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

The link between the general Enterprise
Management / ERP and the Shopfloor

het collectief centrum van de Belgische technologische industrie

Or: The link between

Production Planning and - Execution

het collectief centrum van de Belgische technologische industrie

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

2 pathways for manufacturing execution

From 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


Production Planning vs. Execution: the Wall

Customer-
orders /
forecast
Office Shopfloor

ERP/MRP


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)
 …


Production Planning vs. Execution: the Wall

Customer-
orders / Office Shopfloor
forecast

ERP MES/APS


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


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


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…)


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 Control
Inventory 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


MES layer


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


ERP / MES integration


Best Practice for Production Planning & Execution

M
E Self organizing
Execution system
T Customer-
Execution
Optimises for
H orders / setups,
nestings,
O forecast colors, …

D Limited Work-In-Process
S = known lead time !

T
O
O ERP Planning Execution MES/APS
L
S

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


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


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 and
inventory


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


Two future development paths for MES

1. 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)


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


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)

+

Decision support systems require
predictive 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


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.


Production Radar (or Holonic Manufacturing
Execution 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


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)


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


Contact

Mark Van Pee
Sirris – Advanced Manufacturing
Tel: +32 498 91 93 45
mark.vanpee@sirris.be


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

Empfohlen

Empfohlen

Weitere ähnliche Inhalte

Was ist angesagt?

Was ist angesagt? (20)

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

Ähnlich wie Sirris Digitale Fabriek IV - Informatiebrug tussen productieaansturing en het algemeen bedrijfsbeheer - Mark Van Pee, Sirris (20)

Mehr von Sirris

Mehr von Sirris (20)

Kürzlich hochgeladen

Kürzlich hochgeladen (20)

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