manufacturing execution system in automotive supply chain

ICEIS 2002

Manufacturing Execution System in Automotive Supply Chain

Oleg GusikhinFord Scientific Research Lab

e-Technology Research

Analytical Framework for Data Integration

ICEIS 2002

Ford Research Laboratory

e-Technology Research(Information Science, Operations Research,Data-mining, Neural Nets, Statistics)

ICEIS 2002

Presentation Outline

• Background• Manufacturing Execution System (MES)• Data Integration Issues• Data Integration Analytical Framework • MES Functional Diagram Review• Summary

ICEIS 2002

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

ICEIS 2002