A case illustrates how Manufacturing Execution Systems enable a manufacturer to keep track of the production progress and contribute to an optimized execution on the workfloor. A vision is posted on two possible future orientations of MES systems which lead to optimized and self-organizing execution on the shop floor.

1. S ir r is M anuf act ur ing Day
The future of smart manufacturing execution
Erwin Vervondel
De Clercq Solutions
© 10 – 05 – 2011

2. S ir r is M anuf act ur ing Day Agenda
part 1 : Challenges & Goals
part 2 : MES functionalities by example
part 3 : Next steps, Innovations
© 10 – 05 – 2011

3. S ir r is M anuf act ur ing Day Challenges
• Flexibility – Everything and everyone needs to be more
‘flexible’
• Company: production demands (make to stock  make to order)
• Customer specific demands
• Workforce optimization
• Complexity
• Product variance
• Laws / regulations strictness
• Supply Chain integration
• Focus on all costs
• Cost control = control of Machine + Labour hours
• Material cost: focus on Scrap and Rework
• Be competitive across borders
© 10 – 05 – 2011

4. S ir r is M anuf act ur ing Day Challenges
There is a clear need for
• Integration of several information sources regarding “business intelligence,
manufacturing, logistics, reporting, alerts, analytical tools”
• Determining company’s key performance indicators (KPI’s)
 ? Production quota, how much, when
 ? Production interrupts
 ? Tracking en tracing requirements/regulations
 ? Key quality indicators
 ? Root cause analysis, most occuring scrap reason
 ? Control WIP stock
 ? Material consumption
 ? Setup / Change over Costs
 “you cannot manage what you cannot measure”
© 10 – 05 – 2011

5. S ir r is M anuf act ur ing Day Setting goals
• Setting application domain scope
• First determine scope, then look at technical concepts
 Determine need for integration of several application domains ?
• HR (T&A)
• Production (MES)
• Logistics (WMS)
• Defining Information flows
• One way versus two way
• On-line integrated environment – is this possible ? Wanted ? Required ?
• Determine level of detail
• Detailed info
• A lot of input / interfaces
• Much data available
• Easier to analyse, more flexible reporting
• Less Detailed info
• Basic Input
• Crucial data available (? What is crucial)
• Analysis only based on crucial data
© 10 – 05 – 2011

6. S ir r is M anuf act ur ing Day Agenda
part 1 : Challenges & Goals
part 2 : MES functionalities by example
part 3 : Next steps, Innovations
© 10 – 05 – 2011

7. S ir r is M anuf act ur ing Day MES functional model
ERP
MES Operations
Management
P(roduction) Q(uality) L(ogistic) Planning & Reporting
Supervisor
Execution Tracking
Operator
Data Collection &
Process Integration
Infrastructure
© 10 – 05 – 2011

8. S ir r is M anuf act ur ing Day MES – ERP Interaction
ISA 95 model based Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Product Production Production Production
Definition Resource Scheduling & Data Collection
Management Management Execution & Analysis
(How to make (What is (What to (What was
a product) available for use) make and use) made and used)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
© 10 – 05 – 2011

9. S ir r is M anuf act ur ing Day MES functional model
ERP
MES
P(roduction) Q(uality) L(ogistics)
 Integration ERP/MES
 ERP is master
 MES is slave/master
(WMS is slave/master)
Infrastructure
© 10 – 05 – 2011

10. S ir r is M anuf act ur ing Day MES – Infrastructure interaction
Host
MES
Data Collection Process Control
Systems SCADA
Mobile DC Intelligent Printing Weighing
RF - Batch - Tag •© De Clercq
Workstations 05 – 2011
© 10 – Labeling Measuring
Machines

11. S ir r is M anuf act ur ing Day MES functional model
ERP
 Production Scheduling/dispatching
• Resource allocation
• Realtime Planboard
MES
 Time and Quantities
P(roduction) Q(uality) • Labor : order/indirect
L(ogistic)
• Machine : Up/Downtime
• Order : costing – planning
• Quantities : Good/Scrap/rework
Dashboard on production
• OEE on all levels
• Realtime views
Infrastructure
• Actual/historical analysis
© 10 – 05 – 2011

