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Manufacturing Enterprise Solutions Association Manufacturing Enterprise Solutions Association Scheduling & Leadtime Reduction Th K HDW ThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA Int. & MPDV Partner Manager BOMAG M hi B ildi Machine Building Plant-to-Enterprise
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Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl...

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Page 1: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Manufacturing Enterprise Solutions AssociationManufacturing Enterprise Solutions Association

Scheduling & Leadtime ReductionTh K HDWThyssenKrupp HDW

Ship Building & Engineer to Order

Karl Schneebauer, Board MESA Int. & MPDV Partner Manager g

BOMAGM hi B ildiMachine Building

Plant-to-Enterprise

Page 2: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

MESA OrganizationMESA Organization

• MESA International Board– Committees

• Adjunct Board for EMEA– Committees/teams for various regions

• RUSSIAN WORK GROUP

• MESA Head Quarters– Execution by KCA

107 S Southgate Dr. Chandler, AZ 85226-3222

MESA International – Oct 2009 2

,– DeAnn, Katie, Brandy and others

Page 3: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Details under www mesa orgDetails under www.mesa.org

• Globale Events & White Paper Database

B d M b f L di M f t• Board Members of Leading Manufacturers

• Leading Vendors• Leading Vendors

Page 4: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Welcome atWelcome atWelcome at Welcome at BOMAGBOMAGBOMAGBOMAG

Page 5: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Our productsOur products

Page 6: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Our machinesOur machines

Page 7: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

MES functions BOMAGMES functions BOMAG1. Time and attendance (badge per person)

2 Order tracking2. Order tracking

3. Material provisioning to line

4 Monitoring of interupt (capturing triggers)4. Monitoring of interupt (capturing triggers)

5. Serial number per machine (detailed assembling history: geneology)

Werner Burum( g y g gy)

6. Completion feedback to SAP IT-Head BOMAG werner burum@bomag [email protected]

Page 8: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Time and attendance (badge per person)

Page 9: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Accountability per Person HYDRAAccountability per Person HYDRA

terminalterminal

Page 10: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Order tracking and materialOrder tracking and material

Page 11: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Complex workplan / parallel orComplex workplan / parallel or alternative or optional sequences

- Advanced SAP interface functionality

- High flexability for manual assembly operations

- Jumping back and forth in operations

- Workflow trigger if missing material

- Rework in line possibleRework in line possible

Page 12: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

BOMAG line: HYDRA terminalBOMAG line: HYDRA terminal

Page 13: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

GeneologyGeneology

Page 14: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Geneology / serial numberGeneology / serial number

Page 15: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

COMPLETE GENEOLOGYCOMPLETE GENEOLOGY

• Traceability over all assembly departmentsTraceability over all assembly departments

Page 16: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Painting integration to SCADAPainting integration to SCADA

Page 17: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Hydra: HardwareHydra: Hardware•

• 2 Server (Prod + Test, Cold standby)• Win2000 + Oracle 8.1.7

• 3 * 1,6 Ghz, 2 GB• 0,4 TB Disc, 12 discs: 1 Opsys, 1 Hydra , 3

Redo 7 DBRedo, 7 DB• GB-Ethernet

• 10 CT381 Time and attendance terminals10 CT381 Time and attendance terminals• 6 CT835 Access control terminals

• 44 CT830 BDE-Terminals44 CT830 BDE Terminals• Above 120 Consoles

Page 18: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

AmortizationAmortization •

•Bomag Situation 2001 before HYDRA:•5 persons handwriting •WIP material reduction

•Lead time reduction•Less and shorter interruptions•Less and shorter interruptions

• Exact sallary master date (assembly time per person)

• ----> Amortisation in 0,8 Year

Mr Werner Burum IT ManagerMr. Werner Burum, IT Manager

Page 19: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Process Efficiency by MES24. März 2010

Page 20: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Our ShipsOur ShipsOur ShipsOur Ships

Commercial VesselCommercial Vessel

SubmarinesSubmarines Mega-YachtsMega-Yachts

Page 21: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

MESA PriorizationMESA Priorization

• High Prio Challenges:+ military is customer (engineer to order)+ military is customer (engineer to order)+ civilian ship building‘s volatility:

fast rescheduling from boom to bust

• Low Prio

as esc edu g o boo o bus+ lead time of 3-5 years+ leasing workers and subcontractors Low Prio

