Production Planning and Scheduling with PREACTOR AS · Production Planning and Scheduling with ......
Transcript of Production Planning and Scheduling with PREACTOR AS · Production Planning and Scheduling with ......
Production Planning and Scheduling withPREACTOR AS
siemens.com/panelbuildingIntern © Siemens AG 2017
Intern © Siemens AG 2017
Siemens WKC – Werk für Kombinationstechnik Chemnitz
Location
30.10.2018Seite 2 B. Vogel | DI MC MTS MF-WKC
Saxony
State Capital: Dresden
Further big cities: Leipzig, Chemnitz
Chemnitz
Berlin
Denmark
Lux.
Nether-
lands
Belgium
France
SwitzerlandAustria
Czech Republic
Poland
Germany
Intern © Siemens AG 2017
Siemens Chemnitz
Strong tradition over 125 years
30.10.2018Page 4 B. Vogel | DI MC MTS MF-WKC
1953
VEB Starkstromanlagen-bau Karl-Marx-Stadt
Founding of Siemens Automatisierungstechnik GmbH
Opening of Technical Office of Siemens & Halske AG
1889/1903
Dispossession and commutation in state-owned enterprise
Renaming in VEB NUMERIK Karl Marx
2.600 employees,
turnover of 480’ Mark
Products: CNCs, PLCs,
Robot Controls
Integration into Siemens AG
Start of co-operation with Siemens (after sales service in East Germany and Europe)
Sales, build-up and repair of electrical installations
Switchboards and control panels
1948/49
1965 / 66
2006
2008
2014
19831978
New buildings atClemens-Winkler-Str. new buildings at
Leipziger Straße
First numerical control ENC
1982
1991
1992
1996
> 15.000 cabinet sections p.a.;extension of production and logistics buildings
Siemens SiemensSAK / Numerik
2nd place European Factory Award
Intern © Siemens AG 2017
Werk für Kombinationstechnik Chemnitz
Structure (market logic)
QM
Quality Management
CI 1
Machine Tools
(Unique)
ISO
Infrastructure,
Security, Org
LogisticsShared Services:
Procurement, IT, HR
CI 2
Machine Tools
(large customer)
CI 3
Production
Machines &
Automotive
CI 4
Logistic Solutions
& Energy
& Intra Company
Business
CI 5
Sales Support
BA
Business
Administration
Customer
(via Regional Sales or Headquarter)
CI
Customer Interface
DE
Design Engineering
MFE
Manufacturing Engineering
PROD
Production
Central Functions
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 5
Intern © Siemens AG 2017
Logistic Solutions & Energy & Intra Company Business
characteristic of production
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 6
nu
mb
er
ofu
nits
product lifecycle
Industrialization,
Prototyping
large-scale production Discontinued
production,
repair
Customizing
Low volume / high mix
0%
50%
1 5 10 20 50 100 More
Batch size of devices
0%
20%
40%
5 20 50 100 More
Batch size of PCBs
0%
50%
5 10 15 More
Number of value-added steps
0%
20%
40%
5 20 100 500 1000 More
Yearly quantity per PCB
Intern © Siemens AG 2017
Integrating and digitalizing the entire value chainis key to staying competitive in the future
Cloud-based, open IoT operating system: MindSphere
Third party applications
Suppliers and logistics
Collaboration platform: Teamcenter
ServicesProduction
execution
Production
engineering
Production
planning
Product
design
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 7
Intern © Siemens AG 2017
Planning and Scheduling
Typical detail and horizon
High
Detail
Low
Detail
Hours Days Weeks Months Quarters Years
Scheduling
• What to make
• When to make it
• How much to make
• Where to make it
• Resources Required
Planning
Scheduling • How best to make it
• Sequencing
• Priorities, constraints
and conflicts
• Managing change
• Execute against plan
• Synchronization
• Monitoring execution
Planning
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 8
Intern © Siemens AG 2017
Preactor AS
Advanced Scheduling
▪ Considers detailed production demand to
provide production sequence
▪ Predicts effects of change in production, e.g.
