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The document discusses the development of an open-source manufacturing execution system (OpMES) aimed at small and medium-sized enterprises as part of the Industry 4.0 initiative. It highlights the system's ability to enhance production efficiency through data analysis and real-time decision-making, achieving 76.22% similarity to commercial systems while being 55.3% cheaper. The OpMES was successfully implemented in a company with complex production processes, demonstrating its effectiveness in improving operational efficiency.

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Labidi Zouhaier
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0% found this document useful (0 votes)
4 views

Development_of_an_open_source-based_manufacturing_

The document discusses the development of an open-source manufacturing execution system (OpMES) aimed at small and medium-sized enterprises as part of the Industry 4.0 initiative. It highlights the system's ability to enhance production efficiency through data analysis and real-time decision-making, achieving 76.22% similarity to commercial systems while being 55.3% cheaper. The OpMES was successfully implemented in a company with complex production processes, demonstrating its effectiveness in improving operational efficiency.

Uploaded by

Labidi Zouhaier
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP.

1 — 11, 2019

Development of an open source-based


manufacturing execution system (MES): industry
4.0 enabling technology for small and medium-
sized enterprises
Rangel Besutti*, Vanessa de Campos Machado†† e Ivandro Cecconello†

Abstract
The companies’ production systems have been transformed by industry 4.0 technologies, therefore increasing their sophistication.
Vertical integration, one of industry 4.0 pillars, is filling the gap between lean manufacturing and industry 4.0 through manufacturing
execution systems (MES), that aid in process control and improvement through data analysis. As a contribution to enterprises migration
towards industry 4.0, this work aims to develop a MES based on open source technologies and functional characteristics similar to those
systems available on the market, although the system developed aims at small and medium enterprises. In order to do so, the t echnologies
and software available on the market were assessed against characteristics defined as important in the evaluation of similar systems. The
MES developed through the use of open source technologies resulted in 76.22% of characteristics similar to other systems, besides having
a sale price up to 55.3% lower than other commercial systems. OpMES, the developed system, was successfully implemented in a company
whose production process is complex due to the high level of customization of the product.

Keywords
Manufacturing execution system. MES. Industry 4.0. Open source. Internet of Things. NodeMCU.

I. INTRODUCTION standards are well defined, with these two as pillars of


industry 4.0, that is, vertical and horizontal integration assists
Industry 4.0 has brought a new concept to companies that is
the improvement of these processes [6]. The problems faced
changing manufacturing processes, business models and
by manufacturing companies during lean implementation and
results. Technical advances are incorporated by them
integration can be solved through the use of technologies that
increasing productivity, flexibility, production speed, mass
are part of industry 4.0, one of them is MES, which fits into a
customization, which results in greater quality and
vertical integration of information that helps to control and
productivity to enterprises [1,2]. An important factor in the
improve during reduction processes of non-value-added
implementation of industry 4.0 is the data collection and
activities, also called waste. The MES fills a gap in the
analysis for real-time decision making, so the company
integration between industry 4.0 and lean manufacturing, that
becomes more flexible and improves its processes based on
is, by implementing industry 4.0 companies will become lean
evaluation of immediate situation data, therefore optimizing
because of the need to have well-defined processes [7,4].
production [3,1].
Thus, it is highlighted the importance of developing open
The market competitiveness has created new challenges,
source MES, which tends to have a reduced price, especially
leading companies to seek fundamental solutions in quality,
for small and medium companies that do not have the
performance and agility in their processes and products,
resources to acquire closed systems.
hence, the manufacturing execution system (MES) has been
Given the presented context, this work addresses the
indispensable to assist them in this process. The system brings
development and implementation of a manufacturing
together the company's planning and production, providing
execution system through the use of C and PHP programming
access to information displayed in graphics, that enables to
languages, open source hardware and software, enabling
monitor and analyze production, as well as products and
industry 4.0. A data collector with Wi-Fi network, a web
equipment status, making it possible to trace its use which
interface and database were developed to store the
leads to idleness minimization. The MES function is to
information for later analysis in dashboards.
manage resources, improve equipment usage through data
This article is organized as follows: Section 2 presents the
trend and historic analysis [5].
fundamental theoretical references for the characterization of
Industry 4.0 has brought advanced information and
this research based on industry 4.0, MES, lean, OEE and
communication systems to companies, but to implement them
technologies relevant to its development. Section 3 describes
it is necessary for processes to function efficiently. In this
material and methods presenting the evaluation of the
context, lean production systems are fundamental for
available resources in the market, comparing its
processes implementation where there is no waste and the
* † Departament of Technology and Engineering - University of Caxias do Sul, UCS, RS, Brasil; †† Professor of logistics course at the Federal Institute of
Rio Grande do Sul, IFRS, RS, Brasil.