– No ringtraceable per OP & area (espionage for fuel cell battery)+ external sourcing risk (inhouse+ external sourcing risk (inhouse Duplication capability)

Page 22: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Benefit after MES

+ Delivery accurace from ca. 65% in year 2000 to 95% in year 2006

Benefit after MES

+ Reduction of external LEASING workers by estimated 15 % (ONSITE re-allocation of assembly teams)

+ DAILY material consumption bookings back in SAP due to immediate Hydra bookings drastic

reduction of „typical missing part“ problem

+ Reduction of LEAD TIMES of core components by 30% (tubes)

+ Visiblitiy of Bottlenecks and INTERRUPTS

+ Strong IMPROVEMENT regarding INHOUSE manufacturing or external subcontracting of PARTS

Page 23: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Howaldtswerke Deutsche Werft

+ Mechanical Assembly in Dock

Dock 8A

Naval Arsenal

Howaldtswerke Deutsche Werft

+ Mechanical Assembly in Dock

+ CNC-Departments

+ Small assembly lines DoD

Dock

Dock 8+ Small assembly lines

+ Inhouse component making

+ ETO-indiv Parts (Tubing Cables)ock 5

Dock 6

ck 7

sse+ ETO indiv. Parts (Tubing, Cables)Werfts

trass

Page 24: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

System Landscape

1x per day Import

System Landscape

HR

BI

1x per hourUpload

PP1x per day planned absence of

4x per hourDownload order

1x per dayΔ hr master data

employees

HYDRA (MPDV Mikrolab GmbH)

Page 25: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

System Components MESSystem Components MES

+ Graphical Order Sequencing- SCHEDULING (HLS)

Complex BOMs and order structures with bottleneck scheduling

+ graphic worker scheduling (including LEASING Personell)

+ Absence Management with SAP HR (Capturing of coming & going)

+ Exact Reporting

+ 50 DC-Terminals for data collection (order- and people times simultaneously) for each

production unit, partially wireless Notebook solutions

Page 26: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Touchscreen DC via BarcodeTouchscreen DC via Barcode

Page 27: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Touch Screen ExamplesTouch-Screen Examples

Page 28: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Two directional ReschedulingTwo-directional Rescheduling

Planniung dilemma:•Personell 1-n (flexible groups)•Personell 1-n (flexible groups)•Parallel & Alternative sequences•Changing milestones Ops via SAP

Page 29: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Scheduler Group LoadScheduler Group Load

Per Assembly Team:yPlanned vs. Available

Hours per Week

Page 30: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Scheduling in DetailScheduling in Detail

• In SAP only order header dates are used

• Simultaneous Forward and Backward scheduling creates windows

Page 31: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Scheduling in Detail DetailScheduling in Detail Detail

• Per OP 10 individual dates are recalculated permanently• Per OP 10 individual dates are recalculated permanently

3 WeeksTime for

Stamp-OP

Page 32: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Personell DemandPersonell Demand

Page 33: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Personell Scheduling on OPsPersonell Scheduling on OPs

Page 34: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Shift Protocol per Customer ProjectShift Protocol per Customer Project

Page 35: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

SAP Missed Dates StatisticsSAP Missed Dates Statistics

Page 36: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Benefits of Hydra MESBenefits of Hydra MES

+ Delivery accurace from ca. 65% in year 2000 to 95% in year 2006

+ Reduction of external LEASING workers by estimated 15 % (ONSITE re-allocation of assembly teams)

+ DAILY material consumption bookings back in SAP due to immediate Hydra bookings drastic

reduction of „typical missing part“ problem

+ Reduction of LEAD TIMES of core components by 30% (tubes)

+ Visiblitiy of Bottlenecks and INTERRUPTS

+ Strong IMPROVEMENT regarding INHOUSE manufacturing or external subcontracting of PARTS

Page 37: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Th k f I t t!Thanks for your Interest!

Page 38: Scheduling & Leadtime Reduction Th K HDWThyssenKrupp · PDF fileScheduling & Leadtime Reduction Th K HDWThyssenKrupp HDW Ship Building & Engineer to Order Karl Schneebauer, Board MESA

Ingo Pedersen

ThyssenKrupp Marine Systems AG

Howaldstwerke-Deutsche Werft GmbH

Werftstraße 112-114

24143 Kiel

Tel.: +49 431 700123787

[email protected]