het collectief centrum van de Belgische technologische industrie The future of Smart Manufacturing Execution
Jan 20, 2015
het collectief centrum van de Belgische technologische industrie
The future of Smart Manufacturing Execution
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
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
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
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
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
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 !
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
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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+
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.
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
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
Contact
Mark Van PeeSirris – Advanced ManufacturingTel: +32 498 91 93 [email protected]
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