In the rapidly evolving landscape of industrial technology, the term “legacy system” often surfaces, particularly in the context of integrating advanced solutions like Manufacturing Execution Systems (MES). Legacy systems refer to older computer systems, software applications, or technologies that, despite being outdated, are still in use. They usually lack the features, flexibility, and scalability of modern solutions but continue to operate due to their embeddedness in an organization's processes. Integrating MES into these systems presents unique challenges and opportunities.
What is a Legacy System?
A legacy system, in the context of computing and technology, refers to outdated computer software, hardware, or systems that are still in use. Despite being surpassed by newer technology, these systems remain operational and are often integral to the functioning of an organization. The term “legacy” implies that the system is a holdover from a previous era and, although potentially less efficient, continues to fulfill certain needs or functions that prevent an organization from discarding or replacing it.
Characteristics of Legacy Systems include:
Outdated Technology: They are built on older technology platforms, which may not be compatible with current standards or systems.
Limited Support: Often, the original manufacturers may have ceased support for these systems, making maintenance and troubleshooting more challenging.
Crucial Functionality: Despite their age, legacy systems often perform critical functions within an organization and may contain valuable data or unique processes that are essential for daily operations.
Integration Challenges: Legacy systems may have difficulty integrating with newer technologies, leading to issues in data sharing, communication, and overall operational efficiency.
High Replacement Costs: Replacing a legacy system can be costly and complex, involving significant investment in new hardware and software, as well as training and transition support.
In many cases, organizations continue to use legacy systems due to the high costs of replacement, the risk of disrupting stable processes, or because the systems continue to meet the business's specific needs adequately. However, reliance on legacy systems can also pose risks and limitations, such as increased vulnerability to security threats, decreased competitiveness due to inefficient processes, and challenges in scalability and adaptability to new business requirements.
Role of New Sensors
Contrary to common belief, legacy machines can run MES by installing new sensors and data collection devices. These sensors gather real-time data on machine performance and operational parameters, feeding it into the MES for analysis and optimization.
New sensor technologies play a pivotal role in bridging legacy systems with MES. These sensors, when attached to older machines, collect various data types, from temperature and pressure to operational speed. This data is then used by the MES for real-time monitoring and decision-making.
Upgrading to MES or also Known as Retrofit to Deploy MES
Evaluate Goals & Outcomes
Before retrofitting the current legacy machines with additional hardware, a plant must decide what goals they are trying to achieve. For example, If Traceability is an outcome desired, then it requires a hardware set up of scanners, barcodes, and supporting hardware / software combination.
Selection and Evaluation of Existing Equipment
It is important to select the processes and equipment that need to be connected with MES in order to achieve plant goals. It may not be a good idea or investment to upgrade or retrofit all machines at once, so this selection is critical and all stakeholders must be consulted for their buyins before this decision is made. Second step will be to evaluate functionalities and features of existing equipment such as SCADA, Interfaces, Security, Communication protocols, PLC’s etc.
Sensors and Devices for Inputs
Depending on the needs and evaluation criteria, different types of sensors or devices may be needed such as Encoders, Temperature Sensors, Vision Cameras, Pressure Sensors, Heat Sensors, Proximity Sensors, Gateway. It is not difficult to install these as often projected, you must choose a good automation partner which is also cost effective. The inputs form the base of MES so consider the best options available.
Select a MES Vendor that meets you where you are.
Every plant is different, some plants bought equipment in the 90's and some in the new century and their equipment is still working fine after 20 years. MES vendors must meet where you are in the snapshot of time and not all of them do this. There are MES companies who are willing to put in extra yards to make things work for manufacturers with older equipment, while there are some who only work with plants that have newer upgraded equipment. Ask the right questions and select the vendor that can work on legacy systems, because it may require software customization and protocol testing instead of a plug and play.
Plan for Data Security & Production Downtime
Consider the timing for upgrades and Retrofits to deploy MES. It is advisable to allow an extra week of cushion as many times there can be bugs that need to be fixed. At no point should you get into a situation where the production is compromised and you accumulate downtime. The goal of MES is production efficiency, not downtime. Also be mindful of data security threats, ensure all tests are done and fully validated by your cybersecurity teams and specialists.
