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het collectief centrum van de Belgische technologische industrie

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

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:

12-10-2011© Sirris | www.sirris.be | [email protected] | 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)


A 1 B 1

C 1

C 2

A1

B1

B1

C1

B1

C2

B1

C2

B1

C1

B1

C1

ERP/MRP

Production Planning vs. Execution: the Wall


Customer-

orders /

forecast

ShopfloorOffice

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)

…


MES/APSERP

Production Planning vs. Execution: the Wall


Customer-

orders /

forecast

ShopfloorOffice

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

Level 3

Level 0, 1, 2

Business Management

Production Management

(Resource Mgt,

Production Planning,…)

Production

Control & Automation

ERP/

MRP

Advanced

Planning &

Scheduling

PLC/

SCADA

MES

Systems

MES Systems / APS

integration

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


MPRII/ERP

Forecasting

Costing

Production Planning

Product Definition

Process Definition

SOP

Human Resources

Inventory Management

Purchasing

Distribution

MES

Resource Alloc./Status

Operations Scheduling

Production Dispatching

Document Control

Data Collection/Acq.

Labor Management

WIP Status/Traceability

Quality Management

Performance Analysis

Process Management

Product Tracking

and Genealogy

Maintenance

Management

Order Status/COmpletions

/Start-Due-End

Resource Status/Usage

Labor Status/Usage

Material Status/Usage

Actual BOM/Formula/Recipe/

Drawing/Part Program

Actual Routing/Process

Product Genealogy/Traceability

/As Built Information

Scrap/Waste

Product Demand

BOM/Formula/Recipe/Drawing

/Part Program

Resources

Routing/Process

Labor Characteristics

Inventory Status

SOP, HEALTH, WORK Instructions

Monitoring & SensingProcess

Equipment

Environment

Labor

Material

ControlMachine Control

Regulatory Control

Realtime QC

Advanced Process Controls

OperationsProcess Sequencing

Machine & Process Instructions

Labor Instructions

Human Machine Interfacing

Safety

Maintenance

Process Instructions: Recipes,

Work Instructions, Part Programs,

Order Specific, Machine

Utilization, Work Certification

Requirements

Operator Instructions: Scheduled

(predictive) & Preventative

Maintenance,

Material Safety Instructions

(documents), Machine Operation

Instructions (documents)

Drill Down (inquiries) Status

Process Status

Batch End Reports

Ad Hoc Inquires

Materials Analysis

Events: Time/Date/Lot/Alarms

Data Collected from Monitoring

Functions: Process, Equipment,

Environment, Labor, Material, Product

Parameters

Focus:

Customer

Decision Location:

Office

Focus:

Product

Decision Location:

Factory

Focus:

Process

Decision Location:

Shop Floor/Plant Floor

Planning Execution Control

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


Customer-

orders /

forecast

Execution

Optimises for

setups,

nestings,

colors, …

Planning Execution

Self organizing

Execution system

Limited Work-In-Process

= known lead time !

ERP MES/APS

M

E

T

H

O

D

S

T

O

O

L

S

Customer-

orders /

forecast

Execution

Optimises for

setups,

nestings,

colors, …

Planning Execution

Self organizing

Execution system


= known lead time !

MES/APS

Best Practice for Production Planning & Execution


ERP

M

E

T

H

O

D

S

T

O

O

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

A PULL system authorizes production based on system status: it

DOES limit Work-In-Process


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 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

* Buffer Management: defining optimal combination of three buffers, time, capacity and

inventory


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 for

order promising towards customers


Customer-

orders /

forecast

Executie

Optimaliseert

ifv. setups,

nestings,

kleuren, …

Planning Executie

Self organizing

Execution system


= 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. 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


A 1 B 1

C 1

C 2

A1

B1

B1

C1

B1

C2

B1

C2

B1

C1

B1

C1

POLCA

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)


+

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

Decision support systems require

predictive character


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.

2. Holonic Manufacturing Execution System

(HMES - K.U.Leuven, Paul Valckenaers, Bart Saint Germain)


Production Radar (or Holonic Manufacturing

Execution System

(HMES - K.U.Leuven, Paul Valckenaers, Bart Saint Germain)


Level 4

Level 3

Level 0, 1, 2

Business Management

Production Management

(Resource Mgt,

Production Planning,…)

Production

Control & Automation

ERP/

MRP

Advanced

Planning &

Scheduling

PLC/

SCADA

Intelligent

HMES

Sched.

Tool

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

[email protected]


mailto:[email protected]



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