industry. He possesses extensive experience in machining processes, fabrication technologies, welding techniques for various material specification and hands-on experience with special treatment processes for aerospace components.
Sreenivas has demonstrated proficiency in shipside support of aircraft assembly build processes, providing critical production team support. His experience includes PPAP, FAIR & quality control & assurance procedures. He also has a strong background in new product development, supplier coordination & providing technical assistance for outsourced parts.
Solution Designs from Solumina
Solumina MES provides various solution designs specifically tailored for the diverse requirements of complex manufacturing sectors such as aerospace, defence, electronics, and medical devices. Here are some of the key solution designs:
Evolution of Solumina MES: A Look at Version Histories
Recent Developments (2020s)
- Continuous enhancements in user experience and analytics.
- Introduction of AI-based predictive quality solutions.
- Emphasizes digital thread and digital twin concepts for improved lifecycle integration across design, manufacturing, and maintenance processes.
These major versions reflect the system's growth from basic shop-floor control to a modern, cloud- enabled MES designed for Industry 4.0 needs.
Main Features
3D Models:
Users can link parts from 3D designs to their tasks, making planning easier.
3D Work Instructions:
Workers get clear visual guides in 3D to help them do their jobs more accurately and efficiently.
Interactive Viewing:
The model lets users zoom in and rotate views to see details, providing useful information as they work.
Main Features available in the latest Solumina i-110 series
The Solumina i110 release introduces MBE Advanced, which includes the latest updates to Solumina’s leading model-based MES capabilities, crucial for a model-based enterprise (MBE). This release also brings various improvements aimed at enhancing quality, efficiency, and stability in process planning, shop floor operations, supplier management, backups, and upgrades.
Key Improvements in Solumina i110 Feature:
Model-Based MES: MBE Advanced offers the most sophisticated model-based MES features as follows:
Process planners can now use the Solumina WebUI to link components from the 3D model to specific operations or steps in a Process Plan. This feature offers a user-friendly visual interface for planners, ensuring that planners and technicians share a consistent view of the information.
When a component is selected on the 3D model, it is simultaneously highlighted in the Parts List and the "Need to Collect / Parts Collected" Panel, helping ensure accurate execution of each step.
Technicians receive guidance for each operation through clear visual cues that enhance efficiency and minimize errors.
3D components are allocated to steps and operations during the process authoring phase. Once a component is selected in the Part Data Collection Grid, it is highlighted on the 3D model.
Advantages of Cloud Hosted Solumina MES
WinClient and WebUI
Solumina Interfaces:
Solumina has two interfaces that can be used in iSeries
- WinClient
- Web UI
Case Study 1
WinClient
WinClient: The WinClient is widely used by:
The Solumina WinClient used various roles in the organization. One is a Process planner and Quality engineer.
Quality Engineer
A Quality Engineer uses the WinClient to
- Author rework instructions.
- Create or edit action plans.
- Create inspection blocks in Process Plans and work orders.
- Create, edit, and monitor corrective actions and Create or edit engineering changes.
Process Planner
A Process Planner uses WinClient to setup, organize, and manage manufacturing Process Plans. For example, it is used to:
- Create and revise Process Plans.
- Alter work orders.
- Supersede and update Operational Flow Diagrams.
- Manage bill of materials.
- Engineering change management and Create release packages.
Case Study 2
WebUI
The Solumina Web Ul is accessed by logging onto the web-based system. It is most commonly used by
to input data and view work order instructions and statuses.
Shop Floor Technician
- The Shop Floor Technician uses the WebUl to review:
- Work order and operation dispatches and Notes and Holds to see what needs to be worked on.
- The Shop Floor Technician also uses the WebUl to execute work orders.
Shop Floor Supervisor
- Shop Floor Supervisors use the WebUI to get a summary of what is going on in the Shop Floor to resolve issues, keep work running smoothly, and effectively use resources.
- Shop Floor Supervisors can easily get an idea of:
- Operations on time and late
- Open holds
- Open discrepancies and
- Pending crew assignments
Quality Technician
- The Quality Technician uses the WebUI to look up information on open and closed discrepancies such as
- Status
- Assignee
- Workflows
- Serial number(s) and affected unit(s) and
- Scheduled end dates
Quality Technician
- Quality Technicians also use the WebUI tolook up open and closed Quality buyoffs including information such as
- Associated work order and operation where buyoff is located
- Serial/lot of unit(s)
- Due dates
- Required quality/inspector certifications and Holds
- Supplier Quality uses the WebUI to Manage source and receiving inspection
- Review As-inspected History and Review calculated supplier rating and metrics
Common roles in Solumina
Case Study 3
QTECH - Quality Technician
Buyoffs
The Solumina dashboard features several key tools that assist the Quality Technician in their duties. One of the most important components is the Buyoffs View, which enables the technician to track the approval status of products following inspection. This view provides essential details, including whether an item has been approved or rejected, the results of quality checks, and timestamps for when the buyoff was completed, ensuring traceability and accountability throughout the inspection process.