Emails: [email protected], [email protected], [email protected].

Received: 03/09/2018
Accepted: 01/03/2019

http://dx.doi.org/10.18226/23185279.v7iss2p1
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

characteristics to define the development requirements, also improvements, better staff and talent management, lower
describes how the development of the OpMES, its structuring production costs, and reduction of manual data entry [14].
and cost were planned. Section 4 presents the OpMES Every MES presents characteristics like operation
implementation results during its testing. Finally, Section 5 composition, functions and results, because these
presents the final conclusions and recommendations for future characteristics greatly define the component efficiency. In
researches. installed systems, the client rarely requires all the features and
they are not necessarily present in the installed modules [15].
II. THEORETICAL BACKGROUND According to Martin Naedele et al. in [14] one of the most
important factors in a controlled process is the measurement
A. Industry 4.0
collection of various processes, based on which a
The industrial production is inserted in a paradigm of a new manufacturing MES supports ten functional areas such as:
change based on the advanced digitalization that combines work management, resource allocation and status, dispatching
internet and future technologies, hence combining objects, production units, product tracking and source, quality
machines and intelligent products, thus in such scenario the management, performance analysis, process management,
product will be able to control its own factory process operations, document control and maintenance management.
allowing mass customized production [8]. In this The information efficiency contained in a MES strongly
environment, humans and machines will use technologies that depends on the user who informs the data, once the system
allow them to work collaboratively, so for the most part of does not control or change the production operations, but
work intelligent machines will be able to help, using speech through the data generates indexes that allows the company to
recognition, computer vision and machine learning [9,10]. make decisions.
Intelligent manufacturing will be fully integrated into the
product development lifecycle through information and C. Lean manufacturing metrics in the context of the 4th
communication technologies, science and intelligent industrial revolution
manufacturing technologies that encompass design,
The lean concept, which is also known as the Toyota
manufacturing, management, testing and integration.
Production System (TPS), is based on the elimination of waste
Autonomous sensors, adaptive models of decision making,
and lean thinking, which can be translated as to do more with
intelligent devices, analysis, cognition, control and execution
less, reducing human effort, equipment, time and space, that
of human, mechanical, material and environmental aspects
at the same time offer the customer exactly what is wanted.
compose the manufacturing life cycle [11]. In addition to
The consistent and complete elimination of waste by
generating opportunities, globalization creates challenges for
increasing production efficiency is the main goal of TPS,
industries by forcing companies to market new and more
therefore lean thinking aims at giving immediate feedback on
individual products, increasing productivity and flexibility,
actions to turn waste into value. Even though it originates
which forces companies to improve their performance to meet
from manufacturing environments, lean can be applied
mass customization. The technological basis for an evolution
universally [16,17]. The rising integration of information and
in the industry is through the use of digitized processes with
communication technologies can unite industry 4.0 to lean
open bases for industrial hardware and software foreseeing a
production, which by having a leaner process supports
comprehensive technology of distributed production and
industry 4.0 more easily, proposing an acceleration in the shift
embedded controllers [12].
to the 4th industrial revolution [18].
The industry 4.0 basis is made by nine fundamental pillars
With the evolution of technology and the emergence of the
described as: Intelligent Robots; Simulation; Systems Vertical
industry 4.0 the production systems experienced a strong
and Horizontal Integration; Industrial Internet of Things;
influence in their development. Efficiency is directly
Cyber Security; Big data; Cloud Computing; Additive
connected to these production systems, with the former
Manufacturing; and Augmented Reality [2]. The production
depending on each machine productivity and the system
environment will be influenced by industry 4.0, therefore
control. For the evaluation of activities within the
manufacturing industries will incorporate the great majority
manufacturing, performance indicators are used [19].
of the concepts above highlighted, with the most significant
One of the main performance indicators is the overall
changes being in the operations execution and in the
equipment effectiveness (OEE), which is based on the
production planning, where production real-time planning
multiplication of three parameters associated to equipment,
will be allowed along with a dynamic optimization, as well as
availability, performance and quality [20]. Used as a tool in
systems featuring human-machine interaction [7].
total productive maintenance (TPM), OEE is the key
performance indicator for all organizations committed to
B. Manufacturing Execution System (MES)
eliminating waste [21].
The manufacturing execution systems (MES) can be Equipment availability (𝜇1 ) is associated to manufacturing
defined as a system that performs the integration between the interruptions, and it is a relationship between operating time
planning layer and the production layer of a company, and planned operating time [20]. The equation to calculate
therefore supporting factory floor processes and integrating availability was adapted from Seiichi Nakajima in [22], and it
with others systems within a company, making companies is defined as
more flexible, reconfigurable and appropriate [13]. The MES TP−TI
arises through the need for a system that assists managers' μ1 = TP
× 100 (1)
decisions, including better planning, support for process
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

