A GENERIC CONCEPT OF A MANUFACTURING SYSTEM FOR VARIOUS PLANNING AND EXECUTION SYSTEMS Nico J....
Transcript of A GENERIC CONCEPT OF A MANUFACTURING SYSTEM FOR VARIOUS PLANNING AND EXECUTION SYSTEMS Nico J....
A GENERIC CONCEPTOF A MANUFACTURING
SYSTEMFOR VARIOUS PLANNING
AND EXECUTION SYSTEMS
Nico J. VandaeleUniversity of Antwerp
Department of Technology [email protected]
Prof. Dr. Nico Vandaele, University of
Antwerp
Basic Dimensions of Planning
Material
Time
Resources
Prof. Dr. Nico Vandaele, University of
Antwerp
Lead Time Distribution
0
0,01
0,02
0,03
0,04
0,05
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65
f(t)
Lead Time
Prof. Dr. Nico Vandaele, University of
Antwerp
Lead Time Distribution
0
0,01
0,02
0,03
0,04
0,05
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65
f(t)
Lead Time
Prof. Dr. Nico Vandaele, University of
Antwerp
Lead Time Reduction
0
0,01
0,02
0,03
0,04
0,05
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65
Safety time
What about customer service and lead times quotes?
Prof. Dr. Nico Vandaele, University of
Antwerp
Lead Time Variability Reduction
0
0.01
0.02
0.03
0.04
0.05
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65
Safety time
What about customer service and lead times quotes?
Prof. Dr. Nico Vandaele, University of
Antwerp
Combined
0
0,01
0,02
0,03
0,04
0,05
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65
Safety time
What about customer service and lead times quotes?
Prof. Dr. Nico Vandaele, University of
Antwerp
Production Lead Times:Application for Planning?
Material Requirements Planning Just In Time Theory Of Constraints Finite Scheduling ACLIPS POLCA ...
Prof. Dr. Nico Vandaele, University of
Antwerp
MRP Logic
Tubex
Cap1
Leg4
Surface1
Screw16
Box1
Table1
Prof. Dr. Nico Vandaele, University of
Antwerp
MRP Logic
Time 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Table 20 Leg 80 80 80 80 80 Surface 20 20 20 20 20 20 20 20 20 20 20 20 20 20 Box 20 20 20 20 20 20 20 20 20 20 20 20 20 20 Screw 320 320 320 320 320 320 320 320 320 320 320 320 320 320 Tube X X X X X X X X X X X X X Cap 80 80 80 80 80 80 80 80 80 80 80 80 80
Prof. Dr. Nico Vandaele, University of
Antwerp
JIT Logic
Box
Surface Screw
Cap
Tube
Cutting
Welding
Chroming
Fixing Cap
Assembly
Quality Control
Packing
Prof. Dr. Nico Vandaele, University of
Antwerp
TOC Logic
Tube
Cutting
Welding
Cap
Chroming
Fixing Cap
Surface
Assembly
Box
Quality Control
Packing
Screw
Prof. Dr. Nico Vandaele, University of
Antwerp
TOC Logic
20 21 22 23 24 31302928272625
constraint rope
constraintoperation
shipping rope
release due-date
Prof. Dr. Nico Vandaele, University of
Antwerp
TOC Example 101
Time:
Cash: 3000
Week
Su Machines
Pace: D-FG
9876
4
3
5
2
1
RM
Length in weeks: 2 Weekly expenses: 11 000
H
B-20
G
C-10
R
M-10
W-30
2 2
200
43
6
3
4 4
1
3
2
100
DC F
20
4050350
3
2
1 2
7
1
2 2
1
A B
60
10
40
95 7 8 10
3
3
3
3
4
2 2
2 2
2
2
2
1
1
1
1
6
4 4
7
GE
Prof. Dr. Nico Vandaele, University of
Antwerp
FS Logic
packingquality control
assemblyfixing capchroming
cuttingwelding
Prof. Dr. Nico Vandaele, University of
Antwerp
ACLIPSA
Capacity and Lead Time Integrated
Procedure for Scheduling
Lot Sizing & Lead Time Estimation
Phase
Lot Sizing & Lead Time Estimation
Phase
Tuning PhaseTuning Phase
Scheduling PhaseScheduling Phase
Execution PhaseExecution Phase
OrdersOrders
ResourcesResources
CalandarsCalandars
BOMBOM
RoutingRouting
OvertimeOvertime
OffloadsOffloads
Late Orders
Late Orders
Lot SizesLot Sizes Lead TimesLead Times
Dispatch Lists
