Software and systems for production control and planning in process industry. CHEM-E7155 Production Planning and Control

Transcription

1 Software and systems for production control and planning in process industry CHEM-E7155 Production Planning and Control

2 Contents Introduction Manufacturing Execution System (MES) Enterprise Resource Planning (ERP) Advanced Planning and Scheduling (APS) Production control and planning in Finnish process industry

3 Introduction Globalization and corporate mergers have led to larger units in process industries Communication need has been grown Operation planning consists of control of all functions of the company including production management as well as employee, sales and financial control

4 Introduction Production planning system includes Manufacturing Execution System (MES) Enterprise Resource Planning (ERP) Advanced Planning and Scheduling (APS)

5 Introduction: Example A new proprietary technology, BeepNTrack, was developed by Implanet with the help of IBM InfoSphere Traceability Server and IBM RFID Solution for Pharmaceutical track and trace technology. IBM was able to provide Implanet with the global, durable solution that offers an on demand portal where information is secure and easily accessible for all stakeholders.

6 Automation pyramid Production management Processs control Measurements and actuators Knowpap2004

7 Contents Introduction Manufacturing Execution System (MES) Enterprise Resource Planning (ERP) Advanced Planning and Scheduling (APS) Production control and planning in Finnish process industry

8 Manufacturing Execution System MES (Manufacturing Execution System) Optimization of production activities From orders to the finished product MES- system relaying information between the ERP system and the actual factory automation system

9 Production management Processs control Measurements and actuators Knowpap2004

10 MES Sales and customer service management The supply chain management Delivery of production units Labor management Operations / detailed schedule Product tracking Maintenance management Resource distribution and status Performance analysis Process management Enterprise resource planning Document management Product / process development Quality control Data collection Controls MES system

11 Production management The main steps: Basic information maintenance budgeting Creating of rough production plan Processing of orders Production planning Shipment planning

12 Production management Production Quality control Warehouse management The loading Invoicing Customer service Reporting Connects

13 Order management ways of delivery Delivery from stock Stock generate additional subscription CONFIRMED ORDER Production Order recorded in the production period Delivery from interim storage Generates supplement

14 Requirements for production planning Late changes in the order Minimum amount of changes Orders Production Transportation planning Production planning Storage Right amount & right time Minimize: Storage Size Time Production times/orders OPTIMUM???

15 Quality Data Management Process analysis Customer service Quality sertificate AUTO- ELREPHO colorimeter Laboratory Quality documents Process automation Connections Process quality control Quality OK Quality control Knowpap2004

16 Database reporting ON-LINE REPORTS HISTORY REPORTS PRODUCTION EVENT INFORMATION ON-LINE DATABASE HISTORY DATABASE Knowpap2004

17 MES has traditionally happened in plant level Orders for the plant Transportation planning New systems have multi-factory optimization Production planning to more than one plant in the same time in order to achieve overall optimum

18 MES ISA95 International MES-standardization Started1995 First version in 2001 Describe processes and terminology Wider than traditional MES as a new term: Manufacturing Operations Management (MOM) Management of security

19 Product definition Resource information Production capability Production schedule Production performance Physical Assets Production resource management Detailed production scheduling Production tracking KPIs (Part 4) Production dispatching Production Performance analysis Product definition management Production data collection Production execution management Equipment and process specific production rules Operational commands Operational responses Equipment and process specific data Level 1-2 Functions 2009 Denins Brandl BR&L Consulting, Inc

20 Operations definition Resource information Operations capability Operations schedule Operations performance Physical Assets KPIs (Part 4) Equipment and process specific production rules Operational commands Operational responses Equipment and process specific data 2009 Denins Brandl BR&L Consulting, Inc Level 1-2 Functions

21 MES Commercial production planning systems ABB Industrial IT Production Planning Honeywell Experion PKS Optivision Metso DNA MES Tietoenator TIPS Siemens Simatic IT Delfoi Planner (includes APS) MES systems according to ISA95 are already available

22 Contents Introduction Manufacturing Execution System (MES) Enterprise Resource Planning (ERP) Advanced Planning and Scheduling (APS) Production control and planning in Finnish process industry

23 Production management Processs control Measurements and actuators Knowpap2004

24 Enterprise Resource Planning ERP (Enterprise Resource Planning) Developed specifically for the firm's comprehensive management Does not control the activities, but to help decision makers to make better decisions Decision-maker follows the operation, records the decisions, and notifies others

25 ERP Consists of modules Economic Administrative Production Logistic In addition, for example Customer Service Management (CSM) Supplier Management (SP) MONEY FLOW AND DEMAND Customers Sales Sales receivable Process management Material acquisition Production management Nominal ledger Accounting Suppliers Acquisitions Trade accounts payable PRODUCTION AND DELIVERY

