Sirris Digitale Fabriek IV - Informatiebrug tussen productieaansturing en het algemeen bedrijfsbeheer - Mark Van Pee, Sirris

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Belang van de informatiebrug tussen productieaansturing en het algemeen bedrijfsbeheer: best practices, huidige standaardoplossingen en toekomst op dit gebied. …

Belang van de informatiebrug tussen productieaansturing en het algemeen bedrijfsbeheer: best practices, huidige standaardoplossingen en toekomst op dit gebied.
Mark Van Pee - Sirris Advanced Manufacturing

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  • 1. The link between the general EnterpriseManagement / ERP and the Shopfloor het collectief centrum van de Belgische technologische industrie
  • 2. Or: The link betweenProduction Planning and - Execution het collectief centrum van de Belgische technologische industrie
  • 3. Goal of this presentation To establish the need for BOTH a production planning AND manufacturing execution system To introduce following speakers by enlightening two possible (future) pathways for manufacturing execution: © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 3
  • 4. 2 pathways for manufacturing executionFrom production planning to: 1. Beyond MES: Production Radar (or Holonic Manufacturing Execution System) 2. Self Organizing Systems (Polca, CONWIP  Pull systems) B1 C1 C1 B1 B1 B1 A1 C1 C1 C2 B1 A1 B1 B1 C2 C2 © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 4
  • 5. Production Planning vs. Execution: the WallCustomer- orders / forecast Office Shopfloor ERP/MRP © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 5
  • 6. ERP / MRP Do not use MRP (Material Requirements Planning) for production execution purposes. MRP = OK for purchasing Some disadvantages of MRP:  Inflated, fixed lead times  WIP increases due to lead times  Expediting due to inaccuracies  MRP-Schedules are ignored  PUSH system (see further)  … © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 6
  • 7. Production Planning vs. Execution: the WallCustomer- orders / Office Shopfloor forecast ERP MES/APS © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 7
  • 8. MES? Why is MES (Manufacturing Execution System) necessary? Because ERP doesn‟t end where PCS (Production Control Systems) begin. ERP systems handle financial functions, demand management, customer orders and send production requests to the factory floor. MES provide overall control and management of the factory floor, and provide updated information the ERP. Every tool that assists in processing production orders on the shopfloor can be called a MES © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 8
  • 9. Positioning of MES systems(Manufacturing Execution Systems) Level 4 Business Management ERP/ MRP Level 3 Production Management Advanced (Resource Mgt, MES Systems / APS MES Planning & Production Planning,…) integration Systems Scheduling Level 0, 1, 2 PLC/ Production SCADA Control & Automation Feedback from Workfloor © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 9
  • 10. MES functions  Resource Allocation and Status  Operations/Detail Scheduling  Dispatching Production Units  Document Control  Data Collection/Acquisition  Labor Management  Quality Management  Process Management  Maintenance Management  Product Tracking and Genealogy  Performance Analysis  (some ERP and MES functions overlap…) © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 10
  • 11. Planning – Execution – Control Flow Planning Execution Control Process Instructions: Recipes, Monitoring & Sensing MPRII/ERP MES Work Instructions, Part Programs, Product Demand Process Order Specific, Machine BOM/Formula/Recipe/Drawing Forecasting Resource Alloc./Status Utilization, Work Certification Equipment /Part Program Requirements Environment Costing Resources Operations Scheduling Operator Instructions: Scheduled Production Planning Routing/Process Production Dispatching Labor (predictive) & Preventative Labor Characteristics Material Product Definition Document Control Maintenance, Inventory Status Process Definition SOP, HEALTH, WORK Instructions Data Collection/Acq. Material Safety Instructions Control (documents), Machine Operation SOP Labor Management Machine Control Instructions (documents) Human Resources WIP Status/Traceability Regulatory ControlInventory Management Order Status/COmpletions Quality Management Drill Down (inquiries) Status Realtime QC /Start-Due-End Process Status Advanced Process Controls Purchasing Performance Analysis Batch End Reports Resource Status/Usage Distribution Labor Status/Usage Process Management Operations Material Status/Usage Product Tracking Ad Hoc Inquires Process Sequencing Actual BOM/Formula/Recipe/ and Genealogy Materials Analysis Machine & Process Instructions Drawing/Part Program Events: Time/Date/Lot/Alarms Maintenance Labor Instructions Actual Routing/Process Data Collected from Monitoring Product Genealogy/Traceability Management Human Machine Interfacing Functions: Process, Equipment, /As Built Information Environment, Labor, Material, Product Safety Scrap/Waste Parameters Maintenance Focus: Focus: Focus: Customer Product Process Decision Location: Decision Location: Decision Location: Office Factory Shop Floor/Plant Floor MESA International-White Paper © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 11
  • 12. MES layer © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 13
  • 13. MES implementation If your standard ERP does not feature sufficient MES functionality, an additional standard MES implementation is required = additional implementation project = linking two standard solutions – make them talk with one another = made to measure © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 14