12. S ir r is M anuf act ur ing Day MES functional model
ERP
MES
 Inline production QC registration
P(roduction) Q(uality) L(ogistic)
 Offline production QC registration (Spec)
 Proces integration/monitoring
 SPC
 Operator instructions
 Document control
Infrastructure
© 10 – 05 – 2011

13. S ir r is M anuf act ur ing Day MES functional model
ERP
MES  Product Identification
• Dynamic modelling
P(roduction) Q(uality) L(ogistic)
• Inline labeling/printing
• SSCC
 Tracking and Tracing
• Lot registrations / creation
 WIP
 WMS or WM Middleware
Infrastructure
© 10 – 05 – 2011

14. S ir r is M anuf act ur ing Day MES platform
Integration at different levels of the organization
Responsible
 Ideal platform for production monitoring and steering
 The perfect tool for evaluation and analysis from efficiency through quality
Operators
 Optimized support for the workfloor employees (empowerment)
 Steering
 Registrations
Production Lines/Machines
 Technical integration with the processes
 Automate data input & Increase data quality
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15. S ir r is M anuf act ur ing Day MES by example
Planner: Production dispatching
Overview of open orders / dashboard
Easy production order creation with wizard
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16. S ir r is M anuf act ur ing Day MES by example
Planner: Production dispatching
Releasing orders
to production
Running production orders
& order queue
© 10 – 05 – 2011

17. S ir r is M anuf act ur ing Day MES by example
Planner: Realtime planboard
Intuitive view on Indication of production status
production planning e.g. “late start”
Compact production order information
© 10 – 05 – 2011

18. S ir r is M anuf act ur ing Day MES by example
Operator: Operator Dashboard
Real-time view on production progress
© 10 – 05 – 2011

19. S ir r is M anuf act ur ing Day MES by example
Operator: Operator Dashboard
© 10 – 05 – 2011

20. S ir r is M anuf act ur ing Day MES by example
Operator: Process info
Real-time
data collection
Registration of
machine interrupts
© 10 – 05 – 2011

21. S ir r is M anuf act ur ing Day MES by example
Operator: quality control
© 10 – 05 – 2011

22. S ir r is M anuf act ur ing Day MES by example
Supervisor: OEE analysis
OEE reporting (real-time & historical)
© 10 – 05 – 2011

23. S ir r is M anuf act ur ing Day MES by example
Supervisor: Pareto analysis
Easy drill-down
Machine-based Pareto
Reason-based Pareto
on selected machine
© 10 – 05 – 2011

24. S ir r is M anuf act ur ing Day Production Logistics / WIP
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25. S ir r is M anuf act ur ing Day MES by example
Operator Material identification
Identification of material
& characteristics
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26. S ir r is M anuf act ur ing Day MES by Example
Operator: Material output
Produced Logistic Units to be put away
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27. S ir r is M anuf act ur ing Day MES by example
Supervisor: Traceability
Tracking & tracing
drill-down
Backward/forward
product genealogy
© 10 – 05 – 2011

28. S ir r is M anuf act ur ing Day Agenda
part 1 : Challenges & Goals
part 2 : MES functionalities by example
part 3 : Next Steps, Innovations
© 10 – 05 – 2011

29. S ir r is M anuf act ur ing Day Next Steps
Next Step : Intelligent Manufacturing
• Need for significant improvement of various Key
Performance Indicators:
 Minimizing Cycle Time;
 Reducing Work in Progress;
 Better Delivery on Time;
 Higher Throughput
• Better use of resources
• How?
 Using Intelligent Manufacturing Methods and Systems
© 10 – 05 – 2011

30. S ir r is M anuf act ur ing Day Next Step: Intelligent Manufacturing
Methodologies
 Decision Support
 Operations Research
 Manufacturing Science
 Factory Physics
 Production Methods
 Supply Chain Management
 Mathematical Optimization
 Modeling & Simulation
Advanced Planning & Scheduling
© 10 – 05 – 2011

