Contenu connexe Similaire à Sirris manufacturingday2011 the-future-of-smart-manufacturing-execution-de-clercq (20) Sirris manufacturingday2011 the-future-of-smart-manufacturing-execution-de-clercq1. S ir r is M anuf act ur ing Day
The future of smart manufacturing execution
Erwin Vervondel
De Clercq Solutions
© 10 – 05 – 2011
2. S ir r is M anuf act ur ing Day Agenda
part 1 : Challenges & Goals
part 2 : MES functionalities by example
part 3 : Next steps, Innovations
© 10 – 05 – 2011
3. S ir r is M anuf act ur ing Day Challenges
• Flexibility – Everything and everyone needs to be more
‘flexible’
• Company: production demands (make to stock make to order)
• Customer specific demands
• Workforce optimization
• Complexity
• Product variance
• Laws / regulations strictness
• Supply Chain integration
• Focus on all costs
• Cost control = control of Machine + Labour hours
• Material cost: focus on Scrap and Rework
• Be competitive across borders
© 10 – 05 – 2011
4. S ir r is M anuf act ur ing Day Challenges
There is a clear need for
• Integration of several information sources regarding “business intelligence,
manufacturing, logistics, reporting, alerts, analytical tools”
• Determining company’s key performance indicators (KPI’s)
? Production quota, how much, when
? Production interrupts
? Tracking en tracing requirements/regulations
? Key quality indicators
? Root cause analysis, most occuring scrap reason
? Control WIP stock
? Material consumption
? Setup / Change over Costs
“you cannot manage what you cannot measure”
© 10 – 05 – 2011
5. S ir r is M anuf act ur ing Day Setting goals
• Setting application domain scope
• First determine scope, then look at technical concepts
Determine need for integration of several application domains ?
• HR (T&A)
• Production (MES)
• Logistics (WMS)
• Defining Information flows
• One way versus two way
• On-line integrated environment – is this possible ? Wanted ? Required ?
• Determine level of detail
• Detailed info
• A lot of input / interfaces
• Much data available
• Easier to analyse, more flexible reporting
• Less Detailed info
• Basic Input
• Crucial data available (? What is crucial)
• Analysis only based on crucial data
© 10 – 05 – 2011
6. S ir r is M anuf act ur ing Day Agenda
part 1 : Challenges & Goals
part 2 : MES functionalities by example
part 3 : Next steps, Innovations
© 10 – 05 – 2011
7. S ir r is M anuf act ur ing Day MES functional model
ERP
MES Operations
Management
P(roduction) Q(uality) L(ogistic) Planning & Reporting
Supervisor
Execution Tracking
Operator
Data Collection &
Process Integration
Infrastructure
© 10 – 05 – 2011
8. S ir r is M anuf act ur ing Day MES – ERP Interaction
ISA 95 model based Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Product Production Production Production
Definition Resource Scheduling & Data Collection
Management Management Execution & Analysis
(How to make (What is (What to (What was
a product) available for use) make and use) made and used)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
© 10 – 05 – 2011
9. S ir r is M anuf act ur ing Day MES functional model
ERP
MES
P(roduction) Q(uality) L(ogistics)
Integration ERP/MES
ERP is master
MES is slave/master
(WMS is slave/master)
Infrastructure
© 10 – 05 – 2011
10. S ir r is M anuf act ur ing Day MES – Infrastructure interaction
Host
MES
Data Collection Process Control
Systems SCADA
Mobile DC Intelligent Printing Weighing
RF - Batch - Tag •© De Clercq
Workstations 05 – 2011
© 10 – Labeling Measuring
Machines
11. S ir r is M anuf act ur ing Day MES functional model
ERP
Production Scheduling/dispatching
• Resource allocation
• Realtime Planboard
