Manufacturing Production Planning AI - ERP system

MANUFACTURING PRODUCTION PLANNING {AI - E|R|P} SYSTEM FUNDAMENTALS
L | C | LOGISTICS
PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT
Engineering-Book
ENGINEERING FUNDAMENTALS AND HOW IT WORKS
July 2019
Expertise in Process Engineering Optimization Solutions & Industrial Engineering Projects Management
Supply Chain Manufacturing & DC Facilities Logistics Operations Planning Management
Engineering Maintenance | Machine Operation | Warehousing & Transportation

MANUFACTURING PRODUCTION PLANNING {E|R|P} SYSTEM FUNDAMENTALS
Abstract
Manufacturing / Production Planning, across any industry in Thailand; is one of the
most important activities in the 24 hrs, 7 days, 52 weeks cycles per year, as planning is
dynamically linked to the following operational functions:
• Machinery / Equipment, Utilities Maintenance and Sanitation
• Production, which in some processes includes a KANBAN type system
• Open Customer Orders, Demand planning and Sales Forecast
• Warehousing, urban delivery and nationwide delivery Transportation
• Inbound / Outbound customs clearance and global sea-air-land freight forwarding
• Raw Materials, Packaging, Finished Goods, Services, Spare parts specifications, and inventories
• Procurement anti corruption rules and regulations practices
Most Enterprise Resource Planning (ERP) Computer systems cover the following functions
• Accounts Receivable, Customer Service and basic Inventories control
• Accounts Payable including basic Purchasing, and Banking
Meaning of Manufacturing Production Planning

However, there is always missing the integration of the other interrelated operational functions;
and that is the link that needs to be developed and to be integrated with any AI - ERP computer
system, whether it is based on a computer cloud wave site, portal or an intranet server’s system
This document has the objective to show the planning interrelated operations and how those
operational functions most be integrated to any existing ERP computer system in any
Manufacturing / Production Planning system
Due to its repetitive cycles and array of parameters, and branched decision tree, it is also
recommended to Automate the planning decision making process using fundamental Artificial
Intelligence Concepts Approach

In Summary, the Planner information Dash Board computer system can be illustrated with the
following
Database
Application
Planner
Dash Board
Production
Maintenance Warehouse
Logistics
ERP
ERPCustomer Service
Planning
Line/Machine #
Job order no
status
Line/Machine #
status
Job order no
status
Line/Machine #
Job order no
transportation
Customer status
Customer
Job order no
transportation
status
Customer
Job order no
Transportation
status

Background and Statement of the problem
Accross most industries, data processing, in manufacturing / production planning , is done using
Microsoft Excel spread sheets, and it is almost the same case in regards to demand planning, sales
forecasting, spare parts, raw materials, packaging materials, finished goods inventories,
warehousing, urban deliveries, nation wide transportation, customs clearance, freight forwarding,
Engineering maintenance, sanitation and manufacturing/production operations, including
procurements, and quality
This Excel data processing general practicing is complex, and the data in Excel files are almost
never standard, besides not being centralized, and integrated in a unique Data Base; cross data
processing operational functions are complex, and seldom integrated with any ERP systems, or
cloud wave site

Background and Statement of the problem…..continue…..
There are individual computer management systems, for those operational functions such as
warehousing, transportation, customs clearance, freight forwarding, enginering maintenance,
materials resource planning, KANBAS, spare parts inventory control, and some ERP computer
systems attempting to cover some of the activities of the planner, the main warehouse,
manufacturing and so on; but they never really fit into the manufacturing / planning functional
operation
As a result of that weakness, planners never know in real time if their plans are progressing as it is
expected, and there are a great number of situations disrupting the original production plan, such
as a machine / equipment break down, shortage of materials, work in progress reworks, un
recoverable scraps, managing FIFO stocks, replanning transportation for delayed production
deliveries, intensive labor shortages, materials handling vehicles breakdown, quality issues in the
production process, and others

Objective
The purpose of doing this document, is to open the Industrial Engineering practitioners their view,
on how to integrate computer systems of interrelated or cross functional manufacturing
operations, with the aim to have a real time communication across all operational functions, and
be able to have a fast respond to operational situations as are required in real time through a
centralized dash board, which visually in real time, can tell the progress of every customer order,
and the production of buffer stocks