in which TP represents planned time and TI represents GPIOs and also use the Arduino programming environment
inactive time. [27,28,29].
The second indicator is performance (𝜇2) that measures the XAMPP is a non-profit Apache Friends distribution that
equipment theoretical processing speed in relation to real allows one to have an Apache web server that contains PHP,
processing speed [20], that is calculated as follows Maria DB (equivalent to MySql), and Perl. It is distributed to
QP ×TCT Windows, Linux and OS X as a compilation of free software
μ2 = × 100 (2)
TO (comparable to a Linux distribution), being free and free to be
in which QP represents the processed quantity, TCT copied under the terms of the General Public License GNU
represents the theoretical cycle time and TO represents [30]. The PHP programming language Hypertext
operational time, also adapted from Seiichi Nakajima in [22]. Preprocessor mentioned above is open source with wide use,
The third and last parameter is the quality rate (𝜇3 ) that this programming language is suitable for web development
measures manufacturing quality waste relating the real and it can be merged within the HTML code. Its syntax
production quantity to the planned production quantity [20], resembles C, Java and Perl, and can be easily understood, but
and it is defined by its main objective is to enable the development of pages that
μ3 =
QP− QD
× 100 (3) will be dynamically and quickly generated [31].
QP Created in 1995, web server software named Apache
in which QP represents processed quantity and QD is the maintains its commitment to open development and is one of
defective quantity, that was adapted from Seiichi Nakajima in the influencers of open source. Open source software offers
[22]. many benefits, including reduced cost, and its quality benefits
Among the advantages of OEE in relation to other those who adhere to a high development speed and business
indicators, what stands out the most is the unification of three advantage [32]. MariaDB is a fast and robust database,
separate parameters into a single indicator, considering the developed by the original creators of MySQL and guaranteed
overall performance of an equipment [20]. The fundamental to be a database with structured information being an evolved
equation for the calculation of OEE was adapted from Seiichi MySQL substitute. It is considered one of the most popular
Nakajima in [22], being defined as: databases in the world, provided by its developers to remain
𝑂𝐸𝐸 = ∏3𝑛=1 𝜇𝑛 (4) open source, providing a SQL (Structure Query Language)
interface to access data [33].
The overall equipment efficiency (OEE) calculated through
equation (4) shows the equipment efficiency, according to the
equipment’s programmed operation time [23]. III. MATERIALS AND METHODS
This work aims at the development of a low cost
D. Technologies that allow MES development manufacturing execution system (MES), by searching for
components and open source technologies that allow its
The breakthrough in IoT (Internet of Things) technologies development while maintaining the minimum possible of the
in recent years is exponential, many of them aimed at main characteristics of a MES.
improving human life and advanced automation. The study
areas are focused on several segments such as houses, cities,
A. Requirements and resources evaluation
farms, agriculture, industry, roads, parking lots, transportation
and many other areas, leaving everything more and more To define the requirements for the MES development, some
connected and intelligent [24]. The productivity and important parameters present in a MES were selected, through
profitability of companies are improving due to the an evaluation between two MES systems available in the
implementation of IoT in their business models and processes, market. The sale price of the systems consists of the sum of
thus helping them to make more assertive decisions [25]. the price of software and collectors divided by the quantities
In most cases, manufacturing companies uses IoT to budgeted, product A has a sale price of R$ 4.953,90, and
monitor and diagnose operations as to ensure processes product B has a sale price of R$ 5.666,67, in no system was
quality, reliability and safety, therefore reducing the added the monthly fee charged. The development was divided
likelihood of product and process failures [24]. With the help in two parts, one contemplates the data collector, the other
of IoT it is possible to collect information in real time in contemplates the software provided by the companies, both
different parts of the value chain, so data collection becomes have basic products, intermediate and advanced, but the
efficient, fast and flexible [26]. comparison was made with the basic products supplied by
One of the onboard processing and storage hardware that is them.
used in open source IoT development is the NodeMCU, which The characteristics desired for the data collector were
was developed by Espressif that makes a System on Chip selected with the intention of keeping low costs, but meeting
(SoC) called the ESP8266. In addition to being extremely the minimum possible of what is present in the systems
economical, it has Wi-Fi and through the moon scripting available in the market. As shown in TABLE I, it was selected
language can simplify the programming and execution of for the data collector features such as: connection to the 2.4
programs. Besides, it also has an ESP-12E, CP2102 module GHz Wi-Fi network and buttons for user interaction, with the
and USB connector for power. This module was selected buttons limited to 18 and two leds were added to inform the
because it is low price and can be directly integrated with user if the appointment is open or closed. Based on these
specific actuators and devices through its programmable definitions, hardware evaluations were performed for the
development of the data collector.
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