  • 14. ERP / MES integration © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 15
  • 15. Best Practice for Production Planning & ExecutionME Self organizing Execution systemT Customer- Execution Optimises forH orders / setups, nestings,O forecast colors, …D Limited Work-In-ProcessS = known lead time !TOO ERP Planning Execution MES/APSLS © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 16
  • 16. Best Practice for Production Planning & ExecutionME Self organizing Execution systemT Customer- Execution Optimises forH orders / setups, nestings,O forecast colors, …D Limited Work-In-ProcessS = known lead time !TOO ERP Planning Execution MES/APSLS © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 17
  • 17. Difference Push - Pull  A PUSH system plans production based on demand: it doesn‟t limit Work-In-Process. It‟s allowed to keep adding (releasing) production orders Push M1 M2 M3 M1 M2 M3 Pull  A PULL system authorizes production based on system status: it DOES limit Work-In-Process © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 18
  • 18. GAP between Best Practices and Tools METHODS advise us to use PULL / Self Organizing systems  Until now no support within existing standard TOOLS Existing TOOLS for Advanced Planning & Scheduling within MES (~ Finite Schedulers) are still PUSH systems  Because of variability in production a schedule can become invalid from the moment it is released…  Implementations often fail © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 19
  • 19. APS & Finite Scheduling Only with help from BUFFER MANAGEMENT*, it is possible to make a scheduler work: using the right amount of time or capacity buffer drastically increases delivery reliability Aantal orders ~ levertijd* Buffer Management: defining optimal combination of three buffers, time, capacity andinventory © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 20
  • 20. APS & Finite Scheduling Using APS & Finite Planning/Scheduling does not exclude the implementation of a Self Organizing PULL system on the workfloor:  Finite capacity Planning/Scheduling can be used also „in front of the wall‟ (Planning level) for creating a valid plan and for order promising towards customers Self organizing Execution system Executie Customer- Optimaliseert orders / ifv. setups, nestings, forecast kleuren, … Limited Work-In-Process = known lead time ! Planning Executie © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 21
  • 21. Two future development paths for MES1. Adding IT support for Self Organizing Pull systems to MES (Project Aldiss, De Clercq Solutions; Bosch Scharnieren)2. Beyond MES: Production Radar or Intelligent Holonic Manufacturing Execution System (HMES) based on exploring agents „ants‟ (K.U.Leuven, Paul Valckenaers, Bart Saint Germain) © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 22
  • 22. 1. MES and Pull Systems(Project Aldiss, De Clercq Solutions) Adding IT support to Self Organizing Pull systems at production execution level Easily defining Work-In-Process loops and WIP limits within ERP/MES system B1 C1 C1 B1 B1 B1 A1 C1 C1 C2 B1 A1 B1 B1 POLCA C2 C2 © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 23
  • 23. MES and Pull Systems(Bosch Scharnieren, monitoring system with touch screens) Adding algorithms for order mixing and balancing of production system Monitoring system at IT level on top of Polca / Conwip / Polwip card system – Allows for „behind the screens‟ mixing of order sequence) + © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 24
  • 24. Decision support systems requirepredictive character MES systems are all about the present and the past (or not?) To take the right decisions you need a fully informed, intelligent view on the future states of the production system © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 25
  • 25. 2. Holonic Manufacturing Execution System(HMES - K.U.Leuven, Paul Valckenaers, Bart Saint Germain) Agents explore all possible routings/solutions for production execution and an optimal solution is then selected. Based on distributed interactive simulation models of all resources – More robust compared to one single simulation model of the whole. © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 26
  • 26. Production Radar (or Holonic ManufacturingExecution System(HMES - K.U.Leuven, Paul Valckenaers, Bart Saint Germain) Level 4 Business Management ERP/ MRP Level 3 Production Management Advanced (Resource Mgt, Planning & Production Planning,…) Scheduling Intelligent HMES Level 0, 1, 2 Sched. Tool PLC/ Production SCADA Control & Automation © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 27
  • 27. Future of standard ERP and MES? Standard ERP and MES systems are becoming immobile, inflexible dynosaurs. “The speed of business is not just increasing; it is growing at a skyrocketing pace while the ability of ERP solutions to change is approaching an asymptotic path.” “The gap between the speed of business and the speed of ERP is expanding not contracting at many firms.” (ZDNet) In the future ERP and MES will have to be modular and offer a set of solutions PER manufacturing process according to branch/typology (as opposed to present situation, where you select one ERP or MES with maximum fit, which is never good for all business/mfg processes). (cf best of breed) © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 28
  • 28. Which system for your company? Analysis based on Production Screening Proven methodology from Buffer Management Research Project and Industrial Cases for Self – Organizing Pull Systems © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 29
  • 29. Contact Mark Van Pee Sirris – Advanced Manufacturing Tel: +32 498 91 93 45 mark.vanpee@sirris.be © Sirris | www.sirris.be | info@sirris.be | 12-10-2011 30