manufacturing execution system in automotive supply chain
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TRANSCRIPT
ICEIS 2002
Manufacturing Execution System in Automotive Supply Chain
Oleg GusikhinFord Scientific Research Lab
e-Technology Research
Analytical Framework for Data Integration
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Ford Research Laboratory
e-Technology Research(Information Science, Operations Research,Data-mining, Neural Nets, Statistics)
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Presentation Outline
• Background• Manufacturing Execution System (MES)• Data Integration Issues• Data Integration Analytical Framework • MES Functional Diagram Review• Summary
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Automotive Supply Chain
Final Assembly
Paint Shop
Body Shop
Stamping
AP1
AP15
APN
tier 1 suppliers
tier 2 suppliers
tier 1 suppliers
tier 2 suppliers
tier 2 suppliers
Dealers
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EnvironmentBusiness
First-tier automotive supplier with established business practices Mixed-volume commodity productsOver 100 End Items supplied to several dozens customers
IT InfrastructureTCP/IP Network Interface to corporate MRPIINumerous Plant Floor Automation Systems of different types and vendors evolved over time
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Production System for 1st Tier Supplier
Area A Area B Assembly
DistributionSupply
Uncertainties:Rate, Yield, Downtime
Demand variability
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Distribution
Rail
Truck
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Premium Freight
Rail
Truck
Air
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Cost Savings Opportunities
• Premium Freight • Inventory• Overtime• Excessive Material Handling
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Manufacturing Execution Cycle
Resource Allocation and Scheduling
Dispatching Monitoring
Balance on Hand, Work in Process
Plant Floor Resource Status
Production Rate, Downtime, Yield
Customer Requirements
Plant Floor Data
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IT Infrastructure
CustomerIn Transit
ShippingFinal Assembly
Plant Inventory
ProcessingReceiving
Plant Floor Automation
End ItemsEnd ItemsWork in Process
MRPManufacturing Execution
Raw Material
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IT Infrastructure
CustomerIn Transit
ShippingFinal Assembly
Plant Inventory
ProcessingReceiving
Plant Floor Automation
End ItemsEnd ItemsWork in ProcessRaw Material
MRPManufacturing Execution
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Data Integration Environment
Bar code Scanner
MRPII
Special-purpose software system
AS/RS
RobotAGV
PLC
Plant HUB
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• Asynchronies in Snapshot Data Retrieval• Transactional Data Only• Disjointed Data• Inaccurate and/or Incomplete Data• Lack of Data• Information System Failures
Data Integration Issues
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Asynchronies in Snapshot Data Retrieval
Missed Counts
System A System B
Production Status Snapshot
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Production Status Snapshot
Double Counts
System A System B
Asynchronies in Snapshot Data Retrieval
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Transactional Data Only
Work In Process ?
Cycle Count Cycle Count
Bar Code Reader
Work In Process ?
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Disjointed Data
Part-AA
Part-A
Part-B
Part-C
?