TABLE I: Data collector comparison Pareto chart, by time, frequency


  
and average

Product Product Desired Scheduled Stops Chart and Table   


Characteristics
A B Characteristics Unscheduled Stops Chart and
Table   
2,4 GHz Wi-Fi Transmition   
Production Chart and Table   
RJ45 Ethernet Transmition   
Events Table (Logbook)   
Emergency mode   
Hourly parts and goals   
Interaction display   
Production Order Report   
Interaction buttons   
Rework report   
Built-in keyboard    Web interface for registration
Machine connection (analog and and report manufacturing orders   
digital input)   
Web interface web for TV
Barcode reader input    visualization on manufacturing   
floor
The evaluated systems software is usually proprietary, that is, Machine program sending   
it is developed by the company, however in the proposed MES Management from mobile
devices   
the intention is to bring the important information that others
Monthly Software Maintenance
software generate, but by using third party software it is Fee (Fixed)   
possible to minimize development costs. TABLE II shows all Software maintenance fee per
items compared and what was defined as important to be hour (when required)   
present in the low cost MES to be developed.
Among all the characteristics described above it was selected
TABLE II: MES comparison that system and database installation can be performed either
on a server or on a computer (desktop); it was defined that the
Product Product Desired software and database are local and not on the cloud and that
Characteristics
A B Characteristics
machine appointments can be customized. The main reports
Installed on a server    and graphs, such as stop and production appointments in the
Installed on a desktop    machines, indexes of appointment occurrences, availability,
Local Software    performance, quality and OEE calculation, production orders
produced report, manufacturing orders and parts produced
Cloud software    report and rework report were maintained, and to carry out the
Causes for stopping limited
register    calculation of all of them, it was proposed to use Microsoft
Causes for stopping unlimited Excel software in direct connection with the database. In order
register    to carry out the registration of manufacturing orders, it was
Appointment personalization    proposed the development of a software that facilitates the
ERP connection    user's use at the time of the registration, for that was used the
language PHP that is a language for open source web
OEE calculation    development.
Availability calculation   
Performance calculation    B. Development
Quality calculation    Development was divided in four stages, first the data
Graphs and Tables available on collector development as well as all its preparation for the
web interface or proprietary    network connection and data sending, after the web interface
software was developed for the registries and reports of manufacturing
Charts and tables on third-party
software Example: Spreadsheets orders and server scripts for data inclusion and updating, in
on Excel or Business
   the third step an apache web server and a MariaDB database
Intelligence (BI) software (equivalent to Mysql) were implemented, where the tables
OEE graphs and tables    were created to receive data from the collectors and web
Charts and tables of OEE, interfaces and finally the connection was made with the
Availability, Efficiency and    database and the assembly of results reports and graphs.
Quality Evolution
1) Data collector cards were evaluated, all of them could meet this project, each
For the development of the collector an evaluation was one with its peculiarities. The NodeMCU (Esp8266) shown in
made about the necessary characteristics of the embedded Fig. 1 was selected for the project because its cost and size was
hardware to be used in the apparatus, in this evaluation some better than the others, taking into account the necessary
of the open source hardware available in the market to characteristics.
maintain the prerequisites defined in the elaboration
preserving the lowest possible cost were included. The
selection of the hardware included three different boards,
Raspberry pi zero w, Raspberry pi 3 and NodeMCU (Esp8266)
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

Because it is open source, the hardware programming


interface does not need to be the default moon language, and
can be replaced by the Arduino interface. In the project the
Arduino interface was used due to familiarity with the
programming environment, the logic that was implemented
can be visualized in Fig. 2, which demonstrates the logical
operation of the notebook collector.

