January 2008 www.ceni.pt

Activities with regard to Production System Evolution

Mission

PAMCENI is a member of the Portuguese Alliance for Science-based Innovation in Manufacturing Industry (PAM)

Mission and Objectives

The mission of CENI relies on the creation of a dynamic information, knowledge and learning network that will provide collaboration between Higher Education Institutions and Technology Organizations to join research and strategic knowledge transfer activities in projects of Industrial Logistic and Organizational Process in a way to improve the qualification of human resources and technology development.

ObjectivesTo promote technology transfer to industrial companies through research and development projects and other actions;To offer advanced engineering services to companies;To develop software tools as part of systems and innovative solutions for companies and industrial sectors;To contribute to the development of human resources skills through training actions.

StakeholdersIndustrial companies

Students

Researchers

Instituto Politécnico de Setúbal

Service industries

Industrial Associations

Local government

Research societies and foundations

.Setúbal

Lisboa Évora

Univ.Algarve

Aveiro

Porto

Leiria

Braga/Minho

Location

- Private and non-profit R&D association

Organisation

• General assembly

• Board of directors

• Scientific board

• Industrial board

• Accounting board

PAM

Associate members and Organization

Portuguese Alliance for Science-based Innovation in Manufacturing Industry (PAM)

The challenges can only be met by a responsive, qualified organisation that bring scientific knowledge together with valued solutions for companies.

Production systems evolution challenge small and medium industrial enterprises to search for skilled people and engineering support.

Industry, generally, has been very open to invest in technology and in new management concepts.

Opportunity and Motivation

CeniAss.I&D

PIONEER

OM2A

SECIL

CITRI VIROC

SAPEC

IPS PORTUCEL

ADP

EX: INESC

The sustainable development of the region of Setúbal and Palmela requires innovative projectsto attract technical and scientific expertise.

Industrial companies perceive the need for cooperation in a global base.

Information systems

Planning models

Control and monitoring techniques and communication technology

Product data management

Process simulation

Supply chain management

Integration systems

Data analysis and processing

Logistics and organization

Production systems modelling and planning

Analysis and optimization of materials flow

Logistic systems for industry and services

Design and implementation of production networks

Reverse logistics

Process Development

Product and process modelling, planning, control and analysis

Product lifecycle and management

Environmental, social and economic sustainability

Evaluation and process improvement

Simulation of manufacturing systems

Process optimization

Collaborative work

Activities

Research Services Training

Skills and capacityCENI relies on a network of researchers, engineers, managers and skilled people from complementary knowledge areas.

Knowledge Transfer Development Applied

Production technologies Statistic Operational research Quality Computer scienceMaterials Maintenance Environment Management

Inte

grat

ion

Inno

vatio

n

Skills and capacity

CeniAss.R&D

TrainingControl and monitoringManagement systemsMaintenanceEnvironment and safetyWaste management

TrainingDemonstration

LogisticsManagement systemsLean processesEnvironment and safetyQuality

Automation and roboticMaintenance

Industrial architectureFactory design

Information systemsIntegration systems

EnvironmentControl and monitoring Waste management

Control and monitoring

Skills and capacity

Synergies of existing skills within the network powering new skills and services:

• Feasibility studies• Factory design• Industrial Architecture

Study through virtual visualisation of production flows extends logistics design and factory modular design.

Output data

• to management• to maintenance staff

IMPLEMENTATION OFSAVING ACTIONS

• no cost• low cost• high cost

INTERFACES

•Condition assessments

•Environmental activities

•Quality and security

issues

MANAGEMENTSYSTEMS

•Energy consumption monitoring•Energy management•Environmental management

Objective:Material flow and the energy consumption analysis and evaluation; saving actions and reporting of attained value.

Projects ”Manufacturing System Energy Consumption Evaluation”

Method:Material Flow Analysis and Process Industry Energy Analysis: a) Specification of needs, b) Analysis of data results from different perspectives (product-, process-, equipment -...), b) Saving actions definition and c) report the findings.

ELECTRICITY

WATER

HEAT & FUELS

RENEWABLES

ENERGY PRODUCTION ON SITE

BUILDING

SERVICES

PROCESS

COREPROCESS

Energy policy

Energy Audits

Energy targets

Energy Programme

Training and information

Energy savingmeasures

Follow-up,Monitoring

Yearly reporting

Results:Yearly report, energy policy, energy audits, follow-up and monitoring, information and training.

P1:Tronco Descascado

P2: Casca de pinheiro

P3:Tronco T2:Destroçadora P6:Aparas T3: Afinadores

P7:Solução de Sil icato de Sódio

P8: Solução de Sulfato de Alumínio

P9:Água

P10:Cimento

P11:Apara fina

P13:Apara Grossa

T5:ConformadorT6:Prensa

T7:Endurecimento

P16:Colchão

P15:Painel

T8:Secagem T9:Esquadriamento P18:Painelem esquadria

P21:Painel endurecido

P25:Painel seco

T1: Descascador

T19: Misturador 2P40: Mistura

T12: Armazenamento

P17: Painel acabado

T10:Pré-Esquadriamento T11: MaturaçãoP12: Painel em pré-esquadria P20: Painel maturado

T13 P5:Cimento

T15:Reactor 2

T14:Reactor 1

P22:Sil icato de Sódio

P23:água

P24:Sulfato de aluminio

Objective:Factory reorganization and processes improvement.