The Buyoff Display Information records various details for each inspected item, such as the part number, inspector's name, comments or notes related to the inspection, and a digital signature for approval. This thorough documentation helps maintain a clear record of quality evaluations.
Discrepancies View
Another crucial feature of the dashboard is the Discrepancies View, which organizes any quality issues identified during inspections. The technician can easily monitor the status of each discrepancy, whether it is open, under review, or resolved. This view also facilitates root cause analysis by linking to investigations aimed at understanding underlying issues.
The Discrepancies View in Solumina is essential for effectively managing quality issues. It includes filtering options that allow the technician to sort discrepancies by severity, date reported, or personnel responsible for resolution. This functionality helps prioritize actions based on urgency and impact.
For each discrepancy, the displayed information includes a unique Discrepancy ID, a detailed description of the issue, its location, the reporting date, the assigned personnel, and the current resolution status. It also outlines any corrective actions taken, providing a comprehensive overview of the situation.
Note : The QTECH Case study Images are sourced from iBASEt.
Therefore, Quality Technician at QTECH, supported by the Solumina dashboard, is crucial in upholding the company’s commitment to quality. The dashboard's features facilitate efficient monitoring and management of buyoffs and discrepancies, enabling quick resolutions and ensuring compliance with industry standards. This integration ultimately enhances QTECH’s quality assurance processes and overall operational effectiveness
Business Benefits
Implementing Solumina MES (Manufacturing Execution System) brings numerous business benefits to manufacturers, especially in industries such as aerospace, defense, electronics, and medical devices.
Enhanced Operational Efficiency
- Solumina MES streamlines manufacturing processes, reducing waste and improving cycle times, leading to a 15-25% increase in productivity.
- By eliminating inefficiencies, the system minimizes downtime by 10- 15% and ensures optimal use of resources.
- Integrating quality management features helps manufacturers maintain high standards and comply with industry regulations, which can result in a 30-50% reduction in defects and rework, further reducing manufacturing costs by 10-20%.
Real-Time Decision-Making
- Solumina MES provides real-time insights into production processes, allowing faster decision-making and more effective problem-solving.
- This transparency helps identify bottlenecks, which contributes to a 20-30% improvement in lead time and on-time delivery, and significantly reduces inventory carrying costs by 20-30%.
Scalability and Flexibility
- Solumina’s adaptable architecture allows companies to scale their systems as they grow, incorporating new products or processes with minimal disruptions.
- The MES enhances the compliance process by up to 20-30% faster, ensuring timely adherence to evolving regulatory standards.
Enhanced Workforce Management
- Through performance tracking and training integration, Solumina MES enhances workforce efficiency, aligning employee skills with operational needs to achieve a 15- 25% boost in overall productivity.
- This approach also minimizes data entry errors by 50-70%, streamlining administrative processes.
Continuous Improvement and Cost Savings
- Solumina enables companies to foster a culture of continuous improvement, achieving a 5-15% annual improvement. Additionally, maintenance costs see a 10-20% reduction, enhancing operational sustainability and profitability.
Conclusion
In summary, MES Solumina, offers a transformative MES solution tailored for complex discrete manufacturing industries such as aerospace, defense, electronics, and medical devices. Its modular architecture, real-time data integration, and seamless compatibility with enterprise systems provide manufacturers with the tools essential to enhance operational efficiency and agility.
By focusing on quality management, workforce optimization, and advanced analytics, Solumina enables organizations to maintain compliance, improve product quality, and drive continuous improvement. Ultimately, Solumina empowers manufacturers to achieve operational excellence through informed decision-making, optimized processes, and maximized productivity.
About the Authors
Rekha R is a Software Engineer with a Master of Technology (MTech) in Computer Science and Engineering. She brings over four years of experience in the manufacturing systems and quality management domain. She possesses practical expertise in implementing MES solutions such as Solumina and a solid background in Robotic Process Automation (RPA), design, and development. Rekha’s career has primarily focused on design and development, where her innovative approach to complex manufacturing and quality processes enhances operational efficiency and product quality. Her specialized skills drive the development of cutting-edge solutions in dynamic environments.
Prasad Patnam is a Software Developer at Cyient Ltd and a dedicated professional in manufacturing systems and quality management. He has a strong background in implementing Manufacturing Execution System (MES) solutions, particularly Solumina, which has significantly enhanced operational efficiency and product quality within complex manufacturing environments.
Prasad specializes in React.js and front-end development and holds a Bachelor of Science degree. He excels in creating responsive, user-friendly web applications and has expertise in JavaScript frameworks and state management libraries like Redux, enabling him to effectively transform complex requirements into intuitive code.
Padmanabham V is a Software Developer with experience in Solumina, a top software solution for manufacturing operations management, where he has integrated advanced functionalities to streamline processes and enhance data management. His work leverages microservices architecture and web technologies to improve scalability and flexibility, addressing the dynamic needs of clients in the manufacturing sector. He has contributed to various projects, including Windchill, Common Authoring, Configuration, Transformation, Utilities, and Services.
Padmanabham holds a Master of Computer Applications (MCA) degree and is proficient in Java, J2EE, Spring, Spring Boot, microservices, web services, Hibernate, and Angular.