MES
Time and Quantities
P(roduction) Q(uality) • Labor : order/indirect
L(ogistic)
• Machine : Up/Downtime
• Order : costing – planning
• Quantities : Good/Scrap/rework
Dashboard on production
• OEE on all levels
• Realtime views
Infrastructure
• Actual/historical analysis
© 10 – 05 – 2011
12. S ir r is M anuf act ur ing Day MES functional model
ERP
MES
Inline production QC registration
P(roduction) Q(uality) L(ogistic)
Offline production QC registration (Spec)
Proces integration/monitoring
SPC
Operator instructions
Document control
Infrastructure
© 10 – 05 – 2011
13. S ir r is M anuf act ur ing Day MES functional model
ERP
MES Product Identification
• Dynamic modelling
P(roduction) Q(uality) L(ogistic)
• Inline labeling/printing
• SSCC
Tracking and Tracing
• Lot registrations / creation
WIP
WMS or WM Middleware
Infrastructure
© 10 – 05 – 2011
14. S ir r is M anuf act ur ing Day MES platform
Integration at different levels of the organization
Responsible
Ideal platform for production monitoring and steering
The perfect tool for evaluation and analysis from efficiency through quality
Operators
Optimized support for the workfloor employees (empowerment)
Steering
Registrations
Production Lines/Machines
Technical integration with the processes
Automate data input & Increase data quality
© 10 – 05 – 2011
15. S ir r is M anuf act ur ing Day MES by example
Planner: Production dispatching
Overview of open orders / dashboard
Easy production order creation with wizard
© 10 – 05 – 2011
16. S ir r is M anuf act ur ing Day MES by example
Planner: Production dispatching
Releasing orders
to production
Running production orders
& order queue
© 10 – 05 – 2011
17. S ir r is M anuf act ur ing Day MES by example
Planner: Realtime planboard
Intuitive view on Indication of production status
production planning e.g. “late start”
Compact production order information
© 10 – 05 – 2011
18. S ir r is M anuf act ur ing Day MES by example
Operator: Operator Dashboard
Real-time view on production progress
© 10 – 05 – 2011
19. S ir r is M anuf act ur ing Day MES by example
Operator: Operator Dashboard
© 10 – 05 – 2011
20. S ir r is M anuf act ur ing Day MES by example
Operator: Process info
Real-time
data collection
Registration of
machine interrupts
© 10 – 05 – 2011
21. S ir r is M anuf act ur ing Day MES by example
Operator: quality control
© 10 – 05 – 2011
22. S ir r is M anuf act ur ing Day MES by example
Supervisor: OEE analysis
OEE reporting (real-time & historical)
© 10 – 05 – 2011
23. S ir r is M anuf act ur ing Day MES by example
Supervisor: Pareto analysis
Easy drill-down
Machine-based Pareto
Reason-based Pareto
on selected machine
© 10 – 05 – 2011
24. S ir r is M anuf act ur ing Day Production Logistics / WIP
© 10 – 05 – 2011
25. S ir r is M anuf act ur ing Day MES by example
Operator Material identification
Identification of material
& characteristics
© 10 – 05 – 2011
26. S ir r is M anuf act ur ing Day MES by Example
Operator: Material output
Produced Logistic Units to be put away
© 10 – 05 – 2011
27. S ir r is M anuf act ur ing Day MES by example
Supervisor: Traceability
Tracking & tracing
drill-down
Backward/forward
product genealogy
© 10 – 05 – 2011
28. S ir r is M anuf act ur ing Day Agenda
part 1 : Challenges & Goals
part 2 : MES functionalities by example
part 3 : Next Steps, Innovations
© 10 – 05 – 2011
29. S ir r is M anuf act ur ing Day Next Steps
Next Step : Intelligent Manufacturing
• Need for significant improvement of various Key
Performance Indicators:
Minimizing Cycle Time;
Reducing Work in Progress;
Better Delivery on Time;
Higher Throughput
• Better use of resources
• How?