Dispatch Lists
Picking Lists
Picking Lists
WIP LotsWIP Lots
New LotsNew Lots
F.G. Inventory
F.G. Inventory
ScrapScrap
ReworkRework Real Time Update
Work Progress
Work Progress
Prof. Dr. Nico Vandaele, University of
Antwerp
Mini Metal
Cutter
Grinder
Lathe
P P
S
S
Prof. Dr. Nico Vandaele, University of
Antwerp
Customer Orders
Product P Order 1 2 3 4 5Quantity 1 5 3 2 4Due Date 22 28 37 41 44
Product S Order 1 2 3 4 5Quantity 1 3 2 3 1Due Date 17 18 19 22 24
Order 6 7 8 9 10Quantity 1 3 2 3 1Due Date 26 27 30 33 34
Order 11 12 13 14 15Quantity 2 3 3 1 1Due Date 35 36 39 42 44
Prof. Dr. Nico Vandaele, University of
Antwerp
Production Parameters
Product Machine Average Variance Average VarianceSetup Setup Processing ProcessingTime Time Time Time
P Cutter 20 0 30 0Grinder 20 400 10 100Lathe 24 0 12 0
S Lathe 16 0 8 0Grinder 20 400 10 100
Prof. Dr. Nico Vandaele, University of
Antwerp
Lot Size and Lead Time Results
Product Optimal Operation Utilization Waiting Setup Processing Lead Lot Size Time Time Time Time
P 4 cutter 73 7 20 120 147 grinder 87 109 20 40 169 lathe 82 41 24 48 113 collection 72 total 501
S 6 lathe 82 41 16 48 105 grinder 87 109 20 60 189 collection 61 total 355
Prof. Dr. Nico Vandaele, University of
Antwerp
Grouping Customer Orders
Lot Customer # Average Planned Due Release Orders Lead Lead Date Date Time Time
P1 1-2 6 534 719 528 -191P2 3-4 5 482 521 888 367P3 5 4 430 472 1056 584S1 1-2-3 6 295 351 408 57S2 4-5-6 5 277 336 528 192S3 7-8 5 277 336 648 312S4 9-10-11-12 9 349 397 792 395S5 13-14-15 5 277 336 936 600
Prof. Dr. Nico Vandaele, University of
Antwerp
Networka(50)
7(140)
c(30)
1(200)
4(170)
3(96)
6(84)
9(72)
b(84)
8(60)
d(80)
2(80)
5(70)
11(80)
19(70)
13(70)
15(70)
17(110)
10(64)
18(56)
12(56)
14(56)
16(88)
E
B
Prof. Dr. Nico Vandaele, University of
Antwerp
Gantt-chart
11
12
11
12
21
22
21
32
31
42
13
52 3222
332351
ij
ij
operation j of order i of product P
operation j of order i of product S
41
31
100 20 30 40
Prof. Dr. Nico Vandaele, University of
Antwerp
The POLCA Control System
Paired-cell Overlapping Loops of Cards with Authorization
Relates the releases on the shop floor to a push-signal and a pull-signal
Suri, Quick Response Manufacturing, 1998
Krishnamurthy, 2004
Prof. Dr. Nico Vandaele, University of
Antwerp
For P1 to start working on the order, the order needs to be authorized and P1 should have a P1/F2 POLCA card
2
P1
F2
P1/F2 LOOP
MATERIAL IN P1’S INPUT BUFFER
P1/F2
F2’S INPUT BUFFER
P1
AVAILABLE P1/F2 CARDS
P1/F2
P1 Cell Team’s Decision Process (after Authorization)
Prof. Dr. Nico Vandaele, University of
Antwerp
2
P1
F2
P1/F2 LOOP
MATERIAL IN P1’S INPUT BUFFER
P1/F2
F2’S INPUT BUFFER
P1
AVAILABLE P1/F2 CARDS
P1 Cell Team’s Decision Process (after Authorization)
For P1 to start working on the order, the order needs to be authorized and P1 should have a P1/F2 POLCA card
Prof. Dr. Nico Vandaele, University of
Antwerp
2
P1
F2
P1/F2 LOOP
MATERIAL IN P1’S INPUT BUFFER
P1/F2
F2’S INPUT BUFFER
P1
AVAILABLE P1/F2 CARDS
P1 Cell Team’s Decision Process (after Authorization)
For P1 to start working on the order, the order needs to be authorized and P1 should have a P1/F2 POLCA card
Prof. Dr. Nico Vandaele, University of
Antwerp
For F2 to start working on the order, the order needs to be authorized and F2 should have an F2/A4 POLCA card
F2/A4 LOOP
P1/F2 LOOP
P1
A4
F2P1/F2
F2/A4
F2/A4F2/A4
AVAILABLE P1/F2 CARDS
P1/F2
F2 Cell Team’s Decision Process (after Authorization)
Prof. Dr. Nico Vandaele, University of
Antwerp
F2/A4 LOOP