Expected benefits
In the day to day manufacturing/production operations; the starting point is either to build buffer
finished goods inventories, or to produce them as per customer orders, servicing the just in time
operation; in the worst case, they produced logged back orders
However, to complete the production work instructions, it depends on the reliability of the
production machines and supporting utilities equipment; it depends also on the quality of the raw
materials, the availability of raw and packaging materials, the availability of storage space and
transportation, the production yield and production rates affecting the total production order
quantities; and to some extend the machines technical know how, and available technical - labor -
operators skills

Expected benefits…… continue…..
The backbone of the production planning operation, is the real time information communicated,
across all interrelated operational functions; in order to be able to adjust and make changes to the
production plan in real time, at the same time, this type of information allows to make fast
response operational activities adjustments; in engineering maintenance, warehousing,
transportation, production, besides affecting other operational functions, such as quality, sanitation
and procurement
Because of the repetitive nature of the operational cycle, it is recommended to introduce Artificial
Intelligence Algorithms, to take fast, accurate decisions, and communicate them in real time
The expected benefit is real time digital, visual, video and voice information communication
across functions, keeping in mind that the main goal of any manufacturing/production operation
management is to achieve the highest level of yield and production rates; that means minimize
waste by all means; and to achieve that, there is a long list of actions to be done and sustain at all
times
Always observing, to meet the Finish Goods product specifications, or expected quality

Conceptual Framework
There is a general attempt made by many manufacturing companies across all industries in
Thailand; following the success of economies such as Japan and Germany over the last 70 years
Implementing famous single techniques, used mainly by Japanese companies; trying to emulate
several Japanese methods, such as:
• Quality circles, continuous improvements, six sigma, Kaizen events
• Total Production Maintenance, lean manufacturing, the Toyota method
And the list keeps growing; using also many measurement formulas, such as:
• mean time between failure MTBF, mean time to repair MTTR,
• overall equipment efficiency OEE, key performance indicators KPI’s,
• cost per parts deliveries, milk run transportation, just in time JIT deliveries,
New fashionable terminology, like:
• operations excellence OPEX, 5S’, Lean manufacturing concepts, Innovation Technology and
new terminology yet to come along in all industries

Conceptual Framework……. Continue …..
There is also the use of smart phone technology and social media applications such as line among
others, and the flexibility that comes along with those devices, such as:
• sharp digital photography with large digital data storage capacity, voice recording, video clips,
• e-mails, text notes, full business Microsoft and Google cloud business applications,
• ERP cloud business applications
•and the re-introduction of Artificial Intelligence (AI) which has been in the development over
several decades

Research Methodology
The research method used, is the direct mapping of the manufacturing/production process flow,
regardless of the type of finish goods products, manufacturing/production method, process,
industry; using intensive labor, fully mechanized, semi automated, or fully automated; including
different types of management methods; among them Thai, Asian or Western family business,
Global corporate business
The mapping includes the analysis of existing individual piramid organizations or integrated
matrix cross operational functions; focus on the flow of information in real time and the response
time to take cyclical repetitive decisions and fast response repetitive actions to solve recurring
manufacturing/production operational problems

Research Results
The following is an example of an initial Industrial Engineering assessment of a factory facility:
The factory Industrial Engineering Assessment initially identifies the following issues:
• Production Planning software, currently based on Excel files
• Product’s quality issues, observed from, production machines molds dimensions accuracy,
bottom, top, center tip, machine parameters’ settings
• Finish Goods quality issues, inherited from work in process materials quality; bottom, top,
center, tip, dimensions accuracy by a mm, a second, a mg, a ml
• Finish Goods quality “black spots” issues, due to indoor polluted dirty air flow, into the facility

Research Results ……. Continue …..
• Machine breakdown due to poor maintenance, lack of pro-active maintenance, and spare parts
• Maintenance only during the day shift with over time as required, and if approved
• Night shift without maintenance technicians
• Time to attend and repair a machine breakdown, can take from hours to days, including the lack
of spare parts availability in Thailand with long internal purchasing approval lead time
• Production planning issues to match customer delivery time expectations
• Warehouse storage space issues
• Finish goods packing issues due to ergonomics, available equipment and tools
• Scrap-waste control issues
• Overall manpower utilization, operational procedures and ergonomic issues
• Stocks on hand control (finished goods, materials and packaging)
• Customer complains due to incomplete delivery order quantity
• Planning-production-logistics-delivery loading documents flow and information content

