Activities with regard to Production System Evolution · P23:águ a P24:Sulfato de alumini o....
Transcript of Activities with regard to Production System Evolution · P23:águ a P24:Sulfato de alumini o....
January 2008 www.ceni.pt
Activities with regard to Production System Evolution
Mission
PAMCENI is a member of the Portuguese Alliance for Science-based Innovation in Manufacturing Industry (PAM)
Mission and Objectives
The mission of CENI relies on the creation of a dynamic information, knowledge and learning network that will provide collaboration between Higher Education Institutions and Technology Organizations to join research and strategic knowledge transfer activities in projects of Industrial Logistic and Organizational Process in a way to improve the qualification of human resources and technology development.
ObjectivesTo promote technology transfer to industrial companies through research and development projects and other actions;To offer advanced engineering services to companies;To develop software tools as part of systems and innovative solutions for companies and industrial sectors;To contribute to the development of human resources skills through training actions.
StakeholdersIndustrial companies
Students
Researchers
Instituto Politécnico de Setúbal
Service industries
Industrial Associations
Local government
Research societies and foundations
.Setúbal
Lisboa Évora
Univ.Algarve
Aveiro
Porto
Leiria
Braga/Minho
Location
- Private and non-profit R&D association
Organisation
• General assembly
• Board of directors
• Scientific board
• Industrial board
• Accounting board
PAM
Associate members and Organization
Portuguese Alliance for Science-based Innovation in Manufacturing Industry (PAM)
The challenges can only be met by a responsive, qualified organisation that bring scientific knowledge together with valued solutions for companies.
Production systems evolution challenge small and medium industrial enterprises to search for skilled people and engineering support.
Industry, generally, has been very open to invest in technology and in new management concepts.
Opportunity and Motivation
CeniAss.I&D
PIONEER
OM2A
SECIL
CITRI VIROC
SAPEC
IPS PORTUCEL
ADP
EX: INESC
The sustainable development of the region of Setúbal and Palmela requires innovative projectsto attract technical and scientific expertise.
Industrial companies perceive the need for cooperation in a global base.
Information systems
Planning models
Control and monitoring techniques and communication technology
Product data management
Process simulation
Supply chain management
Integration systems
Data analysis and processing
Logistics and organization
Production systems modelling and planning
Analysis and optimization of materials flow
Logistic systems for industry and services
Design and implementation of production networks
Reverse logistics
Process Development
Product and process modelling, planning, control and analysis
Product lifecycle and management
Environmental, social and economic sustainability
Evaluation and process improvement
Simulation of manufacturing systems
Process optimization
Collaborative work
Activities
Research Services Training
Skills and capacityCENI relies on a network of researchers, engineers, managers and skilled people from complementary knowledge areas.
Knowledge Transfer Development Applied
Production technologies Statistic Operational research Quality Computer scienceMaterials Maintenance Environment Management
Inte
grat
ion
Inno
vatio
n
Skills and capacity
CeniAss.R&D
TrainingControl and monitoringManagement systemsMaintenanceEnvironment and safetyWaste management
TrainingDemonstration
LogisticsManagement systemsLean processesEnvironment and safetyQuality
Automation and roboticMaintenance
Industrial architectureFactory design
Information systemsIntegration systems
EnvironmentControl and monitoring Waste management
Control and monitoring
Skills and capacity
Synergies of existing skills within the network powering new skills and services:
• Feasibility studies• Factory design• Industrial Architecture
Study through virtual visualisation of production flows extends logistics design and factory modular design.
Output data
• to management• to maintenance staff
IMPLEMENTATION OFSAVING ACTIONS
• no cost• low cost• high cost
INTERFACES
•Condition assessments
•Environmental activities
•Quality and security
issues
MANAGEMENTSYSTEMS
•Energy consumption monitoring•Energy management•Environmental management
Objective:Material flow and the energy consumption analysis and evaluation; saving actions and reporting of attained value.
Projects ”Manufacturing System Energy Consumption Evaluation”
Method:Material Flow Analysis and Process Industry Energy Analysis: a) Specification of needs, b) Analysis of data results from different perspectives (product-, process-, equipment -...), b) Saving actions definition and c) report the findings.
ELECTRICITY
WATER
HEAT & FUELS
RENEWABLES
ENERGY PRODUCTION ON SITE
BUILDING
SERVICES
PROCESS
COREPROCESS
Energy policy
Energy Audits
Energy targets
Energy Programme
Training and information
Energy savingmeasures
Follow-up,Monitoring
Yearly reporting
Results:Yearly report, energy policy, energy audits, follow-up and monitoring, information and training.
P1:Tronco Descascado
P2: Casca de pinheiro
P3:Tronco T2:Destroçadora P6:Aparas T3: Afinadores
P7:Solução de Sil icato de Sódio
P8: Solução de Sulfato de Alumínio
P9:Água
P10:Cimento
P11:Apara fina
P13:Apara Grossa
T5:ConformadorT6:Prensa
T7:Endurecimento
P16:Colchão
P15:Painel
T8:Secagem T9:Esquadriamento P18:Painelem esquadria
P21:Painel endurecido
P25:Painel seco
T1: Descascador
T19: Misturador 2P40: Mistura
T12: Armazenamento
P17: Painel acabado
T10:Pré-Esquadriamento T11: MaturaçãoP12: Painel em pré-esquadria P20: Painel maturado
T13 P5:Cimento
T15:Reactor 2
T14:Reactor 1
P22:Sil icato de Sódio
P23:água
P24:Sulfato de aluminio
Objective:Factory reorganization and processes improvement.