Method:Definition and implementation of a system to evaluate the performance of the manufacturing system.Characterization of a performance “baseline” for comparison.Promotion of empowerment improvement at different organizational levels.Availability of data to support decision making and to drive actions for process improvement and for actions evaluation.

Results:Promotion of empowerment at different organizational levels.

Projects ”Manufacturing Reorganization”

Departments involvementDepartments involvementCommunicationInterdependent functions integration

Interdependent functions integration

TranslationPerformance driversPerformance driversManufacturing systems

(Critical factors)

Manufacturing systems (Critical factors)

Company objectives and strategy

Commitment

Adherence

KPI and targets

Visibility

Process KPI and targets

Results: A framework for the evaluation of a manufacturing system performance.

Deployment[Management Team]

Contribution[Process Owners]

Management ORGANISATIONAL modelDRIVE by ProcessIMPROVEMENT by ProcessRESOURCES management

P

D

C

A ProcessKPI

monthly

Process Owners

EFQMManagement “mind structure”MEASURING system for enhancementsFacilitates mid-term PDCAPioneer BENCHMARKING

Management Team

Evaluate & benchmark[Management Team]

P

DC

A EFQME & R

1~3 yrs

(modified) BSCLong Term STRATEGYMacro VIEWStrategic Indicators drivingProfitability Card Owners

P

D

C

A BSCARD

6~12 mo.

VISION & MISSIONManagement review

TARGETS settingPRIORITIES settingRESOURCES allocation

Steering Team

P

D

C

A KEY PERFORMANCE INDICATORS (KPI)PERFORMANCE/EFFICIENCY of ProcessesHOW Processes are progressingIMPROVEMENT of ProcessesConsequences of PCI’sMonthly revision Process Owners

PROCESS CONTROL INDICATORS (PCI)How the Processes are CONTROLLEDBASIS for improvementsEFFECTIVE RESOURCES managementEnable an effective control of ACTIVITIESDaily monitoring Sub-Process Owners

STRATEGIC (LEAD) INDICATORS (SI)Direct CONTRIBUTION to results & strategyCorrelation to KPI’sRevisions by Quarter Card Owners

Projects ”Manufacturing Reorganization”

Objective:Place the company in a more competitive position in the global market of construction materials supplying engineering solutions with the reduction of the construction time per square meter, decreasing the construction costs per square meter, assuring the reliability of the product/solution and assuring the adaptability of the solution through its modularity.

Method:Develop a new concept for building design, construction, installation and use.

Cement Bonded Particle Board (CBPB)

“Active Component“

Modular and Integrated Constructive System

Use variant

Adaptability to the locations

Pre-manufactured and assembled

ProductBrand

“BuildingIntegratedSystem”

Results:It is expected: i) The development of an integrated, modular and

pre-manufactured and assembled system; ii) Variant of uses such as Services, Industries and

Residences;iii) The design and implementation of an new

industrial process for manufacturing and assembly;

iv) “Portability”: The development of a “packing”solution for expedition; v) Definition of a architecture with a modern and industrial design.

v) Development of a product/label where everything is conceived from the constructive elements to the packaging solution.

Projects “Building Integrated System”

Objective: Integration of maintenance with production planning, taking into account the needs of both production planning and maintenance systems and accommodating the equipment/system reliability forecasting.

Results:The operational schedules contribute for an effective exploitation and performance of equipment/system and optimizes the cost function and will calculate the optimum frequency to perform preventive maintenance.

Method: Development of a new model to integrate the historical data of equipment/system failures and its use, giving inputs data for an effective product life cycle management and promoting the linkage between the design or manufacturing and assembly functions.

Projects “Productive services planning and control system”

(Productive Service Module -PSM)

(1) Forecasting

(2) Forecast.condition monitoring

(3) Forecasting MTBF

(4) Production planning

(5) Maintenance planning

(4) Production planning

(5) Maintenance planning

(1) (2) (3)

(4) (5)

(9)

Objective:Development and implementation of an information system that is conceived in order to support the decision and documentation in the design and manufacturing of tools and dies..

Project management Data management Process planning Tool lifecyclemanagement

DB

Projects “Information system to support the design, manufacturing and tryout of tool and dies”

Method:Process mapping and operational requirements definition to tackle the needs of tool and dies business unit.

Objective:To support the production processes and the production management tasks with an information system for planning and control.

Production planning Operations scheduling Inventory management Monitoring and control

BD

Method:Based on a full process mapping and operational requirements, a system was designed to tackle the needs of aquiculture activity, using processes parameters, forecasting, and other operational data.

Projects “Process Management in Traditional Sectors – Aquiculture”

Organisation

Technology HumanResources

Forumtecnologia e inovação

Other Initiatives

Industry ecosystems: Beyond Lean manufacturing• New organizational models. • Change management. • Disperse and grid manufacturing. • Resource efficient, sustainable production systems. • Challenges in lean management; leanness and agility. • Human resources and technological factors. • Extended value chains and cash flow modelling. • Performance management.

Other Initiatives

Portuguese Alliance for Science-based Innovation in Manufacturing Industry (PAM)

PAM

Alliance for Science in Manufacturing Industry

Thanks for

your attention

January 2008