sirris manufacturingday2011 future-of-mes-sirris
DESCRIPTION
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.TRANSCRIPT
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het collectief centrum van de Belgische technologische industrie
The future of Smart Manufacturing Execution
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Positioning of MES systems(Manufacturing Execution Systems)
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Level 4
Level 3
Level 0, 1, 2
Business Management
Production Management(Resource Mgt,
Production Planning,…)
ProductionControl & Automation
ERP/MRP
Advanced Planning & Scheduling
PLC/ SCADA
MES Systems
MES Systems / APS integration
Feedback from Workfloor
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Best Practice for Production Planning & Execution
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Customer- orders / forecast
ExecutionOptimises for
setups, nestings, colors, …
Planning Execution
Self organizingExecution system
Limited Work- In- Process= known lead time !
ERP MES/APS
METHODS
TOOLS
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Customer- orders / forecast
ExecutionOptimises for
setups, nestings, colors, …
Planning Execution
Self organizingExecution system
Limited Work- In- Process= known lead time !
MES/APS
Best Practice for Production Planning & Execution
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ERP
METHODS
TOOLS
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Difference Push - Pull
• A PUSH system plans production based on demand: it doesn’tlimit Work-In-Process. It’s allowed to keep adding (releasing) production orders
• A PULL system authorizes production based on system status: itDOES limit Work-In-Process
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M1 M2 M3
M1 M2 M3
Push
Pull
M1 M2 M3
M1 M2 M3
Push
Pull
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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 withinMES (~ Finite Schedulers) are still PUSH systems
Because of variability in production a schedule can becomeinvalid from the moment it is released…
Implementations often fail
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APS & Finite Scheduling
• Only with help from BUFFER MANAGEMENT*, it is possible to make a scheduler work: using the right amount of time orcapacity buffer drastically increases delivery reliability
* Buffer Management: defining optimal combination of three buffers, time, capacity and inventory
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Aantal orders ~ levertijd
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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 fororder promising towards customers
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Customer-orders / forecast
ExecutieOptimaliseert
ifv. setups, nestings, kleuren, …
Planning Executie
Self organizingExecution system
Limited Work-In-Process= known lead time !
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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. Intelligent Holonic Manufacturing Execution System (HMES) based on exploring agents ‘ants’(K.U.Leuven, Paul Valckenaers, setting up O&O project with Sirris)
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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 withinERP/MES system
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A 1 B 1
C 1
C 2
A1
B1
B1
C1
B1
C2
B1
C2
B1
C1
B1
C1
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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)
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+
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2. Holonic Manufacturing Execution System(HMES - K.U.Leuven, Paul Valckenaers)
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• Agents explore all possible routings/solutions for productionexecution and an optimal solution is then selected.
• Based on distributed interactive simulation models of all resources – More robust compared to one single simulationmodel of the whole.
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Holonic Manufacturing Execution System(HMES - K.U.Leuven, Paul Valckenaers)
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Level 4
Level 3
Level 0, 1, 2
Business Management
Production Management(Resource Mgt,
Production Planning,…)
ProductionControl & Automation
ERP/MRP
Advanced Planning & Scheduling
PLC/ SCADA
IntelligentHMESSched.Tool
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Which system for your company?
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• Analysis based on Production Screening
• Proven methodology from Buffer Management Research Project and Industrial Cases for Self – Organizing Pull Systems
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Contact
Mark Van PeeSirris – Advanced ManufacturingTel: +32 498 91 93 [email protected]
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