Fig. 1: NodeMCU

Fig. 2: Firmware collector flow chart


Among the evaluated hardware, all options would need an
auxiliary board for buttons coupling. After the hardware
definition, a design of a printed circuit board was done to
couple the embedded hardware with 18 buttons for
appointments digital input and two indicators indicating open
(red) and closed (green). Since the NodeMCU does not have
enough digital inputs to supply the 18 buttons and two led
lights, the board has been developed based on the strategy of
triggering door combinations, i.e. each button activates two
NPN transistors in key configuration, and each transistor fires
one port, two ports being triggered at the same time at each
click of the button, increasing the number of ports available
through the drive combinations. Fig. 3 shows the circuit used
in one of the buttons. The input signal from the attached board
comes from the NodeMCU itself.
Fig. 3: Drive Connection diagram
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

The transistor Q1 and Q2 shown in Fig. 3 are composed of The complete data collector consists of a printed circuit
three terminals, collector (C), base (B) and emitter (E), in the board, a NodeMCU, eighteen buttons in ABS, a wrap to place
key configuration, the base (B) of the transistor is polarized to the board also in ABS, four screws to fasten the board in the
switch between saturation and the cut. When the switch (S1) box, eighteen labels that describe the notes and a cable. All
is open, the current at the base (B) of the transistor is 0V, components can be viewed in Fig. 5.
therefore the current in the collector drops to 0V and with no
current in the resistor of 1K the voltage of the VCC goes to
output 1 and 2. When the (S1) is closed the current arrives at
the base (B) of the transistor, saturating the transistor and
taking output 1 and 2 at 0V [34].
The wrapping that supports the board was developed in a
CAD software and printed on a 3D printer, because the cost of
developing an injection matrix is very high compared to 3D
printing. The prototype shown in Fig. 4 demonstrates the
design in CAD.

Fig. 5: Data Collector Components

2) Interface web in PHP and server scripts


The software for recording and reporting production orders,
along with the two scripts that perform the inclusion and
update of the data in the database, were designed combining
the PHP and HTML language. The web interface shown in
Fig. 6, includes the registration of manufacturing orders and it
is possible to see the daily registered orders report and change
some record if wrong informed. The data reported are used in
Fig. 4: Collector wrapping the calculation of availability, performance and OEE.

Fig. 6: Web interface for manufacturing order registration

On the other hand, the scripts are triggered by the collector which machine sent it, and the time-based server, including
via HTTP protocol, where the collector sends the method that the data in the bank. The script that performs the time update
the files will be sent, the URL with the file and the data to is triggered by the collector and searches the last record in the
execute and the protocol version used by the client. To add the database table to update the end time of the specified
data to the database, the script that includes the data in the machine's point. The logical operation of the scripts can be
database receives the information from the collector's point seen in Fig. 7.
and from there, searches the date and time on the server, adds
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

Fig. 7: (a) Script flowchart for data inclusion and (b) Script flowchart for data update

3) Web Server and database graphs, stop notes, production orders, index of appointments
The XAMPP distribution was selected for the project occurrence and evolution of OEE during the month graphs.
because it is an open distribution and contains an Apache web For future improvements in OpMES the aim is to develop a
server, PHP and a MariaDB database (equivalent to Mysql web interface for analysis and generation of real-time report
database), XAMPP was installed and set on a physical of all this data obtained through dashboards.
Windows server where two tables to store machine data were
created. Each table stores a data type, one for the machines
C. System and cost structure
stopping data that comes from the collector and another one to
store the production orders data that comes from the register OpMES was developed based on the user's digital data
in the web interface. entry, where the user uses the collector connected to the
network via Wi-Fi to open and close an appointment, so the
4) Reports assembly collector sends the data to the server where a PHP script does
For data compilation and analysis, some spreadsheets were the inclusion or update in the database. The user also uses a
built using Microsoft Excel software, which contains graphs web interface to inform the production order that is currently
and pivot tables that connect directly to the database in order running. Finally, managers and supervisors perform the
to generate reports in dashboard format. Some reports were analysis of data availability, performance, quality and OEE by
created to perform the calculation of availability, performance compiling the data in dashboards developed in Excel software.
and OEE, so that the calculations were based on equations (1), The complete diagram of the OpMES is shown in Fig. 8.
(2) and (4) respectively, as well as general appointments
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

