04 02 Schillinger Jacob Siemens Advanced Planning and ... · 6lhphqv 3/0 6riwzduh 7hfqrpdwl[3odqw...

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Siemens PLM SoftwareTecnomatix Plant Simulation Worldwide User Conference

June 20-22 2017 Stuttgart, Germany

Advanced Planning and Scheduling collaboration between Plant Simulation and PreactorPlant Simulation User Conference, 2017, Stuttgart

Realize innovation.Restricted © Siemens AG 2017

Realize innovation.

Jakob Schillinger

Siemens Industry Software GmbHDigital Factory DivisionProduct Lifecycle Management

[email protected]



Restricted © Siemens AG 2017

Siemens PLM Software

ApproachAdvanced Planning and Scheduling collaboration between Plant Simulation and Preactor

Advanced Planning andScheduling

Collaboration betweenPlant Simulation and

Preactor

Scalability Granularity Repeatability Credibility






Preactor






Advanced Planning and Scheduling

LowDetail

HighDetail

Years Months Weeks Days Hours Minutes

Scheduling

• What to make• When to make it• How much to make• Where to make it• Materials Required• Resources Required

Planning

Scheduling • How best to make it • Execute against plan• Sequencing• Synchronization• Priorities, constraints

and conflicts• Monitoring execution• Managing change

Planning



Advanced Planning

A Strategic Decision ToolConsiders forecast and long term orders to decide feasibility and set general direction of production;

Dynamically sets target stock levels to meet future demand;

Load balance across multiple resources considering e.g. constraints, materials shelf life;

Supports major decisions of production capacity:• Extend work force• Extend resource capacity• Extend factories

Planning

SIT Preactor AP

Forecast Demand Starting Stock Orders

Planning periodStock control parametersCapacity

ERP





Advanced Scheduling

A Tactical Decision Support ToolConsiders detailed production demand to provide production sequence, work to list;

Predicts effects of change in production, interruptions, machine breakdown, scrap;

Reacts to real time production efficiency;

Supports decisions:• Overtime• Order prioritization• Split production batches• Due Date Negotiation• Order Promising (CTP/ATP)

Planning

SIT Preactor AP

Forecast Demand Starting Stock Orders

Planning periodStock control parametersCapacity

Scheduling

SIT Preactor AS

Shift Patterns Detailed constraintsSequencing Rules

ERP



Tight integration with both ERP and MES solutions allows rapid response to changes.

ERP

MES/SCADA

SIT Preactor AS

Order Amendments

Material Availability

Order Progress

Breakdowns

Schedule

Schedule

Analyse

Generate

Update Release

Execute

Sequence

NewOrder Update

Demand

Constraints Schedule

The most successful companies are those using lean scheduling software. By connecting such systems to their ERP, MES and shop-floor data collection, they are able to monitor the state of execution against plan.





Basic APS Functionalities

Manual scheduling

Automated forward scheduling

Visualize delivery challenges

Visualize production sequence

Solve challenges with backward scheduling

Visualize resource usage and utilization






Preactor






The Siemens DifferenceThe Digital Enterprise Software Suite

Plant DataServices

Product Design and EngineeringNX Solid Edge Fibersim

Collaboration and Lifecycle ManagementTeamcenter (Digital Enterprise Backbone)

Digital ManufacturingTecnomatix NX CAM

Manufacturing Execution SystemSIMATIC IT Camstar

Quality Management SystemQMS

SCADA

Automation EngineeringTIA Portal

SIMATIC/ SINUMERIK/SINAMICS/

SIRIUS

Lifecycle AnalyticsSimcenter MindSphere (Plant) Omneo (Product)

PLM

MOM

TIA

APSSIMATIC IT Preactor




Plant DataServices






SCADA



SIRIUS


PLM

MOM

TIA


SIEMENS Plant Simulation associatedwith the pre production planning andcontrol activities. Optimization in SIEMENS Plant Simulation will impactlater planning algorithms and parameters.

SIEMENS Preactor is utilized in themanufacturing operations managementarea for classic production planning andcontrol acticities. Optimization in SIEMENS Preactor will impact plans, schedules and utilizations based on material availability, downtimes andothers.

1

1






Plant DataServices






SCADA



SIRIUS


PLM

MOM

TIA


2

SIEMENS Plant Simulation associatedwith the pre production planning andcontrol activities. Optimization in SIEMENS Plant Simulation will impactlater planning algorithms and parameters.

SIEMENS Preactor is utilized in themanufacturing operations managementarea for classic production planning andcontrol acticities. Optimization in SIEMENS Preactor will impact plans, schedules and utilizations based on material availability, downtimes andothers.

2

2



Collaboration between Plant Simulation and Preactor

SIEMENS Preactor and SIEMENS Plant Simulation usage in the loop.

SIEMENS Preactor utilized to validateSIEMENS Plant Simulation models.

SIEMENS Plant Simulation utilized todefine SIEMENS Preactor structures,

rules and algorithms beforeimplementation.

SIEMENS Plant Simulation utilized tooptimize SIEMENS Preactor structures,

rules and algorithms.












High effort in both tools to create outputthat mainly differs due to alignment ofproduct capabilities and planningchallenges.

Valid approach when conducting multiple projects with similar planning challengesand structures.

Great approach providing a flexible sandbox environmant to test system andAPS behaviour before implementation.

Valid approach providing a flexible sandbox environment to optimize fixedsystem against changeable APS behaviour.