Goals:
To improve the factory production, maintenance, sanitation, quality and logistics operations
integrated to the production planning operations
Objectives:
Increase the current available production capacity utilization
Increase the current available storage space utilization
Reduce the production waste-scraps
Provide a production planning tool, to improve the current planning system
Strategy:
Review the complete planning-production-engineering-quality and logistics operations
information management system and implement required adjustments

Actions:
• Re-design the receiving and dispatch areas to prevent the inflow of outdoors dirty air into the
indoors production facility
• Implement a big outdoors-indoors facility clean operation
• Implement an operation to sustain the outdoors-indoors facility cleanliness at all times
• Design and test a new layout to palletize and block stacking Finish Goods and Materials
• Design and test a new pallet block stacking storage operation
• Warehouse storage and production area layout review for dynamic real time space management
• Analyze the Finish Goods process/machine/mold specifications, quality issues by Engineering
• Engineering and Production machines operation, to calibrate the Finish Goods production
machines as per FG design specifications

Actions:…… Continue ….
• Implement engineering and machine operations daily pro-active maintenance, and maintenance
work orders status traceability, and spare parts
• Design the Finish Goods packers operator’s ergonomics, to improve on packing and palletizing
• Design the statistical demand trend analysis, demand forecast software, including SOH control
• Design the dynamic warehouse storage location control software
• Design the barcode system to perform real time traceability of customer production orders
• Design the barcode system to perform real time traceability of production machine status
• Design the operation control of using a delivery truck doors seal including barcode system to
perform traceability
• Design a Dash Board software system tool, to help the planner to produce an effective plan
• Design Artificial Intelligence Algorithms, to take over all cycle repetitive branched decisions
•Incorporate Artificial Intelligence Decisions into the Real time Information Network system

The following flow chart illustrate, the production planning information management system,
which is based on real time feedback information from, the production operations, engineering
maintenance, quality, sanitation, warehousing, transportation logistics, inventory management,
procurement
This information is the base of the Planner Dash Board Computer System, and Artificial
Intelligence Algorithms development.
For this information to flow in real time to the Central Dash Board Computer System, it is
required in real time, the information feed back from all related operations, and, to achieve that, it
is also necessary to improve the related operations within the business process flow

Production planning Dynamic Object Information Dash Board Computer System
Maintenance
Engineering
Production Line
Operators
Central Processing
Planner
Materials & FG
Warehouse
Logistics Transport
Central
Processing
Control
Production
Machine
Information
Real Time
Maintenance
Information
Real Time
Materials & FG
Information
Real Time
Transport
Information
Real Time
Customer Order
Sequence
Optimization
Algorithms
Customer order
Machine queue
Best sequence
Materials WIP
dynamic location
Control
Materials
Transportation
Distance Matrix
Flow Control
Customer Order
dynamic status
Control
Machine
Readiness
dynamic status
Real Time
Customer Order
Materials WIP
dynamic status
Real Time
Customer Order
WIP transportation
dynamic status
Real Time
Machine
performance
Updated data
Real Time
Machine
breakdown
Repairs, PM, etc
dynamic status
Real tTime
Customer Order
Quality issues
Reworks, scraps
dynamic status
Pro Active
Maintenance daily
work orders status
Real Time
Machine
Pro Active
Maintenance
schedule status
Real Time
Machines break
down repairs
schedule status
Real Time
Machines repairs
work orders status
Real Time
Machines PM
work orders
schedule status
Real Time
Machines
maintenance
OEU, MTTR,
MTBF, trend
Machines break
down 9 why’s, root
cause, actions
Schedule status
Daily MOM key
points status
update Real Time
Machine spare
parts ABC, critical
SOH, demand
trend status
Machines parts/
components SPC
failure analysis
status
Machines parts/
components SPC
failure analysis
status
Machine spare
parts ABC, critical
SOH, demand
forecast
Customer Order
materials BOM
readiness status
Real Time
Customer Order
Materials WIP
dynamic status
Real Time
Customer Order
WIP transportation
dynamic status
Real Time
Truck readiness
dynamic location
status Real Time
Truck jobs
dynamic schedule
status Real Time
Customer Order
WIP materials
usage, scrap,
Re-work, ETD
Customer Order
WIP materials
Line ETA, ETD
Real Time
Customer Order
materials usage,
scraps, re-work
Status Real Time
Materials dynamic
travelling routing
best schedule
Truck dynamic
travelling routing
best schedule
Production
Materials ABC,
critical SOH,
demand forecast
Production
Materials SPC
analysis status

