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Belang van de informatiebrug tussen productieaansturing en het algemeen bedrijfsbeheer: best practices, huidige standaardoplossingen en toekomst op dit gebied. Mark Van Pee - Sirris Advanced Manufacturing
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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 | info@sirris.be | 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)
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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
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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)
…
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MES/APSERP
Production Planning vs. Execution: the Wall
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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
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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,…)
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…)
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Planning – Execution – Control Flow
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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
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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
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ERP / MES integration
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Best Practice for Production Planning & Execution
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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
Limited Work-In-Process
= known lead time !
MES/APS
Best Practice for Production Planning & Execution
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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
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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 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
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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 or
capacity 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 for
order promising towards customers
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Customer-
orders /
forecast
Executie
Optimaliseert
ifv. setups,
nestings,
kleuren, …
Planning Executie
Self organizing
Execution 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. Beyond MES: Production Radar or Intelligent Holonic
Manufacturing Execution System (HMES) based on exploring
agents „ants‟
(K.U.Leuven, Paul Valckenaers, Bart Saint Germain)
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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 within
ERP/MES system
12-10-2011© Sirris | www.sirris.be | info@sirris.be | 23
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)
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+
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
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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)
12-10-2011© Sirris | www.sirris.be | info@sirris.be | 26
Production Radar (or Holonic Manufacturing
Execution System
(HMES - K.U.Leuven, Paul Valckenaers, Bart Saint Germain)
12-10-2011© Sirris | www.sirris.be | info@sirris.be | 27
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)
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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
Contact
Mark Van Pee
Sirris – Advanced Manufacturing
Tel: +32 498 91 93 45
mark.vanpee@sirris.be
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