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Sirris manufacturingday2011 the-future-of-smart-manufacturing-execution-de-clercq

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A case illustrates how Manufacturing Execution Systems enable a manufacturer to keep track of the production progress and contribute to an optimized execution on the workfloor. A vision is posted on two possible future orientations of MES systems which lead to optimized and self-organizing execution on the shop floor.

Publié dans : Technologie, Business
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Sirris manufacturingday2011 the-future-of-smart-manufacturing-execution-de-clercq

  1. 1. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 19. S ir r is M anuf act ur ing Day MES by example Operator: Operator Dashboard © 10 – 05 – 2011
  20. 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. 21. S ir r is M anuf act ur ing Day MES by example Operator: quality control © 10 – 05 – 2011
  22. 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. 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. 24. S ir r is M anuf act ur ing Day Production Logistics / WIP © 10 – 05 – 2011
  25. 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. 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. 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. 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. 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. 30. S ir r is M anuf act ur ing Day Next Step: Intelligent ManufacturingMethodologies  Decision Support  Operations Research  Manufacturing Science  Factory Physics  Production Methods  Supply Chain Management  Mathematical Optimization  Modeling & Simulation Advanced Planning & Scheduling © 10 – 05 – 2011
  31. 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. 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. 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. 34. S ir r is M anuf act ur ing Day ALDISSOur Way Forward: ALDISS •Adaptive •Lean •DIstributed •Scheduling •System © 10 – 05 – 2011
  35. 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. 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. 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. 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. 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. 40. S ir r is M anuf act ur ing Day Questions ? © 10 – 05 – 2011
  41. 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

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