Another example used to illustrate the importance of an integrated planning information
system
The main Goal is:
•T o utilize the production lines at maximum capacity available
The main Objectives are:
• To minimize the production lines breakdown, idle time, setting time, and waste
• To produce products within the quality specification
• To minimize the setting scraps/wasted production materials, and re-works
The main Strategy is:
• To modernize the planning management of the production lines

The main Actions are:
• Enforce a compulsory production lines machines daily cleaning and removal of waste, scraps
• Enforce daily pro-active production lines machines maintenance, besides PM schedules
• Enforce the fast break down response, with reliable repair works and re-setting works
• Enforce the good care of production tools and rolling-rotary components, such as dies, rolling
ball bearings, shafts, accumulator pulling, wire reel brakes, rubber belts, sprocket chains
• Sustain control of the wire-cable pulling tension force and wire-cable travelling speed along the
production line, balance and synchronize the travelling speed among machines like capstans,
dancers, accumulators roundup, etc

The main Actions are …… Continue ….:
• Implement WIP materials exact storage location information management in real time
• Implement WIP materials Forklift dynamic travelling route tracking and updating in real time
• Implement a computer dash board and Artificial Intelligence Algorithms tool, to help the
production planner to get information in real time and taking fast response decisions regarding:
Customer order in production line status
Production line machine(s) readiness status
Production line machine(s) maintenance / repair / setting works progress status
Customer order in production line quality issues, re-works, scraps
WIP materials forklift best travelling route and schedule, execution progress
Algorithm to calculate the best sequence for the customer order in production line
Algorithm to calculate best picking/delivery job for the forklift based in current location
Algorithm to analyze the materials demand trend and sales forecast to best manage SOH
The list is not standard, as there are operations which are specific to specific operational
processes, and therefore, a very extensive and diligent analysis has to be completed for each
operational function - activities

The main Actions are …… Continue ….:
• Re-write the Job Description of the Line(s) machines Operators and Technicians, to make sure
they are accountable and understand clearly what is expected from them, in their daily routine
activities; with emphasis to their task of cleaning and housekeeping the Line(s) machines daily
• Re-organize the current Engineering Maintenance organization structure, which do not include
Pro Active Maintenance, machines house keeping and cleaning operations
• Strength the Operations organization, which has the same weakness, and it is important to
correct this organization structures to guarantee the well being of all production line(s) machines
• Start a schedule to carry on all activities mentioned above
Most challenging is to communicate with the existing Management, and make them understand
the scope of works, and how those changes will affect their overall management style,
participation and contributions; as Artificial Intelligence take a great part of their influence in the
cycle repetitive decision making process; in other words, their standard management practices
become un-necessary, such as meeting, reports, analysis, paralysis, and approval process

Summary:
Across all production line(s) machines, and in almost all production lines, there are visual marks
of very low maintenance on the production machines, and its equipment control panel
components; in both mechanical, electrical, instruments and thermal maintenance; including air
ventilation equipment
For example, in rotary parts with ball bearings, bushes, sprockets, chains, rubber belts, pulleys,
and shafts among many others, the maintenance is very limited, probably only to a break down or
to a scheduled maintenance date
All mechanical rotary parts with misalignments have a physical effect on the making of any cables
and wires due to their mechanical vibrations, mechanical surging, mechanical whooping,
mechanical friction and resistance to smooth rotation, affecting the tension and elongation as well
as the centricity of a wire due to their mechanical properties

Summary ……. Continue …..:
The same can be said of compressed air fittings, with air leakages, insulated piping,
electrical cables, machines panel controls electrical parts, and components; as well as
utilities equipments, broken insulated piping transporting chilled water; all of them
covered by dirt, grease, oil, asphalt, material waste, debris, and garbage, affecting the
making of wire and cable; all production machine floors are just as dirty, and filthy with
lots of debris, waste, and garbage
There are also, many very old, not in use, machines, equipment, sometimes almost a
complete line in the abandonment, and occupying productive space
All of those equipments need to be removed to clear the production area, then, re-draw
the production floor layout, and plan to make the best use of the available production
space

