current problems on multi-level computer aided …€¦ · technology process planning production...

Tibor TÓTH Ferenc ERDÉLYI

University of Miskolc

Department of Information Engineering

Miskolc, Hungary

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CURRENT PROBLEMS ON

MULTI-LEVEL COMPUTER

AIDED PRODUCTION

PLANNING AND PROCESS

PLANNING

THE 15th INTERNATIONAL CONFERENCE ON MACHINE DESIGN

AND PRODUCTION, UMTIK 2012.

CONTENTS

1. INTRODUCTION – PRODUCTION SYSTEMS AND PROCESSES

2. ESSENTIAL EXPERIENCES OF THE PROGRESS OF PRODUCTION PLANNING AND CONTROL

3. FUNCTIONAL DIVISION OF LABOUR BETWEEN ERP AND MES- THE ISA-95 MODEL

4. INTEGRATION OF THE PRODUCTION MANAGEMENT FUNCTIONS

5. INTEGRATION OF CAPP AND MES FUNCTIONS

6. CONCLUSIONS

CURRENT PROBLEMS ON MULTI-LEVEL COMPUTER AIDED PRODUCTION

PLANNING AND PROCESS PLANNING

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Nowadays the production

systems of manufacturing

industry show a characteristic

matrix-like functional structure

that is the same to a great extent

both in case of small and medium

size enterprises, as well as for

large company networks too.

Real Factory

Model structure

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CUSTOMER

RELATION

MANAGEMENT

SUPPLY CHAIN

MANAGEMENT ENTERPRISE

MANAGEMENT

SYSTEM

PRODUCT

DESIGN AND

DEVELOPMENT

TECHNOLOGY

PROCESS

PLANNING

PRODUCTION

PLANNING AND

CONTROL

MATERIAL

MANAGEMENT,

LOGISTICS

TOTAL QUALITY

MANAGEMENT MANUFACTURING

OPERATION

MANAGEMENT

PRE-

MANUFACTURING,

PURCHASING

PART AND

COMPONENT

MANUFACTURING

ASSEMBLY,

SALES,

DISTRIBUTION

ENTERPRISE MODELLING The HIERARCHICAL

character of this model is

strongly emphasized.

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Material flow

Information flow

1. ENTERPRISE

LEVEL

2. ENGINEERING

LEVEL

3. OPERATION

MANAGEMENT

LEVEL

4. EXECUTION

LEVEL

4

ENTERPRISE NETWORK

The INTEGRATED character

of this model is strongly

emphasized.

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1. ENTERPRISE

LEVEL

2. ENGINEERING

LEVEL

3. OPERATION

MANAGEMENT

LEVEL

4. EXECUTION

LEVEL

CRM SCM ERP

CAL CAQA MES

PPM FMS FAS

CAD CAPP MRP

MULTI-MODUL TYPE COMPUTER APPLICATION SOFTWARES

INFORMATION TECHNOLOGY

THE CIM PARADIGM

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ENGINEERING DESIGN AND PLANNING

COMPUTER AIDED

PROCESS PLANNING

Main activities separated in

technology process planning

1. ASSEMBLY PROCESS

PLANNING

2. RAW-MATERIAL AND PRE-

PLANNING

3. ROUTING AND OPERATION

PLANNING, NC PROGRAMMING

Specific planning

functions

determined

mainly by the

sequence of

activities in time

CAPP

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ENGINEERING DESIGN AND PLANNING

PPC

COMPUTER AIDED

PRODUCTION PLANNING

Main activities separated in

production planning and control

1. FORECAST AND EXTERNAL

ORDER MANAGEMENT

2. CAPACITY PLANNING AND

MASTER SCHEDULING

3. MATERIAL REQUIREMENT

PLANNING AND JOB CREATING

Specific planning

functions

determined

mainly by the

sequence of

activities in time

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2. ESSENTIAL EXPERIENCES OF THE PROGRESS OF PRODUCTION PLANNING AND

CONTROL

ENTERPRISE MANAGEMENT AND

PRODUCTION PLANNING

ERP

The new paradigm:

The functional models of strategic, long time, and

aggregated production planning (and of Master Plan)

are standing so near to the models of enterprise

business processes (innovation, financial affairs,

purchasing, selling, investments, co-operation, costs,

human resources, etc.) that the resource

management approach of these functions can be

arranged within the framework of a unified enterprise

business policy.