Fig. 8: System diagram

The OpMES cost was divided into 5 parts: components used assembly. The unit cost for a complete system with a collector
in printed circuit board, contracted services, accessories, was realized adding up the hours of total development and
development, assembly, installation and training. The total divided by 80 units and after it was added to the cost of the
cost was calculated based on the programming hours used for collector, so each added collector already has built in the
script development, web interface, database and service development cost for a unit. The detailed cost of each item is
configuration, collector firmware, assembly of the shown in TABLE III.
spreadsheets connected to the database, and collector
TABLE III: System total unit cost
Unit
Description Quantity Total cost
cost
Components for printed circuit
board
NodeMCU R$ 44,37 1 R$ 44,37
Tact switches + Resistors +
R$ 33,60 1 R$ 33,60
LEDs
Transistor R$ 0,80 18 R$ 14,40
Hired services
Printed Circuit Board R$ 100,00 1 R$ 100,00
3D Printing of Box + Cover +
R$ 180,00 1 R$ 180,00
Buttons
Accessories
Descriptive Tags R$ 4,17 18 R$ 75,06
USB cable R$ 15,00 1 R$ 15,00

Development and assembly


Development R$ 172,50 1 R$ 172,50
Assembly R$ 20,00 1 R$ 20,00

Training and installation


Training and installation
R$ 28,75 10 R$ 287,50
(hours)

Total R$ 942,43

Based on the presented cost, it was elaborated a strategy to be sold by companies that feature national SIMPLES tax
obtain the OpMES selling price and come to a common base system, so the taxes calculation is unified.
based on the systems available on the market, as to make a Assuming that the percentages incident on the selling price
comparison around the selling price. In order to calculate taxes of the products are respectively; 7.8% according to SIMLES
applied to the product, it was proposed that this kind of system national taxes, 20% administrative cost and 35% profit
margin, the total incident would be 62.8%. In order to
SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

calculate the index that will be applied to the cost of the decision made in real time, it is able to show machines
product and to realize the formation of the sale price, the efficiency, availability and performance through graphs and
divisor factor is calculated in which it decreases from the total reports, being able to generate a better result from the results
that would be 100% the incident percentage, that is, in the case rapid analysis. Fig. 9 illustrates the OpMES installed in one of
it would be 62.8%, resulting in the value of 0.3720. From this the company's cutting machines.
value the multiplier factor is calculated, dividing 1 by the
divisor factor, resulting in a multiplier factor of 2.6882,
applying this factor to the cost is obtained the sale value of the
product of R$ 2.533,41. This value is significantly lower than
commercial MES evaluated, which does not use open source
technology.

IV. RESULTS
The development and implementation of OpMES took place
in a planned furniture industry, the company offers its
customers the customization by milimetes within the limit of
150 mm up to 2750 mm in length and 150 mm up to 1830 mm
in width, varying the thicknesses between 6 mm, 15 mm, 18
mm, 25 mm and 42 mm and offering a carton of 24 patterns of Fig. 9: System installed in a machine
different colors. In addition to the wood customization, it is
possible to choose aluminum doors with glass or wood, and a The data are reported by the machine operator and stored on
diversity of accessories, all with a delivery time of 5 working the internal server, this information is compiled in the Excel
days from the order release. software, and the stop, production, general and occurrences
The combination of possibilities that the company offers to charts are generated, as shown in Fig. 10. In the sequence,
its customers generates a high complexity in the production according to Fig. 11, a graph of machines availability,
system, a need that demands industry 4.0 technologies to be performance and OEE monthly evolution is generated. The
adequately served. On average, 350 sheets of wood of the most company where it was implemented chose to calculate the
varied combinations of parts, colors and thickness are OEE quality factor in a different way, calculating by group of
optimized and divided among 3 cutting machines available in machines outside the OpMES and not each individual
the company. The cutting sector today is the company’s machine integrated in the OpMES, in order not to affect the
bottleneck due to the high patterns exchange on the machines. OEE calculation the quality was considered 100% in the
The developed and implemented OpMES is in fact an enabling equipment.
technology for intelligent manufacturing and with control and

Fig. 10: Appointment charts


SCIENTIA CUM INDUSTRIA, V. 7, N. 2, PP. 1 — 11, 2019

Fig. 11: OEE evolution chart

V. CONCLUSION
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