Factory Information Systems: Background

TTE-5317 FIS 1

2

General info Course keywords: XML, XML Schema, databases, SQL,

CAMX, Web Services,

Lecturer: Corina Postelnicu Office: RL206 Email: corina.postelnicu@tut.fi

Contacting lecturer : Fridays 08:00-09:50, RL206 (if the schedule

allows) Lecture breaks

All students must register in Moodle2 http://moodle2.tut.fi

Course Schedule All changes/additions will be announced via Moodle

3

Laboratories & Assignments

Labs and assignment presentation: attendance mandatory

Labs: Tuesdays 08-10, 10-12 and 12-14 Room RL201 Check lab student groups and assigned time slots in Moodle

2 assignments Assignment 2 : group assignment

Exam & Grade

Exam date(s): check pop

Grade calculation example ( weight changes possible here): Labs: 25% Assignments: 30% Exam: 45%

In order to pass the course, the student must pass the exam AND all labs AND all assignments

Material

Book: Factory Information Systems in Electronics Production, Ivan Delamer and J. Lastra

Lecture slides

Lecture 1 Outline

1. Enterprise System Architecture Intro 2. Examples ;ajor players in the electronics

production industry 3. Factory Information Systems: Background 4. XML and XSD

1/23/14

0. An Enterprise System Architecture

1/23/14

An Enterprise System Architecture

Supply Chain

Enterprise

Manufacturing Execution Systems (MES)

Factory floor:

Machines, Manufacturing Equipment

Suppliers Customers

ERP, Order Management,

Planning and Scheduling

Maintenance, Control, Quality

An Enterprise System Architecture

Supply Chain

Enterprise

Manufacturing Execution Systems (MES)

Factory floor:

Machines, Manufacturing Equipment

Suppliers Customers

ERP, Order Management,

Planning and Scheduling

Maintenance, Control, Quality

ERP MES

centralized, high-level data management: Scheduling use of materials, human resources, Dispatching work orders, Forecasting sales , Issue of materials purchases

Initiating factory activities Monitoring plant status Short-term scheduling and optimizing multiple work orders Updating assembly line control strategy Managing machine recipes

expensive software & difficult to install (need to tailor business processes during installation of supporting Management Information Systems)

usually one ERP system per company one MES per factory or factory sector (e.g. group of assembly lines).

no knowledge on how to perform operations, only on what resources the operations need

awareness of how the factory works, Capability to give commands and instructions to the correct machines at the correct time.

Different Points of View Business Systems Manufacturing Systems

Time Horizons Long-term view Real-time view

Point of View View from the boardroom View from the workcenter

Interested in Accounting reference points

Inventory value Buyers Suppliers New entrants Rivals Substitutes

Material movement reference points (Does the product stop moving? If not, dont model separately)

Suppliers Customers

Typical Enterprise Model

Product Realization Process

Order Fulfillment Process

Order Capture Process

Support Processes

Enterprise

Demand

Offer

Product Realization Process

Order Fulfillment Process

Order Capture Process

Support Processes

Enterprise Enterprise Enterprise

Product Realization

Process Cycle Time

Manufacturing

Cycle Time

Sales Cycle Time

Supply Chain Cycle Times

Supply Chain Cycle Times

Manufacturing cycle time: the time to transform an order into a deliverable product

Sales cycle time: the time it takes from the moment a customer issues a purchase order until delivery

MCT< SCT MCT>SCT Factories can build to order Factories must build to forecast Reschedule production very frequently

Schedule production over relative long periods of time

Very small inventories

Increase of inventory stocking levels

Supply Chain Cycle Times

Manufacturing cycle time: the time to transform an order into a deliverable product

Sales cycle time: the time it takes from the moment a customer issues a purchase order until delivery

16

MCT< SCT MCT>SCT Factories can build to order Factories must build to forecast Reschedule production very frequently

Schedule production over relative long periods of time

Very small inventories

Increase of inventory stocking levels

Mass Production Lean Production

Influencing MCT-SCT relationship Mass versus Lean production

Criteria Mass production Lean production

Goal Good enough Perfection (zero defects, zero

inventories) Authority to stop the

line The manager Everyone

Errors Corrected at the exit from the line

Corrected on-the-fly (zero defects)

Inventory Days to weeks Minutes (zero inventories)