The comprehensive, long

term and responsible

requirement system of

enterprise management,

as well as the unified

owner, organizational and

technology oriented

engineering system of the

firm require harmonizing

the functions.

This demand has created an enterprise level

planning and decision supporting application

package (ERP, Enterprise Resources Planning).

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CONTROL

PRODUCTION PLANNING AND CONTROL ERP

MRP II

MES

Separation and integration in the area of production

planning and control application systems

Recently these software applications are operating

on the basis of common technical and economic

data models and data base, and are supporting

the company management (MIS, Management

Information System), the production management

(MRP II, Manufacturing resource planning ) and the

shop floor level operation management too. Production planning and

control tasks are so

complex in themselves

too that their solution

with only one model and

solver is not expedient;

moreover, probably it is

impossible.

The time scale and the degree of details for

long and medium term production planning

require another model than that of short term,

moreover real time manufacturing control.

Two main trends:

The model problem

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CONTROL

OPERATION MANAGEMENT AND SHOP

FLOOR CONTROL

MES Shop Floor Control (SFC) (in a broader sense

Shop Floor Management (SFM), which itself

also consists of several functional

components), become independent. This

experience and demand created the MES

(Manufacturing Execution System) application

package. To meet the coherent modelling

demand of the execution functions of

production management, the ISA-95

production process modelling standard and

the B2MML (Business to Manufacturing Mark-

up Language) connecting to it has been

created. The latter is under development at

present too.

Why MES separated?

Manufacturing Execution

System (MES) is a

computer application

system for managing

planning and monitoring

work-in-process on factory

floor. The main goal of a

MES is to improve

productivity and reduce all

cycle-times, to produce a

dependent order.

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Nowadays there are no reference models accepted by everybody both for ERP,

MRP and MES, as fundamental components of Production Information

Engineering

ERP reference model: SAP R3 MES reference model: ISA-95

The reference model problem

MES modules

ERP modules

ERPPRODUCT

DEFINITIONS

PRODUCTION

CAPABILITY

PRODUCTION

ORDERS

PRODUCTION

PERFORMANCE

DETAILED

PRODUCTION

SCHEDULING

PRODUCTION

DISPATCHING

PRODUCTION

EXECUTION

PRODUCT

DEFINITIONS

MANAGEMENT

MANAGEMENT

PRODUCTION

DATA

COLLECTION

PRODUCTION

PERFORMANCE

ANALYSIS

PRODUCTIONPRODUCTIONRESOURCE

MANAGEMENT TRACKING

MESM

J

KPI S

FASFMSPPM IM

F

O

T

V

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The MES network platform on shop floor level

Nowadays the

main network

platform for MES

applications:

Industrial Ethernet

Wireless networks

Profibus MMS

Device networks

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The ISA-95 standard defines two level

hierarchical manufacturing control model

MES

PRODUCTION

OPERATION

MANAGEMENT

MAINTENANCE

MANAGEMENT

QUALITY

MANAGEMENT

SHOP FLOOR

LOGISTICS

DETAILED SCHEDULING

RESOURCE

MANAGEMENT

TRACKING AND

ANALYSIS

PRODUCTION DISPATCHING

PROCESS

DEFINITION

DATA

COLLECTING

EXECUTION MANAGEMENT

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THE INTEGRATION PROBLEM

MES

ERP

MRP CAPP

The MES systems have been created in possession of

the experiences obtained by ERP and MRP systems

respectively. In accordance with this fact, the

components are designed such a way that they should

stand by to solve integration problems, not only from the

point of view of communication but also by using

semantic and pragmatic approach as well. This reduces

the work necessary for the solutions of interface

problems appearing in the course of software

implementation. However, it does not eliminate the

strong model dependency of the functions

The separated planning and controlling

functions and models require a new developing

activity, namely “integration” in the course of

industrial practice.