interruptions, machine breakdown, scrap
▪ Reacts to real time production efficiency
Planning
Preactor AP
Forecast Demand
Starting Stock OrdersPlanning period
Stock control parameters
Capacity
Scheduling
Preactor AS
Shift Patterns
Detailed constraints
Sequencing Rules
ERP
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 9
Intern © Siemens AG 2017
Preactor AS
Fine-grained scheduling
TasksResources
Machine
breakdown
Planned
Maintenance
Planned
availability / shift
systemSeite 10 30.10.2018 B. Vogel | DI MC MTS MF-WKC
Intern © Siemens AG 2017
Preactor AS
freely define secondary constraints
specialized
personnel
Equipment
Testing racks
Demand
Supply
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 11
Intern © Siemens AG 2017
Preactor AS
Short demo – scheduling
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 12
Intern © Siemens AG 2017
Goals back in 2012
30.10.2018Seite 13 B. Vogel | DI MC MTS MF-WKC
Shortening
the time to
market
• Individualized mass
production
• Volatile markets
• High
productivity
Increasing
the
flexibility
• Energy and resource
efficiency
as decisive competitive
factors
Increasing
efficiency
Increasing
quality
• Closed
control loop for
quality assurance
• Traceability and
integrated genealogy
• Shorter
innovation cycles
• More complex products
• Larger
data quantities
Products and production
are interwoven Flexible production
Full
process transparency
Optimization of the
resources for product
and production
Classical company goals
Preactor AS helps you to decrase cycle times
▪ Reduction in inventories (WIP)
▪ Increase of delivery reliability
▪ Increase in process quality
▪ Reduction of costs
Intern © Siemens AG 2017
General approach
Project progress and key milestones
Basic idea
and concept
Agreement with
management and
team leaders
Decision for a
new IT solution
Specifications
production
planning
April 2013 December 2013 May 2014
Experimental
PPS
January 2014 February 2014
subdivision
December 2015
1st Project
Completion
Preactor AS
1. production
planning
2. Production
control
September 2016 March 2017
2nd Project
Completion
Preactor AS
Specifications
Production
control
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 15
Intern © Siemens AG 2017
1. identification of workload for scheduling
▪ Transfer of confirmed orders (planned and production)
▪ Transfer of routing
▪ Transfer of material demand and availability dates
2. Sequencing of orders
▪ sorting according to target function
(confirmed customer dates vs. efficiency vs.
small cycle times)
3. Release check according to sequence
▪ New detailed scheduling for operations
▪ Capacity alignment person + machine
4. Release of checked orders
5. Re-iteration from 3rd step until termination criterion (no remaining capacity / no remaining elements)
Basic logic
EOP
time
SOP
-Y (about
24 months)
-X (about
3 weeks)
Start of
Frozen ZoneStart
planningdemand
date
production planning production control
capacity
in
progress
102456781
102456781
102456781
102456781
102456781
in
progress progress
in
progress
in
progress
technolog
y
BEV SMT Hand FEK Prüfday 1 day 1 day 2-4 day 5 day 6-7
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 16
Intern © Siemens AG 2017
Technical system integration and daily routine of Preactor
MES
ERP
• stocks
• production orders
• planned orders
• routings
• BOMs
• Material availability
Preactor
• detailed scheduling
• capacity alignment
• sequence planning
• planning analysis
interface for importing
scheduled tasks
(user-initiated)
MES
ERP
staff
planning
Automated data import
(daily 4 o' clock)
Automated
data import
Extended status information
→ Actual processing status
MES
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 17
Intern © Siemens AG 2017
Preactor only plans up to the resource limit and then shifts the schedule. Thus, scheduling leads to a feasible
plan, but leads to shifts in confirmed delivery dates.
Software does not replace people, but it has changed the
ways in which people can influence and work
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 18
Intern © Siemens AG 2017
Experiences and lessons learned
Experiences▪ Preactor is only as good as the master data quality (workplaces, workforce availability, machine
availability, setup time, processing time)
▪ Out of the box usage not possible
▪ If customized correctly, Preactor can be adapted to most kinds of businesses
▪ The user interface and the planning times have potential for improvement (parallelism is problematic)
Lessons learned▪ The elaboration of the specifications is a huge effort! The analysis of all interrelationships and
restrictions of processes in production takes a lot of time and strength
▪ You cannot think and plan everything in advance. It needs time for improvement even after the GO-
LIVE.
▪ Software cannot solve problems, but it can help with analysis and overall understanding.
30.10.2018 B. Vogel | DI MC MTS MF-WKCSeite 19
Thank you very much.
Any questions?