P1/F2 LOOP
P1
A4
F2P1/F2
F2/A4P1/F2
F2/A4F2/A4
AVAILABLE P1/F2 CARDS
F2 Cell Team’s Decision Process (after Authorization)
• For F2 to start working on the order, the order needs to be authorized and F2 should have an F2/A4 POLCA card
Prof. Dr. Nico Vandaele, University of
Antwerp
F2/A4F2/A4
F2/A4 LOOP
P1/F2 LOOP
P1
A4
F2P1/F2
AVAILABLE P1/F2 CARDS P1/F2
F2 Cell Team’s Decision Process (after Authorization)
For F2 to start working on the order, the order needs to be authorized and F2 should have an F2/A4 POLCA card
Prof. Dr. Nico Vandaele, University of
Antwerp
The POLCA Control System
Trade-off: Push - Authorization: urgency Pull - Card: capacity feasibility
POLCA does control the release as a function of available capacities downstream
Determination ofI. Release authorizationsII. Number of POLCA cards
Prof. Dr. Nico Vandaele, University of
Antwerp
I. Release Authorizations
A Capacity and Lead time Integrated Procedure for Scheduling (Vandaele et al., 1998):
- Lot Sizing and Lead Time Estimation Phase
- Tuning Phase
- Scheduling phase POLCA
- Execution
Prof. Dr. Nico Vandaele, University of
Antwerp
I. Release Authorizations
Product 1: A => B => CProduct 2: C => B
Prof. Dr. Nico Vandaele, University of
Antwerp
II. Number of POLCA Cards
mLT
D
BANumBLTALT *cards A/B ofNumber
mlNum /
Prof. Dr. Nico Vandaele, University of
Antwerp
II. Number of POLCA Cards
A. The number of manufacturing orders that go from workstation l to workstation m during the planning horizon D:
mokkolmkol
kkk
kK
k
O
omkol
OQQY
DOQmlNum
k
)1(
*1 1
Prof. Dr. Nico Vandaele, University of
Antwerp
II. Number of POLCA Cards
B. The weighted ‘average’ lead time:
Weights: relative # of manufacturing orders
Safety cards: on queue time Function of manufacturing batch size
kokkkoq
kkk
kK
k
O
okom
kkk
kK
k
O
okom XOQQTQWS
OQQY
DOQ
OQQY
DOQmLT
m
kk**
%*1 1
*1 1
Prof. Dr. Nico Vandaele, University of
Antwerp
Load Based Version of POLCA
Multiply the number of cards by the average workload of the operations planned in the loop during the planning horizon:
lokkommokkolmkol
kkk
kK
k
O
omkol
K
k
O
o
kokkko
kkk
kmkol
OQQY
DOQXOQQT
OQQY
DOQmlWL
kk
)1()1(
*1 11 1
*
*
Prof. Dr. Nico Vandaele, University of
Antwerp
E-POLCA atSpicer Off-Highway Products Division
A few years ago, the company implemented the software i-CLIPS, which computerizes the aggregate planning. Provides authorizations
At each workstation a display will show: list mentioning the authorized production
orders production orders
Green: capacity is available (POLCA card) Red: capacity not available now (no POLCA card)
E stands for paperless environment
Prof. Dr. Nico Vandaele, University of
Antwerp
Machine X Machine Y
P C N P C NMachine Load Machine Load Machine Load Machine Load Machine Load Machine Load
A 5 X 4 Y 5 X 2 Y 6 A 4
B 7 X 2 F 2 X 3 Y 5 E 8
D 6 X 3 Y 1 A 5 Y 4 G 5
A 4 X 6 Y 1 A 8 Y 8 D 2
C 2 X 5 A 2 A 9 Y 5 A 5
C 5 X 4 D 4 X 4 Y 2 B 1
A 5 X 8 Y 5 C 2 Y 5 B 1
E 8 X 5 B 6 X 5 Y 1 D 4
G 4 X 2 B 8 X 1 Y 3 D 8
D 2 X 5 B 5 D 2 Y 5 B 5
A 3 X 1 Y 2 X 2 Y 8 D 2
B 5 X 1 A 3 X 4 Y 9 D 5
B 8 X 2 C 4 X 8 Y 4 E 1
D 9 X 5 Y 2 C 5 Y 2 E 6
D 4 X 5 Y 1 A 2 Y 6 E 5
E 2 X 6 D 5 X 5 Y 5 A 4
E 5 X 4 D 2 X 1 Y 4 C 8
E 1 X 2 Y 4 A 1 Y 8 B 5
A 2 X 1 Y 1 X 2 Y 5 D 2
C 2 X 3 D 1 D 5 Y 2 A 5
LOOP XY 125 Wait Y 89
Open X 36
Prof. Dr. Nico Vandaele, University of
Antwerp
Conclusions
ARP is a generic approach for many planning and execution systems
ARP is based on stochastic modelling of manufacturing systems
Industry is eager to use the models