Sirris manufacturingday2011 future-of-mes-sirris

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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.

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Sirris manufacturingday2011 future-of-mes-sirris

  1. 1. The future ofSmart Manufacturing Execution het collectief centrum van de Belgische technologische industrie
  2. 2. 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 | 10-5-2011 2
  3. 3. Best Practice for Production Planning & ExecutionME Self organizing Execution systemT Customer Execution Optimises forH - orders / setups, forecast nestings,O colors, …D Limited Work- In- ProcessS = known lead time !TOO ERP Planning Execution MES/APSLS © Sirris | www.sirris.be | info@sirris.be | 10-5-2011 3
  4. 4. Best Practice for Production Planning & ExecutionME Self organizing Execution systemT Customer Execution Optimises forH - orders / setups, forecast nestings,O colors, …D Limited Work- In- ProcessS = known lead time !TOO ERP Planning ExecutionMES/APSLS © Sirris | www.sirris.be | info@sirris.be | 10-5-2011 4
  5. 5. 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 | 10-5-2011 5
  6. 6. GAP between Best Practices and Tools• METHODS advise us to use PULL / Self Organizing systems  Until now no support within existing 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 | 10-5-2011 6
  7. 7. 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 | 10-5-2011 7
  8. 8. 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, forecast nestings, kleuren, … Limited Work-In-Process = known lead time ! Planning Executie © Sirris | www.sirris.be | info@sirris.be | 10-5-2011 8
  9. 9. Two future development paths for MES1. Adding IT support for Self Organizing Pull systems to MES (Project Aldiss, De Clercq Solutions; Bosch Scharnieren)2. Intelligent Holonic Manufacturing Execution System (HMES) based on exploring agents ‘ants’ (K.U.Leuven, Paul Valckenaers, setting up O&O project with Sirris) © Sirris | www.sirris.be | info@sirris.be | 10-5-2011 9
  10. 10. 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 C2 C2 © Sirris | www.sirris.be | info@sirris.be | 10-5-2011 10
  11. 11. 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 | 10-5-2011 11
  12. 12. 2. Holonic Manufacturing Execution System(HMES - K.U.Leuven, Paul Valckenaers)• 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 | 10-5-2011 12
  13. 13. Holonic Manufacturing Execution System(HMES - K.U.Leuven, Paul Valckenaers) 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 | 10-5-2011 13
  14. 14. 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 | 10-5-2011 14
  15. 15. Contact Mark Van Pee Sirris – Advanced Manufacturing Tel: +32 498 91 93 45 mark.vanpee@sirris.be © Sirris | www.sirris.be | info@sirris.be | 10-5-2011 15

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