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Inaccurate Data
Container Scan
Incomplete containerIncomplete container Complete container
Part Count: 4Part Count: 4Part Count: 4
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Incomplete Data (No Part Number)
Batch ABatch BBatch C
Batch Number
Part 3Part 2Part 1
Batch ABatch BBatch C
Style and Paint Codes
Part 3Part 2Part 1
Reader
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Lack of Data
Workstation A
PLC
AGV
No Data Available
Data Collection
Shipping DockWorkstation B
AGV Control AGV Control
AGV
Scanner
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MES Functionality Hierarchy
Integration and Interpretation
Plant Floor Data
MRP Data
Managerial Information
Execution Control Decision Support
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Operation Management vs. Information Technology
What information is needed, When, and
By Whom
How to get the information
Information Technology
Operations Management
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Integrated Approach
What information is needed, When, and
By Whom
How to get the information
Information Technology
Operations Management MES
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Data Integration Framework
1. Design Material Flow Model (MFM)2. Map Data Sources
a. Snapshotb. Transaction
3. Design Internal Logic
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Petri Net Model of Material Flow
p1
p2p4
Part, Tool, ContainerMarkingMEventTransitionTBufferPlaceP
InterpretationElementNotation
t1p3
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Petri Net Data Mapping
Snapshot
Plant Floor Transactions
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Modeling Example
Input Buffer Output BufferWorkstationReader A Reader B
t2t1
p1 p2 p3
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Model Execution
Message From Reader A
t1
t1 t2
t2
Message From Reader B
t1 t2
p1 p2 p3
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Firing Rule
Message From Reader A
t1
t1 t2
t2p1 p2 p3
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Attribute Mapping
<Color> </Color>
Attribute Mapping
Msg Part
Attribute Mapping
Part Msg
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Information Mapping Example
AS/RS
Work Center Shipping
Assembly Plant
Scrap
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Material Flow Model
Rework
Shipping
P3P2P1
P4
Assembly Demand
WC In Transit
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Initial State Mapping
Rework
BOH
P3P2P1
P4
Assembly Demand
WC
MRP
Physical CountsAS/RS
In Transit
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Transaction Mapping
Rework
BOH
P3P2P1
P4
Assembly Demand
WC
AGV Control ScannerPLC
In Transit
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Data Sources Mapping
Rework
BOH
P3P2P1
P4
Assembly Demand
WC
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Internal Logic Design Using Time Parameters
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Timing Parameters
Timer Current Time
<16:54:12> <16:32:08>
Token Time StampInput Arc Delay
00:40:00
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Availability Delay Illustration
ABCBCA
Area A Area BReader
Parts tracked by the model
Parts not tracked by the model
6 parts
3 parts
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Modeling without delay
ABCBCA 6 parts
3 parts
3 parts
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Modeling with delay
ABCBCA
Availability Delay
6 parts
3 parts
4 parts
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Token Clean Up
C
BC
Area A Area BReader
Scrap
C
t1t2t3
Clean Up Timetc
t2t3
Clean Up Time
Current Time - t1 = Clean Up Time
tc
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Place Status
Timer Current Time
<16:54:12> <16:32:08>
Token Time StampInput Arc Delay
00:40:00
Place Status {up, down}
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Place Status Trigger
Machine Up Machine Down<Msg> Machine Down</Msg> <Msg>Machine Up</Msg>
Status: Up Status: Down Status: Up
(Direct Information)
t1 t2 t1 t1t2 t2
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Place Status Trigger
T2 – T1 >ST
ST
Current Time <T2>
Timestamp <T1>
ST<Msg>
Timestamp <T1>
Current Time <T1>
ST<Msg>
Timestamp <T3>
Current Time <T3>
(Indirect Information)
t1t1 t1
t2t2
t2
p2 p2p2
p1p1p1
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Workstation Model
t1p2
c 1
w1
t2
1200
7200source=AGVtransfer_type=RECEIVEtransfer_to=IM100
source=PLCI M100operation=COMPLETE
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Final Model
BOH
P3P1
P4
Assembly Demand
p2
c 1
w1
t2
1200
7200
Scrap
In Transitt1 t3
600
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Actual Inventory vs. Model
ActualModel
Inventory
Time
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Use of the Framework
• System Specification
• Implementation Tool – (example: G2 with Petri Nets libraries)
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MES Architecture
Plant Floor Data Integration
WWW Real-Time Status Display
Plant Floor Automation
Event ManagementpageE-mail
MRP Interface
Scheduling
Dispatching
MES Database
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Summary
• Increase in dynamics and complexity of manufacturing environment creates the need to bridge the gap between corporate planning systems and plant floor process controls
• The success of MESs depends on the availability of accurate, consistent and timely data.
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Summary (Cont.)
• The data integration function is often overlooked: this is a primary source of MES projects failures
• The design of MES information support requires integral analysis of material and information flow
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Summary (Cont.)
The proposed analytical framework1. Provides a systematic approach to analyze
and integrate the critical sources of data for manufacturing (supply chain) execution
2. Emphasizes the possibilities and benefits of incorporating the knowledge of production process to compensate for incomplete and/or inaccurate data
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