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THE INTEGRATION FRAMEWORK

MES

ERP

MRP CAPP

Integration is an abstract and complex concept in the

theory of production systems and processes

Francois Vernadat

Integration is a modern, systems theory based paradigm that

means connecting heterogeneous but autonomous system

components in interest of communication, coordination,

cooperation and collaboration, i.e. using one word, for the

sake of interoperability.

The goal of enterprise integration is the

development of solutions and computer

based tools that facilitate coordination

of work and information flow across

organizational boundaries.

Computer supported integration has

been realized by means of numerous

comprehensive methodological

conceptions..

CIM, MAP, CNMA, Profibus, EAI, SOA, ERP, SCM, MES,

Application of „Java” and „Cloud” techniques

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Theoretical hierarchical model for the properties of information

PRAGMATIC LAYER 4

SEMANTIC LAYER 3

SYNTACTIC LAYER 2

SIGNAL LAYER 1

COMMUNICATION

LAYERS

CONTENT

LAYERS

Relevancies, usefulness, truth value

Meaning, context, concept, aspect

Language, formal definitions, code,

Carrier properties, entropy, byte, bit

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Multi-layer integration has also

become successful at the

integration of the functional

components of production

management.

The internal coherence of

applications can be ensured only if

the applications in question

interpret model objects with the

same semantics in the course of

information changing.

.

Internet

communication

Physical and Data link

(Ethernet) layer

Network(IP) layer

TCP/UDP layer

Application program 2

Internet

communication

Physical and Data link

(Ethernet) layer

Network(IP) layer

TCP/UDP layer

Application

layer

HTTP, FTP

Application

program 1

Integration

Collaboration

New integration methodologies have already applied the proven model of multi-

layer integration

INTEGRATION

SYNTACTIC LAYER

XML

INTEGRATION

SEMANTIC LAYER

B2MML

INTEGRATION

PRAGMATIC LAYER

DATA MODEL

Main goal: INTEROPERABILITY

Application

layer

HTTP, FTP

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Integration tasks for CAPP function

CAD

STEP, IGES, DXF

CAPP

PLM XML

MES

Scheduling

XML

MES DNC Process

definition

NCP MES

Analysis

B2MML

MRP

Master plan

B2MML

ERP

CAD model CAM model MRP model

MES model

The integration of shop floor level manufacturing control (MES) and technology

process planning (CAPP) can prove to be very efficient, because this makes it

possible to increase the robustness and flexibility of technology process

planning, as well as to use a new approach to optimizing the operations.

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Process planning for discrete part manufacturing

CPP

Classical functional

model of 9 layers

ASSEMBLY PROCESS PLANNING

1. ASSEMBLY ROUTING PLANNING

2. ASSEMBLY OPERATION PLANNING

3. ASSEMBLY CYCLE TIME PLANNING

RAW-MATERIAL AND PRE-PLANNING

4. PART ANALISYS, CLASSIFICATION

5. RAW ROUTING CONCEPTION

6. RAW MATERIAL PLANNING

7. PART ROUTING PLANNING

8. PART OPERATION PLANNING

9. MACHINING DATA PLANNING

PART PROCESS PLANNING

LOADING CAD MODEL

ANALYSING FEATURES

GENERATING OPERATION

ELEMENTS

PLANNING TOOLS AND

FIXTURES

PARAMETRIC NC

PROGRAMMING

EVALUATING

PRODUCTION GOALS

ANALYSING PRIORITIES

BUILDING CONSTRAINS

OPTIMIZING CUTTING

RATES

CUMPUTING TIME AND

CUTTING PARAMETERS

NC POST-PROCESSING

New approach for MES „integrated” NC programming and post-processing

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Process planning for discrete part manufacturing

MATERIAL REMOVAL PLAN

(1) TOOLPATH GEOMETRY,

(2) CUTTING PARAMETERS

(3) MACHINE AND TOOLS

SPECIFICATION

GEOMETRY, FEATURES, OPERATION

ELEMENTS

MACHINING TIME, COST, TOOLS, QUALITY

OPERATION SHEET

CAD MODEL

CAM MODEL

DATA CENTRE

MES CAPP

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Process planning for discrete part manufacturing. New approach.