This action will have an impact on the random use of temporary WIP materials, which are left all
over the place, without real location control, and increasing the disorganized WIP materials
storage
There are also several health risk situations observed; such as contractor workers not using PPE
personal protective equipment during welding at high elevation over 2 mts, hot works area with no
enclosed protection to prevent fire, and perimeter tape warning to stop people going under
welding works
At the packaging materials ware house, floors are slippery without warning signs of wet-oil floors
In one extrusion line, the use of gas to melt the PVC compound, expose risk of fire and accident
with injury to the near by operator, including damaging the near by electric machine control panel

Safe guarding within the Aluminum Ovens are missing, and there are very high
temperature materials which could be touched by accident by any operator or people
walking within that area. This also requires increasing the natural light roof sheets to have
more day light going through the roof
Although there are visual indications, that the people at one time, did practice, safety
rules, 5S’s, and other operation excellence activities; currently there are no visual signs
of positive practice results
The following chart are representation of general findings in this Industrial Engineering
Assessment; from this assessment it is clear that the planning function operations are
required to be integrated with all other operational functions, such as engineering
maintenance, warehousing, inventory control, logistics transportation, production
operations and quality control

General Visit Observations
Production Planning Inventories Production Lines Maintenance Prod Lines Safety
Production Lines
idle capacity
Short of planning
software tools
Stocks on Hand
Multiple Storage
Locations with
loose controls
Production lines
with Idle capacity
not utilized
Whole factory
lack interiors and
exteriors house
keeping
Machines
Maintenance
works not
completed
Operator high risk
of injury upon
working accidents
Factory Interior
with polluted Air
due to poor
ventilation
General Findings { system tools lacking and actions to carry on improvement }
Customer
Orders SAP
Back log
integration
ASPROVA
MRP
software
Production
Lines
dynamic
Simulator
Production
Lines order
sequence
Optimizer
Multiple
Storage loc
tracking
Demand
Planning &
Sales
Forecast
Inventory
Levels
Simulator
SAP
Purchasing
module
5 years
Marketing
Plan
SKU’s
segment
Plan
Production
Capacity
Plan
Production
Lines
Assets
Required
Utilities
Assets
Required
Production
Lines
Materials
Handling
Production
Lines
Layout
Revised
Materials
Required
Materials
Storage
Required &
Layout
Sustained
machines
cleaning
Clean
machine
Mech / Elec
component
Daily
Proactive
Machine
Inspections
Daily
Proactive
Maintenanc
Technicians
Operators
maintenanc
Stocks loc
movements
RF Barcode
control
Clean
ventilation
Fans
Upgrade
safety
protection
guards
Upgrade
Floor line
markings
Forklifts
travel way
implement
safety rules
Sustain
clean toilets
Remove
spider webs
Machines
dust/grease
Add more
roof natural
lighting
Protect
machines
from
corrosion
Cost of not
utilizing full
capacity
Cost of SOH
surplus and
shortages
Long Term
Planning
Strategy
Cost of
frequent
break downs
Frequent
breakdowns
Cost of
preventing
accidents
sickness
Focus on
rotation
component
Focus on
sustaining
tension
Focus on
fast
machine
repairs
Remove all
garbage
waste in the
lines

Improvements Phase I ….. Continue …..:
Carry on a very strict house keeping exercise and remove all waste and garbage, cleaning all
working areas, including the machines/equipment; pay attention to all electric machine wires, and
rewire if necessary; this work might require of contractor workers and supervised by a technician
or operator
Implement a very detail mechanical, electrical, instruments, and thermal daily pro-active
maintenance, replacing all worn out mechanical parts such as ball bearings; plan in advance the
ordering of parts like sprockets with dented teeth, before they get broken and disrupt the
production machine operation
This is extremely important to improve on the high and smooth performance of all the machines
and control equipments; the objective is to eliminate the break downs, as well as to bring the
machines to optimal working and smooth conditions
These works require to develop a line(s) machines daily inspection check list, and use it in the
daily Manufacturing Operations Meeting MOM, taking actions and resolving each issue daily

Improvements Phase II:
All production machines preparation setting works, requires a lot of production time; the correct
setting depends mainly on the operator skill, as well as the existing manual tools and worn out
condition, used during the setting of any machine in any production line at any time
It is recommended to use the company’s Engineers and the workshop technicians, to study,
innovate and implement, new, upgraded and, or additional production machine setting tools; using
existing available technology, mechanical equipments and parts, as well as control instruments,
and other technical devices; which can help the machine operator to reduce their setting time,
reduce the machine dependency on the operator skill, make the settings with high precision
accuracy, and make each setting more standard, in regards to the steps required for the setting, and
to reduce the time required, to do any machines settings works
Example: replace mechanical manual operator calibration by using proximity sensors, servo
motors, PLC and automated switches on/off control panel