Benefits of MES Integration into Legacy System
MES serves as a bridge between plant-floor operations and enterprise-level management. It provides real-time monitoring and control of manufacturing processes, data collection and analysis, quality management, and inventory tracking. The integration of MES with legacy systems aims to bring these advanced capabilities to older infrastructures.
a) Increased Efficiency and Productivity: Integrating MES (Manufacturing Execution Systems) into legacy systems can significantly enhance operational efficiency. This integration allows for real-time data analysis and automation of manufacturing processes. It enables manufacturers to monitor and control the production floor more effectively, leading to increased productivity. For example, MES can automate data collection and machine adjustments, reducing the time and errors associated with manual interventions. This leads to faster production cycles and more efficient use of resources.
b) Cost Reduction and Downtime Minimization: By integrating MES into legacy systems, companies can achieve substantial cost savings. This integration often leads to reduced machine downtime and lower maintenance costs, as MES provides real-time monitoring and predictive maintenance capabilities. By predicting potential equipment failures before they occur, manufacturers can schedule maintenance during non-peak hours, thereby minimizing production disruptions. Moreover, the increased efficiency often leads to a reduction in waste and better utilization of raw materials, further driving down costs.
c) Enhanced Quality Control and Compliance: Enhanced quality control and compliance are core benefits of MES integration, as it provides continuous oversight of production processes to ensure adherence to predefined standards. This real-time monitoring enables faster identification and correction of quality issues, significantly reducing defects and enhancing product consistency. Additionally, MES plays a crucial role in maintaining compliance with industry standards by offering comprehensive records of production activities, quality checks, and any adjustments made.
In regulated sectors like pharmaceuticals, food and beverage, and aerospace, where adherence to strict standards is essential, MES systems contribute substantially to maintaining both quality and compliance, as explored in our insights on improving quality and reducing scrap rates with advanced MES.
d) Improved Decision-Making and Market Responsiveness: Integrating MES with legacy systems enhances decision-making by providing managers with real-time data and insights about the manufacturing process. This data-driven approach allows for more informed decisions regarding production planning, inventory management, and demand forecasting. Additionally, the agility provided by MES enables manufacturers to respond more quickly to market changes. For example, if there's a sudden spike in product demand, MES can help quickly adjust production schedules and resource allocation to meet these new demands, thereby improving market responsiveness.
Challenges of Integration
The integration of MES into legacy systems can be challenging due to differences in technology standards, data formats, and communication protocols. For example, an older system might use a proprietary communication protocol that is not supported by the latest MES software. There's also the risk of disrupting ongoing operations and the need for staff retraining.
Strategies for Successful Integration
1. Interface Development
Creating custom interfaces or using middle ware can enable communication between MES and legacy systems. This might involve developing API’s (Application Programming Interfaces) that translate data between different formats.
2. Incremental Integration
Gradually integrating MES advanced features into the legacy system can minimize disruption. This could start with non-critical processes, slowly expanding to more essential areas.
3. Data Harmonization
Ensuring data consistency and compatibility between the MES and the legacy system is crucial. This might involve data cleansing and the establishment of common data standards.
4. Training And Change Management
Adequate training for staff to adapt to the new integrated system is vital. Change management practices can help ease the transition and encourage acceptance among employees.
Conclusion
In conclusion, while integrating MES into legacy systems is challenging, it is a necessary step for manufacturing firms aiming to stay competitive. The careful planning, custom interface development, and gradual implementation strategy can help mitigate risks and maximize benefits. With successful integration, companies can expect increased efficiency, better data management, and enhanced decision-making capabilities, propelling them into a new era of manufacturing excellence. Unlock the potential of your legacy systems with a well-integrated MES solution, designed to enhance efficiency, data accuracy, and decision-making across your manufacturing operations. Visit our MES Solutions Category to checkout range of advanced solutions.