The realization of integration reacts to the algorithms and services of functional

components and determines new requirements, for instance, in optimizing the

technology parameters of operations. Determination of the technology

parameters of operations becomes a multi-level and multi-objective

optimization task, which can only be solved by means of a “robust”

approach in a satisfactory manner.

Previously technology process planning focused on the planning of an

individual operation and its model on the basis of “operation cost”

approach. At the level of manufacturing control (MES), however,

technology parameters become the parameters of a newer model suitable

for planning the fine schedule for the given manufacturing system.

In addition, the rate of operations has a significant impact on the efficiency of

quality assurance, the waste product proportion and tool utilization as well. This

necessitates to know an alternative set of the technology parameters allowed

and efficient in multi-objective sense (Pareto optimum).

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Planning robust cutting parameters

ERP

MRP CAPP

MES

CAPP model

Q [cm3/min]

Q [cm3/perc] 100 200 300

Q1

0 Q3

Q2

Q4

tmax

tmin

Kmin

KVme

Q5

t=f(Q)

K=f(Q) T=f(Q)

V=f(Q)

m

K

m

K

R

Q

QQ

1

11

1)(

=t

MES scheduling model

qi,j [batch/min] nm

q

n

i

m

j ji

== = =1 1 ,

where, 1 t

tt

TuqN = Multi objective optimized

schedule

Robust cutting parameters

M1

M2

J1

J1

J2

J2

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The alternative operation plans of CAPP (or: CAD/CAM) will be actualized by the

detailed scheduling function of MES for the jobs created on the basis of the Master

Plan.

This conception assumes that the scheduling system is able to manage, by means of

AI methods, the numerous allowed alternatives for job-release, lot sizes, operations

sequence, machines and routings, as well as the different combinations of

technology parameter values. A scheduling system having similar capabilities has

recently been developed by a research group of the Department of Information

Engineering at the University of Miskolc.

The dispatcher function of MES is observing the status of the jobs and resources

by means of the real time monitoring of manufacturing processes and determines

the actual values of the Key Performance Indices (KPIs) of “production triangle”

(readiness for delivery, stock level, capacity utilization). If required, it makes real

time decisions to change the status of jobs and resources, as well as to re-

scheduling the process.

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In the field of discrete part manufacturing the robust technology parameter

alternatives (e.g.: alternatives for optimum cutting conditions) can be allocated to the

following objectives and their combinations, respectively:

● Technology parameter values for optimizing (minimizing) the operation cost;

● Production rate level optimum parameter values (maximizing);

● Data for optimizing the usage of tool (edge) and auxiliary materials (constraints);

● Data for optimizing energy usage (constraints) and

● Data for guaranteeing quality, etc.

An important element of the conception is that we prefer the material removal rate

MRR, Q [cm3/min]

as a technology parameter to be optimized at the operation planning (e.g. for cutting

operations). This makes the work of the Master Plan planner, job planner, technology

process planner, as well as the work of scheduler and manufacturing execution

manager (dispatcher) more comprehensive and reliable.

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6. CONCLUSIONS

In the course of the last 20 years a significant paradigm changing and profound

changes have been carried out in the area of planning and control of the

production systems and processes, mainly under the impact of IT.

As a consequence of increasing the number of computer applications, more and

more demands have appeared to their interoperable cooperation and integration.

Integration itself, because of the natural properties of information, also drafts

tasks at syntactic, semantic and pragmatic levels.

At the most abstract level of interoperability the pragmatic aspects can be

ensured by the aid of coherency of the models. The objectives and constraints

used in the models have also been coordinated.

These principles can be ensured by means of the alternative plan variants,

robust planning, as well as the case-dependent and constrained planning of

the parameters. This development process has been well exemplified by the

development of the classic task of determination of optimum cutting conditions

in cutting technology process planning.

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THANK YOU FOR YOUR KIND ATTENTION!

The described work was carried out as part of

the TÁMOP-4.2.2/B-10/1-2010-0008 project in

the framework of the New Hungarian

Development Plan.The realization of this project

is supported by the European Union, co-

financed by the European Social Fund.

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