Improvements Phase II ……. Continue …:
It is extremely important not to depend on the operator’s memory, skills, and physical availability
to do the correct production machine settings, whenever they are required, and for each job, the
operator has to fill up the “check list to do” form again, over and over; even if the operator is
extremely skilful
In this respect; for every product that is to be produced in each production line machines, there
most be controlled settings “check list to do”, step by step, and in sequential order; to be checked
daily/shift by the supervisor. It is also a tool to trace back quality problems happening in the
machines
The operator in every shift has to fill up this “check list to do”, and keep the sheet in their machine
log book, which is to be used by their supervisor; making sure that no setting step has been
missed, forgotten, or avoided. Part of the Quality Assurance operator’s job, is to make sure that,
the operator follows the machine settings process and procedure 100% at all times, with all
products
When the above is done, then, the operator is doing his quality control and quality assurance job.
This also means, reduction in waste and customer product reworks; production delays are also
reduced

Improvements Phase III:
Work in Process Product/material real time transportation is delaying the starting of the already
prepared “setting” production line machine(s) for production
Several times, a product/material has already been reel winding completed, and it is waiting for a
new empty reel, and the removal of the already completed wired reel, but the transportation takes
quite a long time to happen; this situation contributes to the delay of starting the machine
production; adding up to the waste of precious production time, the unutilized production machine
time
There most be a system to coordinate with the fork lift operator and manage the fork lift units in
such a way that, it can eliminate the time waiting for the fork lift to arrive
Further analysis on this transportation operation problem is required, in order to come out with a
solution to this situation, perhaps using Radio Frequency and bar code hand held terminals, digital
transportation KANBAN, and some other ideas which we can be though of, and managed in real
time

Planner Dash Board Computer System
The main objective for the Planner to have a real time information Dash Board
Computer system with Artificial Intelligence Algorithms is, to be able to have a fast response, in
the event of any obstacle along the production-delivery process, and to automatically, make all the
necessary adjustments to the production plan, with optimal criteria, based on the cycle repetitive
parameters decision making, taken over by Artificial Intelligence Algorithms
This can be achieved by integrating all related operational functions, into a real time
data processing mode of operation 24/7 throughout the year
The Dash Board is also capable of optimizing the best customer order sequence to be
produced by an assigned production line machine(s), and to give accurate information regarding
any customer order production status

The Dash Board functionality is best understood by illustrating the whole production
process, as is the case of the two examples illustrated in this research work
Using today’s computer information and data communications technology, based on a
web site portal computer cloud system, the data storage capacity is practically unlimited, the
number of business applications to be integrated into modern smart phones, are also wide open,
including the incorporation of optimization simulation computer models, and artificial intelligent
algorithm in business applications
The future of the planner operations is no longer limited to the computer capabilities of
standard ERP computer systems, which mainly focus on accounting information data processing

Cost of developing and incorporating large computer hardware and software
applications into the manufacturing operations management, is proportionally low in cost, and
large in magnitude of scope
It is recommended to further study the scope of this idea, by developing a prototype computer
system first, in a single computer, and then later, it could be developed in a cloud system, as there
is the need to integrate it with other existing information data systems in place, such as the SAP,
ASPROVA, KANBAN and Excel spread sheets
Below there is an operation procedure flow chart, as it is well noted and identified that, this whole
idea needs to be also, integrated through the KANBAS system to the management of the “re-
works”, the warehousing WIP operations, the WIP transportation, as well as the integration with
materials stocks on hand available, ready to be used for production, and the production line(s)
machines maintenance