26 ERP Board and stock owners Reporting applications Financial applications Cuostomers Employers of sales and customer service Sales applications Customer service applications Central database Human resource management applications Manufacturing applications Stock accounting applications foremen and employers for production Supliers Employers ERP Structure and basic modules

27 ERP financial module Accounting Invoicing Account information Human resource Information related to the employers Tasks Salaries Work- and education history

28 ERP Production functions All the functions in the factory related to production Master Production Schedule (MPS) Material Requirements Planning (MPR) Logistics functions serves material and product management Stock accounting inventory information

29 ERP Market share of ERP Systems

30 SAP Systems, Applications, and Products in Data Processing (SAP) Integrated system The modules designed to share information creates automatically transactions of business processes SAP R/3 Client-Server architecture with GUI

31 SD Sales & Distribution FI Financial Accounting SM Service Mgmt. PP Production Planning MM Materials Mgmt. QM Quality Mgmt. PM Plant Maintenance R/3 Integrated Solution Client / Server Open Systems CO Controlling WF Workflow AA Asset Accounting PS Project System EC Enterprise Controlling HR Human Resources IS Industry Solutions

32 Central Database (Storage of all data) Access to Database: (Read / Write data) Database Application Processing of data using application logic Presentation Presentation of the processed data to the user

33 SAP Features SAP is... Only a program The extensive and very flexible Complex, but easy to use High quality Contains a set of business processes

34 SAP SAP is not... Strategic or operational vision, but only a tool Easy to deploy Usable without the user's commitment to the project

35 Contents Introduction Manufacturing Execution System (MES) Enterprise Resource Planning (ERP) Advanced Planning and Scheduling (APS) Production control and planning in Finnish process industry

36 Advanced Planning and Scheduling APS (Advanced Planning and Scheduling) The solution for supply chain management Originally developed for supply chain management (Supply Chain Management, SCM) In addition, expanded to cover the factory and production planning and optimization, and demand prediction

37 APS The system uses analytical tools for scheduling and to produce realistic plans The system produces optimal production plans, taking into account the actual constraints Number of staff available Material requirements The plant capacity

38 APS Planning of supply chain Company wide planning Production planning Availibility estimate Capacity estimate Principle of APS system

39 APS (Enterprise Wide Planning) Planning in higher level under business constraints and objectives (Production Scheduling) Optimization of production according to planning in higher level

40 APS APS system is able to provide a reliable delivery date estimates (Available Promise & Capable to Promise) Lot of small softwares i2 Technologies SAP AG:n APO software

41 SAP APO Advanced Planer and Optimizer (APO) Designed to optimize the entire supply chain Information flow Material flow Money flow Forecasts and orders Forecasts and orders Forecasts and orders Purchases and orders Supplier Manufacturer Wholesaler Retailer Customer

42 APO Supply Chain Management: Planning horizon Forecast Purchase Production planning Production order 6-24 months 1-6 months 4-8 weeks 1 week

43 MES, ERP ja APS: ABB Metso Automation ERP MES DCS Control and measurements ABB Produce IT ME ABB 800xA ABB Control and measurements Metso DNA Historian, Metso DNA Pulp Reporting, Metso DNA Pulp Tracking ja Metso DNA Paper Quality Monitoring Metso DNA Metso Control and measurements

44 Contents Introduction Manufacturing Execution System (MES) Enterprise Resource Planning (ERP) Advanced Planning and Scheduling (APS) Production control and planning in Finnish process industry

45 The production control systems in the Finnish paper industry Order Taking order Order Production data Plan Trim Plan Production Program Rough production cycle plan Storage Transport Forecast Customer Different systems in production control chain

46 Order Taking order Order Production data Plan Plan Trim Production Program Rough production cycle plan Storage Transport Forecast Customer M-real

47 Order SAP Taking order Order Forecast Plan Rough production cycle plan Plan Trim Production data Program Production Storage Transport Customer Myllykoski paper

48 Order ->SAP Taking order Order Production data Plan Plan Trim Production Program Rough production cycle plan Storage Tdansport Forecast Customer Stora enso

49 Order Taking order Order Production data Plan Trim Plan Production Program Rough production cycle plan Storage Transport Transport planning Forecast Customer UPM-Kymmene

50 Pre-processing and Monitoring Pilot plant S S S S S S IMC-AESOP Service Cloud ApplicationHistorian server server Modelling Cloud Computing Environment ERP -Better optimization and coordination of process chains of whole plant -Improved resource efficiency -Improved product quality -High utilization of equipment -Possibilities to integrate multiple processes -Lower production cost MES Control Sensors / Actuators Legacy systems