31. S ir r is M anuf act ur ing Day Scheduling Challenges
• Scheduling / Release management
• The heart of intelligent manufacturing
• ‘Typical’ Scheduling Methods
• Dispatch Rules, User Defined & Dynamic Rules
• Discrete Event Simulation
• Branch & bound
• Simulated annealing
• Tabu search
• Genetic Algorithms
• Neural Nets
• Mathematical Programming (LP, IP, etc)
• Heuristics
• Hybrid
• …
© 10 – 05 – 2011

32. S ir r is M anuf act ur ing Day Scheduling Challenges
• ‘Classic’ Scheduling techniques
 not always so obvious …
• Cannot handle job dispatch very well
 Not reactive enough
• In scheduling, the gap from theory to practice is HUGE !
 Availability of correct data
 Multiple criteria
 You cannot model everything !
 Variability, variability, variability
 Handling huge problems
 Validity of the schedules often problematic
 Academic methods do not translate as is to industry
• Many scheduling projects … Fail …
© 10 – 05 – 2011

33. S ir r is M anuf act ur ing Day ALDISS
• Industry faces a “scheduling crisis” 
New approaches are required
New approach: self organizing/adaptive systems
DCS is currently building a new scheduling system
called ALDISS …
© 10 – 05 – 2011

34. S ir r is M anuf act ur ing Day
ALDISS
Our Way Forward: ALDISS
•Adaptive
•Lean
•DIstributed
•Scheduling
•System
© 10 – 05 – 2011

35. S ir r is M anuf act ur ing Day ALDISS
Adaptive Lean DIstributed Scheduling System
• Lean scheduling system
• Using local rules and methods, adaptive, intelligent, flexible, self-
organizing
• Distributed
© 10 – 05 – 2011

36. S ir r is M anuf act ur ing Day ALDISS
Goal
 Develop a scheduling system, able to be easily implemented & integrated in already
existing MES system.
 A dynamic system that reacts to real-time situations.
 A distributed system that relies on local information and uses distributed emerging
intelligence to make scheduling decisions.
 A system built upon Basic Principles of Self-Organizing Systems:
• Local decisions
• Local rules
• Self-adaptive
• Flexible
• Resists disruptions
© 10 – 05 – 2011

37. S ir r is M anuf act ur ing Day The project
• Two year R&D project sponsored by IWT .
• Collaboration between De Clercq Solutions, UEG and Sirris
Advanced Manufacturing group.
• Project covers system specification, development, piloting and
benchmarking
• Implementable in a wide variety of industries.
• Applicable to large firms as well as to SMEs.
• The system will be created, developed, piloted and
benchmarked, and of course fully integrated with the Objective
Manufacturing Framework.
© 10 – 05 – 2011

38. S ir r is M anuf act ur ing Day ALDISS
• Specific focus on
 Release Management
 Dispatching rules
• Modelling
• E.g. Provide modelling of ‘control loops’
– Kanban
– Polca loops
– Nr of ‘virtual’ cards in the system
© 10 – 05 – 2011

39. S ir r is M anuf act ur ing Day ALDISS
• Dispatch
 Release jobs filter
 Only allow start of ‘released’ job when allowed
• E.g. Card present
 Operator support for starting the correct job
• Is not always the first job in the ‘classic’ queue
 Dispatch verifier has knowledge of activities/jobs
upstream / downstream allowing balanced job
releases.
© 10 – 05 – 2011

40. S ir r is M anuf act ur ing Day
Questions ?
© 10 – 05 – 2011

41. S ir r is M anuf act ur ing Day Contact Us
Projects www.declercqsolutions.eu
Software www.objective.info
Offices East Flanders – Wichelen (Head Office)
West Flanders – Roeselare
Phone +32 (0)52 43 20 80
Fax +32 (0)52 43 20 81
Email info@declercqsolutions.eu
© 10 – 05 – 2011