Production planning Dynamic Object Information Dash Board Computer System
Maintenance
Engineering
Production Line
Operations
Planning Operations
Central Processing
Materials & FG
Warehouse
Logistics
Forklift Transport
Central
Processing
Control
Production Line
Information
Real Time
Maintenance
Information
Real Time
Materials
Information
Real Time
Forklift
Information
Real Time
Optimization
Algorithms
Customer order
Line queue
Best sequence
Materials WIP
dynamic location
Control
Materials
Transportation
Distance Matrix
Flow Control
Customer Order
dynamic status
Control
Line Readiness
dynamic status
Real Time
Customer Order
Materials WIP
dynamic status
Real Time
Customer Order
WIP transportation
dynamic status
Real Time
Line performance
Updated data
Real Time
Line breakdown
Repairs, PM, etc
dynamic status
Real tTime
Customer Order
Quality issues
Reworks, scraps
dynamic status
Pro Active
Maintenance daily
work orders status
Real Time
Line(s) Pro Active
Maintenance
schedule status
Real Time
Line(s) break
down repairs
schedule status
Real Time
Line(s) repairs
work orders status
Real Time
Line(s) PM work
orders schedule
status Real Time
Line(s)
maintenance
OEU, MTTR,
MTBF, trend
Line(s) break
down 9 why’s, root
cause, actions
Schedule status
Daily MOM key
points status
update Real Time
Machine spare
parts ABC, critical
SOH, demand
trend status
Line(s) Machines
parts/components
SPC failure
analysis status
Line(s) Machines
parts/components
SPC failure
analysis status
Machine spare
parts ABC, critical
SOH, demand
forecast
Customer Order
materials BOM
readiness status
Real Time
Customer Order
Materials WIP
dynamic status
Real Time
Customer Order
WIP transportation
dynamic status
Real Time
Forklift readiness
dynamic location
status Real Time
Forklift jobs
dynamic schedule
status Real Time
Customer Order
WIP materials
usage, scrap,
Re-work, ETD
Customer Order
WIP materials
Line ETA, ETD
Real Time
Customer Order
materials usage,
scraps, re-work
Status Real Time
Forklift dynamic
travelling routing
best schedule
Forklift dynamic
travelling routing
best schedule
Production
Materials ABC,
critical SOH,
demand forecast
Production
Materials SPC
analysis status

Artificial Intelligence Algorithm
Semi optimal customer’s products (orders), production machines route schedule best sequence
The idea of having a “semi optimal” customer products (orders) best sequence; requires, the
combinatorial analysis of several customer products sequences; calculating, which customer
product sequence takes the least production time within the line’s machines, under the customers
products consideration
To do this, it is required to test the idea of using a semi optimizer algorithm to find the “best”
sequence of products (orders) for each product (order) machines route
This exercise is done using an Excel spread sheet, and several options to test the algorithm, like:
Customer product (order) FIFO, highest value, longest in route machines time usage, lowest in
route machines time usage, due date, re-work LIFO, re-work volume grouping
There can be more than these criteria's based on, real production/marketing life situations;
however in this respect, the algorithm is being developed within the Excel spreadsheet, and tested
to make a point of this gross idea, in the search for a “semi optimizing” tool, to minimize the time
used in the production lines machines

Production planning
Customer product Line machine(s)
SOH buffer stocks &
stocks to make
Algorithm KANBAN Ticket
customer product
order parameters:
due date, length,
value,... (rework)
Group Products
BOM and SOH
calculate materials
Qty from SOH
Qty to make
Qty to buy
Check products
BOM / made to
stock ,SOH ready,
stock to buy
Products BOM’s
and Line
machines
Speed mt/min
Product (s) BOM
ready, machines
route sequence
required
Organize Product,
Machines route by
FIFO
FG value
Due Date
>> machine time
<< machine time
LIFO (re-work)
Vol group rework
Determine which
sequence has the
lowest queue
IN / OUT time
Calculate queue
IN/OUT machines
production time
WH Materials
KANBAN ticket
work instructions
Materials
Transportation
KANBAN ticket
work instruction
Product order
Production
machine(s)
KANBAN ticket
Product re-work
Material(s)
KANBAN ticket
Product order
WIP materials loc
production status
traceability
Adjust machines
if required (daily)
Self maintennce
Verify machines
condition prior to
production (daily)
Confirm date/time
machines ready
(daily)
Product machine
status traceability
KANBAN ticket
Break Down delay
Re-Setting delay
Product quality off
Product to rework
Daily schedule
update and
adjustment as
required
New customer
product order
arrival
Go to the queue
Product
quality issue with
re-work
LIFO, vol group
Prepare KANBAN
ticket work order
instructions
Materials
SOH storage
location tracebility
Packaging reels
SOH storage
Materials WIP &
Transportation
movements
coordination
WIP rework
materials storage
WIP materials &
Transportation
Real time control
Materials WH
WIP locations &
Fork lift
coordinated
movements
Line machine(s)
Readiness
Real time status
Line machine(s)
Readiness
Real time status
Line machine(s)
breakdown
Real time status
Line machine(s)
repairs schedule
Real time status
Line machine(s)
repair spare
parts status
Line machine(s)
spare parts SOH