Method:Definition and implementation of a system to evaluate the performance of the manufacturing system.Characterization of a performance “baseline” for comparison.Promotion of empowerment improvement at different organizational levels.Availability of data to support decision making and to drive actions for process improvement and for actions evaluation.
Results:Promotion of empowerment at different organizational levels.
Projects ”Manufacturing Reorganization”
Departments involvementDepartments involvementCommunicationInterdependent functions integration
Interdependent functions integration
TranslationPerformance driversPerformance driversManufacturing systems
(Critical factors)
Manufacturing systems (Critical factors)
Company objectives and strategy
Commitment
Adherence
KPI and targets
Visibility
Process KPI and targets
Results: A framework for the evaluation of a manufacturing system performance.
Deployment[Management Team]
Contribution[Process Owners]
Management ORGANISATIONAL modelDRIVE by ProcessIMPROVEMENT by ProcessRESOURCES management
P
D
C
A ProcessKPI
monthly
Process Owners
EFQMManagement “mind structure”MEASURING system for enhancementsFacilitates mid-term PDCAPioneer BENCHMARKING
Management Team
Evaluate & benchmark[Management Team]
P
DC
A EFQME & R
1~3 yrs
(modified) BSCLong Term STRATEGYMacro VIEWStrategic Indicators drivingProfitability Card Owners
P
D
C
A BSCARD
6~12 mo.
VISION & MISSIONManagement review
TARGETS settingPRIORITIES settingRESOURCES allocation
Steering Team
P
D
C
A KEY PERFORMANCE INDICATORS (KPI)PERFORMANCE/EFFICIENCY of ProcessesHOW Processes are progressingIMPROVEMENT of ProcessesConsequences of PCI’sMonthly revision Process Owners
PROCESS CONTROL INDICATORS (PCI)How the Processes are CONTROLLEDBASIS for improvementsEFFECTIVE RESOURCES managementEnable an effective control of ACTIVITIESDaily monitoring Sub-Process Owners
STRATEGIC (LEAD) INDICATORS (SI)Direct CONTRIBUTION to results & strategyCorrelation to KPI’sRevisions by Quarter Card Owners
Projects ”Manufacturing Reorganization”
Objective:Place the company in a more competitive position in the global market of construction materials supplying engineering solutions with the reduction of the construction time per square meter, decreasing the construction costs per square meter, assuring the reliability of the product/solution and assuring the adaptability of the solution through its modularity.
Method:Develop a new concept for building design, construction, installation and use.
Cement Bonded Particle Board (CBPB)
“Active Component“
Modular and Integrated Constructive System
Use variant
Adaptability to the locations
Pre-manufactured and assembled
ProductBrand
“BuildingIntegratedSystem”
Results:It is expected: i) The development of an integrated, modular and
pre-manufactured and assembled system; ii) Variant of uses such as Services, Industries and
Residences;iii) The design and implementation of an new
industrial process for manufacturing and assembly;
iv) “Portability”: The development of a “packing”solution for expedition; v) Definition of a architecture with a modern and industrial design.
v) Development of a product/label where everything is conceived from the constructive elements to the packaging solution.
Projects “Building Integrated System”
Objective: Integration of maintenance with production planning, taking into account the needs of both production planning and maintenance systems and accommodating the equipment/system reliability forecasting.
Results:The operational schedules contribute for an effective exploitation and performance of equipment/system and optimizes the cost function and will calculate the optimum frequency to perform preventive maintenance.
Method: Development of a new model to integrate the historical data of equipment/system failures and its use, giving inputs data for an effective product life cycle management and promoting the linkage between the design or manufacturing and assembly functions.
Projects “Productive services planning and control system”
(Productive Service Module -PSM)
(1) Forecasting
(2) Forecast.condition monitoring
(3) Forecasting MTBF
(4) Production planning
(5) Maintenance planning
(4) Production planning
(5) Maintenance planning
(1) (2) (3)
(4) (5)
(9)
Objective:Development and implementation of an information system that is conceived in order to support the decision and documentation in the design and manufacturing of tools and dies..
Project management Data management Process planning Tool lifecyclemanagement
DB
Projects “Information system to support the design, manufacturing and tryout of tool and dies”
Method:Process mapping and operational requirements definition to tackle the needs of tool and dies business unit.
Objective:To support the production processes and the production management tasks with an information system for planning and control.
Production planning Operations scheduling Inventory management Monitoring and control
BD
Method:Based on a full process mapping and operational requirements, a system was designed to tackle the needs of aquiculture activity, using processes parameters, forecasting, and other operational data.
Projects “Process Management in Traditional Sectors – Aquiculture”
Organisation
Technology HumanResources
Forumtecnologia e inovação
Other Initiatives
Industry ecosystems: Beyond Lean manufacturing• New organizational models. • Change management. • Disperse and grid manufacturing. • Resource efficient, sustainable production systems. • Challenges in lean management; leanness and agility. • Human resources and technological factors. • Extended value chains and cash flow modelling. • Performance management.
Other Initiatives
Portuguese Alliance for Science-based Innovation in Manufacturing Industry (PAM)
PAM
Alliance for Science in Manufacturing Industry
Thanks for
your attention
January 2008