Part flow coordination

Relies on huge inventories

Just-in-time (kanban) policy

Changeover times Months Days

18

Inbound Supply Chain Outbound

Product Realization Process

Order Fulfillment Process

Order Capture Process

Support Processes

Enterprise

Product Realization Process

Order Fulfillment Process

Order Capture Process

Support Processes

Enterprise

Product Realization Process

Order Fulfillment Process

Order Capture Process

Support Processes

Enterprise

Voice of Customer Voice of Customer

Delivery Orders

Returns/Repairs

Delivery Orders

Returns/Repairs

Selling/Buying

Customer Care

Selling/Buying

Customer Care

Settlements Settlements

Supplier Relationship Processes Customer Relationship Processes

Supply Chain Enterprise Process Model

1. Example: Electronics Production.

Major Players

2. -OEM s original brand owners -- outsourcing of assembly, logistics, marketing to Electronics Manufacturing Service (EMS providers

e.g. Toshiba laptops

1 Original Electronics Manufacturer -In-house expertise - High integration level

3. Contract manufacturers /EMS

- in charge with design , not only assembly

Example Electronics Production. Major Players OEMs: previously responsible for almost every process in the supply chain Manufacturing outsourcing has enabled reduction of costs to an OEM. Initially, contract manufacturing was used by OEMs to manage the

manufacturing peaks and valleys. Nowadays, some OEMs perform little / no manufacturing of their own,

outsourcing it to Electronic Manufacturing Service (EMS) providers. An OEM is more accurately described as the original brand-name owner Through the 1990s, Electronics Manufacturing Service (EMS) providers

have increased their role, offering: Full manufacturing (many OEMs now manufacture nothing) Design services

Major Players in Electronics Production

Component, material and equipment (machines) providers: Printed Circuit Boards (PCBs), Semiconductors (chips), Passives: capacitors & resistors , Power supplies, Etc

Distributors: delivery of finished goods to customers.

Service Providers e.g. maintenance, consulting, customer support, etc. Example: Minimization of downtime of equipment

Web-enabled machines can send information to the service providers

Remote diagnostics Scheduled maintenance

2. Factory Information Systems

Background

Information system

Strong need for integration because: Various implementation levels

Various protocols ...

DATA / INFORMATION

DATA / INFORMATION

Drivers of Change in Manufacturing

Need to: Reduce costs & maximize profit

+ Improve productivity + Improve quality

Adapt to customers needs (be flexible to changes in demand) Information available everywhere, consumer make educated choices

Support faster cycles (business, manufacturing, time to market) Business cycles are getting shorter. Product life time is ever shorter. Factory Information Systems are the enabler of faster cycles

Change enablers

Supply-Chain Fission: outsourcing manufacturing, maintenance, logistics etc.

Supply-Chain Fusion: collaboration, merging of processes typically occuring in different enterprises

Fission

Fusion

FIS Implementation levels IPC/CAMX Standards

IPC Number/ Function -xxx1 Generic

-xxx2 Administ

-xxx3 Document

-xxx4 Board Fab

-xxx5 Bare Bd Test

-xxx6 Assembly Manufact

-xxx7 Assy Test/Insp.

-xxx8 Comp. & Mat'ls

IPC-2500 CAMX Framework

IPC-2501 IPC-2503

IPC-2510 GenCAM Product Data

IPC-2511 IPC-2512A IPC-2513A IPC-2514A IPC-2515A IPC-2516A IPC-2517A IPC-2518A

IPC-2520 Quality Product Data

IPC-2524

IPC-2530 SRFF Process Data

IPC-2531

IPC-2540 Shop Floor Communication (CAMX)

IPC-2541 IPC-2546(incl. Am1&2)

IPC-2547

IPC-2550 Execution Communication (MES)

IPC-2551 (Working Draft)

IPC-2554 (Working Draft)

IPC-2556 (PINS)

IPC-2560 Enterprise Communication

IPC-2570 Supply Chain Communication (PDX)

IPC-2571 IPC-2576 IPC-2577 IPC-2578

IPC-2580 Application Specific Data

IPC-2581 IPC-2582 IPC-2583 IPC-2584 IPC-2586 IPC-2588

http://webstds.ipc.org

Factory Information Systems ...various protocol stacks

IPC 2501

IPC 2541

IPC 2546

IPC 2546 FA

IPC 2547

IPC 2546 SP ...

2. XML and XSD