Using Intelligent Manufacturing Methods and Systems
© 10 – 05 – 2011
30. S ir r is M anuf act ur ing Day Next Step: Intelligent Manufacturing
Methodologies
Decision Support
Operations Research
Manufacturing Science
Factory Physics
Production Methods
Supply Chain Management
Mathematical Optimization
Modeling & Simulation
Advanced Planning & Scheduling
© 10 – 05 – 2011
31. S ir r is M anuf act ur ing Day Scheduling Challenges
• Scheduling / Release management
• The heart of intelligent manufacturing
• ‘Typical’ Scheduling Methods
• Dispatch Rules, User Defined & Dynamic Rules
• Discrete Event Simulation
• Branch & bound
• Simulated annealing
• Tabu search
• Genetic Algorithms
• Neural Nets
• Mathematical Programming (LP, IP, etc)
• Heuristics
• Hybrid
• …
© 10 – 05 – 2011
32. S ir r is M anuf act ur ing Day Scheduling Challenges
• ‘Classic’ Scheduling techniques
not always so obvious …
• Cannot handle job dispatch very well
Not reactive enough
• In scheduling, the gap from theory to practice is HUGE !
Availability of correct data
Multiple criteria
You cannot model everything !
Variability, variability, variability
Handling huge problems
Validity of the schedules often problematic
Academic methods do not translate as is to industry
• Many scheduling projects … Fail …
© 10 – 05 – 2011
33. S ir r is M anuf act ur ing Day ALDISS
• Industry faces a “scheduling crisis”
New approaches are required
New approach: self organizing/adaptive systems
DCS is currently building a new scheduling system
called ALDISS …
© 10 – 05 – 2011
34. S ir r is M anuf act ur ing Day
ALDISS
Our Way Forward: ALDISS
•Adaptive
•Lean
•DIstributed
•Scheduling
•System
© 10 – 05 – 2011
35. S ir r is M anuf act ur ing Day ALDISS
Adaptive Lean DIstributed Scheduling System
• Lean scheduling system
• Using local rules and methods, adaptive, intelligent, flexible, self-
organizing
• Distributed
© 10 – 05 – 2011
36. S ir r is M anuf act ur ing Day ALDISS
Goal
Develop a scheduling system, able to be easily implemented & integrated in already
existing MES system.
A dynamic system that reacts to real-time situations.
A distributed system that relies on local information and uses distributed emerging
intelligence to make scheduling decisions.
A system built upon Basic Principles of Self-Organizing Systems:
• Local decisions
• Local rules
• Self-adaptive
• Flexible
• Resists disruptions
© 10 – 05 – 2011
37. S ir r is M anuf act ur ing Day The project
• Two year R&D project sponsored by IWT .
• Collaboration between De Clercq Solutions, UEG and Sirris
Advanced Manufacturing group.
• Project covers system specification, development, piloting and
benchmarking
• Implementable in a wide variety of industries.
• Applicable to large firms as well as to SMEs.
• The system will be created, developed, piloted and
benchmarked, and of course fully integrated with the Objective
Manufacturing Framework.
© 10 – 05 – 2011
38. S ir r is M anuf act ur ing Day ALDISS
• Specific focus on
Release Management
Dispatching rules
• Modelling
• E.g. Provide modelling of ‘control loops’
– Kanban
– Polca loops
– Nr of ‘virtual’ cards in the system
© 10 – 05 – 2011
39. S ir r is M anuf act ur ing Day ALDISS
• Dispatch
Release jobs filter
Only allow start of ‘released’ job when allowed
• E.g. Card present
Operator support for starting the correct job
• Is not always the first job in the ‘classic’ queue
Dispatch verifier has knowledge of activities/jobs
upstream / downstream allowing balanced job
releases.
© 10 – 05 – 2011
40. S ir r is M anuf act ur ing Day
Questions ?
© 10 – 05 – 2011
41. S ir r is M anuf act ur ing Day Contact Us
Projects www.declercqsolutions.eu
Software www.objective.info
Offices East Flanders – Wichelen (Head Office)
West Flanders – Roeselare
Phone +32 (0)52 43 20 80
Fax +32 (0)52 43 20 81
Email info@declercqsolutions.eu
© 10 – 05 – 2011