Improvements Phase IV
It is necessary to incorporate this idea to the procurement activities, as it also affects the
procurement operations of materials and the inventory control levels
The main objective is to increase the available production machines capacity utilization, reducing
waste, increasing the materials and production yield
WIP storage space utilization across the production floor areas, needs to be reviewed, draw a
layout, and study the WIP flow, to find a better WIP storage space utilization, including WIP real
time tracking

Below is the result of Materials Stocks Analysis for the last seven months for a group of materials
used in the production of customer product orders. The analysis is based on consumption Demand,
consumption Forecast, Stocks on Hand and the classified in groups ABC, 85%, 95 %, 100%
Calculating the weighted average, using a t-distribution value for 7 months data observation,
standard deviation among the 7 months data, the maximum and minimum value observed, the
upper and lower control limit, and the triangular distribution to find the forecast
This is a snapshot of the current materials inventory levels and it is obvious that there is room for
improvement, saving money in large inventories quantities. Below there is a graph corresponding
to the group “A”, which is the accumulated 85% of materials making the highest qty in the
Pareto’s concept

In Summary, the Planner information Dash Board Artificial Intelligence computer system can be
illustrated with the following
Database
Application
Planner
Dash Board
Production
Maintenance Warehouse
Logistics
ERP
ERPCustomer Service
Planning
Line/Machine #
Job order no
status
Line/Machine #
status
Job order no
status
Line/Machine #
Job order no
transportation
Customer status
Customer
Job order no
transportation
status
Customer
Job order no
Transportation
status

Summary of the Study
The study is based on direct plant manufacturing observations, in several industries in Thailand; it
illustrates the cross functional operational activities, and the flow of information at the end of the
day, which is basically isolated and not integrated into one centralized information system in real
time
Although, there are many plant manufacturing sites, with an ERP computer system, covering
basically the full Accounting information system, with some general manufacturing, warehousing
and inventory control functions; they are in some manufacturing sites, complemented by isolated
MRP, KANBAS, WHMS, TMS and other IT technologies

Discussions
There are many ERP computer system which can be used as general public information reference
as follows:
• MAXIMO used to manage the activities of Engineering Management and machines / equipment
spare parts inventory control,
• MAC-5 is a general accounting system covering general activities of warehousing and inventory
control,
• ASPROVA used to plan manufacturing activities, and a great number of general ERP systems
such as SAP, ORACLE, and many more based on IBM-AS400 computer system

Recommendations
The plant/manufacturing operational functions in general are the same, what makes the difference
is the process, as it can be using intensive labor, highly mechanized, semi mechanized, semi
automated, fully automated, handcrafted, low and high production volumes
Some production processes are dedicated processes focus on continuous or large batch volumes,
while others are in low volumes with specific quality standard requirements, to meet GMP,
HACCP, and BRC, HALAL, FDA, and many other quality certifications
However, the basic operational functions are the same; production planning, production
operations, engineering maintenance, warehousing, transportation
There are other supporting functions such as human resources, finance and accounting, quality,
industrial safety and environment, security and some times R&D, marketing and sales, public
relations

Recommendations ……. Continue ….
It is important to make it clear that the main goal of a plant/manufacturing operation is to achieve
the highest possible production capacity available utilization, highest production yield or
minimum waste with highest quality as per product design specifications and highest production
rates
That is achieved based on the technological skills and know how of the people working directly in
the production process, as well as on the technology and innovation available in the production
machines, equipment, and the utilities capacity and performance supporting all the production
machines and equipment
The management of all the production operational functions activities, is made based on
information, and real time information helps to make sound decisions, affecting the production
yield as well as the production rates; and so, and integrated real time information system is a tool
to have, as the backbone for all integrated operational functions activities, in any plant
manufacturing system
Using Artificial Intelligence Algorithms, will change the way Management is done for better

Thank You
L | C | LOGISTICS
PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT
Engineering-Book
ENGINEERING FUNDAMENTALS AND HOW IT WORKS
MANUFACTURING PRODUCTION PLANNING {AI - E|R|P} SYSTEM FUNDAMENTALS
Engineering Maintenance | Machine Operation | Warehousing & Transportation

Manufacturing Production Planning AI - ERP system

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