11














2

2
















3

3














4

4





Comparison Plant Simulation Model and Preactor Schedule

Plant Simulation model, structures and reporting

Importing plant simulation data

Plant Simulation model in Preactor

Priorities based planning

Visualize Resource Usage

Visualize Utilization






Preactor






ScalabilityProduction Planning and Control vs. Integrated Development Environment

Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders

Plant Simulation

Forecasts

Bill ofResources

Bill ofMaterials

Availability

AGVS speed

Control Logic

ShiftModel

Layout

PurchaseOrders

Bill ofResources

ProductionOrders

Preactor supports solving planning andscheduling challenges in a productionplanning and control environment.

Projects with focus on productionplanning and control and holistic datawill be succesfull in Preactor.

Plant Simulation is a flexible integrateddevelopment environment specialisingon business, logistics and productionneeds.

Projects with sufficient data andprocess comprehension detailing thecurrent challenge will be succesfull in Plant Simulation.

1

1




Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders

Plant Simulation

Forecasts

Bill ofResources

Bill ofMaterials

Availability

AGVS speed

Control LogicShift Model

Layout

PurchaseOrders

Bill ofResources

ProductionOrders





2

2






Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders

Plant Simulation

Forecasts

Bill ofResources

Bill ofMaterials

Availability

AGVS speed


Layout

PurchaseOrders

Bill ofResources

ProductionOrders





3

3






Preactor






Granularity

Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders

Any input can be granularized in theproduction planning and controlcontext in Preactor.

Enablers to granularize inputs are: • attribute based planning priorities• directional scheduling• planning events• algorithms• …The Preactor data model remainsfocused on production planning andcontrol.

Any Plant Simulation model sub-system can be restructured, reorganized down to attribute andevent level.

Enablers to granularize are: • Libraries• Structures• Attributes• Events• Methods

1

1



Granularity

Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders





2

2





Granularity

Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders

Any input can be granulized in the production planning and control context in Preactor.

Enablers to granulize inputs are: • attribute based planning priorities• directional scheduling• planning events• algorithms• …The Preactor data model remains focused on production planning and control.

Any Plant Simulation model sub-system can be restructured, reorganized down to attribute and event level.

Enablers to granulize are: • Libraries• Structures• Attributes• Events• Methods

Plant Simulation

Forecasts

Bill ofResources

Bill ofMaterials

Availability

AGVS speed


Layout

PurchaseOrders

Bill ofResources

ProductionOrders

3



Granularity

Preactor

Forecasts

Bill ofResources

Routings

Bill ofMaterials

Customer Orders

InventoryReplenish

-ment

Work Orders

SupplierOrders

PurchaseOrders

Gantt Chart

ProductionOrders

Plant Simulation

Forecasts

Bill ofResources

Bill ofMaterials

Somethingelse…

Zombie speed

Wave heightHumidity

Crash speed

PurchaseOrders

Bill ofResources

ProductionOrders

WeatherLibrary

WeatherStructure












Preactor




Repeatability

Schedule Shopfloor

Scheduling

Operating dataERPMRP…

t

V1

Preactor schedules are created based on ERP, MRP, Operating and other data. New schedules are often created when input data changes over time.

Variants of a schedule can be created and compared using alternate planning rules based on similar data state.

Plant Simulation models are created based on input structures and data. New models are changed manually or automatically based on the Design of Experiments.

Variant models can be created based on ERP, MRP, Operating and other data. Since live data is not predictable this happens outside the Design of Experiment.

Preactor uses current, MES based downtimes, while Plant Simulation works with collected past-time data

1

1

Preactor





Repeatability

Schedule Shopfloor

Scheduling


t

V1

V2

V3

2

Preactor schedules are created basedon ERP, MRP, Operating and otherdata. New schedules are often createdwhen input data changes over time.

Variants of a schedule can be createdand compared using alternate planningrules based on similar data state.

Plant Simulation models are createdbased on input structures and data. New models are changed manually orautomatically based on the Design ofExperiments.

Variant models can be created basedon ERP, MRP, Operating and otherdata. Since live data is not predictablethis happens outside the Design ofExperiment.

Preactor uses current, MES baseddowntimes, while Plant Simulation works with collected past-time data

2

Preactor



Repeatability

Schedule Shopfloor

Scheduling


t

V1

V2

V3

Model

Design ofExperiments

V1 V2 V3





Preactor uses current, MES baseddowntimes, while Plant Simulation works with collected past-time data

33

Preactor Plant Simulation





Repeatability

Schedule Shopfloor

Scheduling


t

V1

V2

V3

Model


V1 V2 V3

ERP, MRP, Operating data, …





Preactor uses current, MES baseddowntimes, while Plant Simulation works with collected past-time data.

4

4




Repeatability

Schedule Shopfloor

Scheduling


t

V1

V2

V3

Model


V1 V2 V3

ERP, MRP, Operating data, …





Preactor uses current, MES baseddowntimes, while Plant Simulation works with collected past-time data.

!









Preactor




CredibilityAlgorithms, scripts and gantt charts vs. animations and visible events

Preactor delivers planning resultsbased on „invisible“ decisions, algorithms and priorities.

In many cases credibility towards theresult must be built.

Plant Simulation delivers planningresults created structured systemsthat relate to reality to a certaindegree.

Credibility can be built using the eventoriented, structured and animatedmodel.

11





CredibilityAlgorithms, scripts and gantt charts vs. animations and visible events

Preactor delivers planning resultsbased on „invisible“ decisions, algorithms and priorities.

In many cases credibility towards theresult must be built.

Plant Simulation delivers planningresults created structured systemsthat relate to reality to a certaindegree.

Credibility can be built using the eventoriented, structured and animatedmodel.

2

2






Preactor






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