Today’s manufacturing is not based on silos. To produce high quality, have real-time visibility, and process efficiency, manufacturers must have a connected ecosystem that seamlessly integrates planning and execution.
In this is where APQP (Advanced Product Quality Planning) and Manufacturing Execution System (MES) come into a pivotal role in the smart manufacturing transformation.
What is APQP (Advanced Product Quality Planning)?
APQP (Advanced Product Quality Planning) is a technique used to ensure the quality of a product or service. It is a systematic process in manufacturing to determine and design product quality requirements prior to manufacturing. It guarantees that all products are planned to meet customer expectations.
APQP includes:
1. The planning tasks for producing a product
2. Design and validation of the process
3. Failure Mode & Effects Analysis (FMEA)
4. Control plan development
5. Sizing and dimensioning (PPAP Submission)
Manufacturers can now efficiently digitize and manage this whole quality planning lifecycle with APQP Software.
What is Manufacturing Execution System (MES)?
A Manufacturing Execution System (MES) is an actual-time manufacturing administration process that keeps track of, tracks and manages manufacturing operations on the shop floor.
It connects planning systems (ERP/APQP) to the production
MES helps in:
1. Real-time production tracking
2. Work order management
3. Shop floor monitoring
4. Machine performance tracking
5. The quality control, quality assurance and quality traceability
MES Software for Manufacturing allows to execute planned processes accurately at real time.
How APQP and MES Work Together
APQP and MES are not distinct systems; rather, they are intelligent manufacturing components. APQP has been introduced to govern the things to be built and how quality should be achieved. MES is responsible for “how” that plan is implemented on the shop floor in real time.
APQP is the Manufacturing Plan defined
APQP establishes:
1. Product requirements
2. Process flow design
3. Quality checkpoints
4. Risk mitigation strategies
5. Control plans
This way, the execution of Advanced Product Quality Planning Software is structured beforehand, prior to the start of production.
2. MES Executes the Plan in Real Time
Once production starts, Manufacturing Execution System Software ensures:
a. The operators work according to the defined processes
b. Work procedures are carried out properly
c. Data is collected to monitor in-line production
d. Deviations are detected on the spot
e. Quality Assurance is observed during production
This allows to track the production in real-time and shop floor control.
3. Digital Link Between Planning and Execution
When APQP and MES are connected:
1. Mechanical drawings are directly transferred to production systems
2. Quality is checked throughout implementation
3. There are few errors and rework is significantly minimised
4. Complete traceability is ensured throughout the production process
5. This provides closed-loop manufacturing system
Benefits of Integrating APQP with MES
The benefits to manufacturers of these two systems integrated:
The product was improved for better quality consistency.
1. Real-time visibility and tracking in production
2. Decreased manufacturing defects and rework
3. New products created more rapidly
4. A more effective implementation of the IATF 16949 standard
5. New product launches that are better known and understood by various parties
6. Improved manufacturing process control
7. Improved digitalization in smart factories
To be sure, manufacturers require APQP and MES. Indeed, manufacturers need both APQP and MES. For the 4th Industrial Revolution in manufacturing, a mix of planning intelligence and execution intelligence is the key to success. APQP Software for Manufacturing is a software program that covers structured product quality planning.
MES software for manufacturing industry has the capability to ensure real time execution and control. Together, they enable:
1. Smart Manufacturing Execution
2. End-to-end process visibility
3. Higher operational efficiency
Conclusion
APQP and Manufacturing Execution System (MES) are not rival solutions, but they are two key elements of the smart manufacturing. APQP assures planning and design of quality products. MES can guarantee real-time execution and production control. Through integration, they create a robust manufacturing ecosystem that enhances efficiency, minimizes defects and facilitates the digital transformation. Smart Factory Solutions can help you to deal with these solution and provide more accurate information.
