MES functionalities and requirements for 11T dipole line at LMF for studying and optimization of Nb3Sn magnet assembly process metrics

Transcription

1 MES functionalities and requirements for 11T dipole line at LMF for studying and optimization of Nb3Sn magnet assembly process metrics Ananda Chakraborti Tampere University of Technology

2 List of Acronyms CERN - European Organization for Nuclear Research ISA International Society of Automation [ ISO Industrial Automation Systems and Integration, strategic area: Smart Manufacturing [ LMF Large Magnet Facility MES Manufacturing Execution System MESA Manufacturing Enterprise Solutions Association [ OEE Overall Equipment Effectiveness

3 Need for this study This study will help us in effective measurement, analyses and optimization of Nb3Sn magnet assembly process metrics resulting in improved transparency, responsiveness and cost efficiency of the current 11T dipole magnet assembly process Thereby, this study will help us in understanding the cost of 11T dipole magnet assembly which can serve as a baseline for scaling the assembly cost of 16T dipole magnets This study will establish best practices from lessons learned in 11T magnet assembly and set guidelines for industrial-scale production of FCC magnets

4 11 MES functions as per MESA guidelines 1. Resource Allocation and Status 2. Operations/Details Scheduling 3. Dispatching production Units 4. Document Control 5. Data collection/acquisition 6. Labor management 7. Quality management 8. Process management 9. Maintenance management 10. Product tracking and genealogy 11. Performance analysis

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6 ISA-S95 Specifies Business to Manufacturing 1. Boundaries 2. Data exchange 3. Format 4. Content Provides common model 1. Functional/Activities 2. Terminologies

7 Key metrics that MES should target on 11T dipole line Metric Category Metrics Description Note Cost Total manufacturing assembly cost per magnet This is a measure of all potentially controllable manufacturing costs that will go into the assembly of a single dipole magnet X 1232 dipole magnets for HE-LHC Flexibility Energy cost per magnet Engineering/Design change over cycle time A measure of the cost of energy (electricity, steam, oil, gas, etc.) required to produce a dipole magnet A measure of the time required after design change of the dipole magnets or minor modifications can be implemented Engineering/Design change over cycle cost The cost associated with Engineering/Design change over cycle time Responsiveness Manufacturing cycle time Measure of time it takes for manufacturing one dipole magnet from the time the order is released to production, to finished magnet

8 Metric Category Metrics Description Note Quality Yield of 11T dipole magnet production Indicates blockage, etc.), a percentage of magnets that are assembled = Equipment correctly uptime, and to specifications = Total time of observation, = Equipment production the first time time, through 11T line without rework product (how output, to handle scrap, rework if any?) OEE = =, = X, =, = Availability efficiency (associated losses include non-scheduled downtime, breakdowns, set-up and adjustments, etc.), = Performance efficiency (associated losses include idle, reduced speed, How to predict Yield of the 16T FCC-hh magnets? = Quality efficiency (associated losses include defects, rework, etc.), = Average actual processing rate for equipment in production for actual = Average theoretical processing rate for actual product output, = Good product output from equipment during, Efficiency Throughput for winding machine at 11T dipole line (then, Throughput for 11T dipole line) = Actual product units processed by equipment during Measures how many dipole magnets are wound on the winding machine over a specified period of time Deciding what should be the time period OEE (Overall Equipment Effectiveness) Production Attainment Samuel H. et. al Percentage of time a target production level is attained within a specific schedule of time Machine utilization

9 MES requirements for 11T dipole line Planning and scheduling Define interfaces between MES and workers Monitoring and Supervisory control (Level 2 of ISA-95) Integrate with existing IT system infrastructure (EDMS and MTF) Flexible UI and intuitive way of use

10 Digitalized Quality management system Add flexibility to design change (Design change Order cycle Time and Cost) Capture and Optimize the Total manufacturing assembly cost per magnet Monitor and reduce Inventory and WIP Improve OEE

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12 Delfoi Planner Delfoi Planner software tool that includes MES functionalities by Delfoi Oy Features of Delfoi Planner Sales and Operations Planning (SOP) Advanced Planning and Scheduling (APS) Shop Floor monitoring and dispatching (MES) KPI reporting Multi-language support Role based user configuration Web based architecture (HTML5) MES interface supported in Android, Windows, ios SaaS or On-Premise capability Link to Delfoi Planner Cost Delfoi Planner (SOP/ASP/MES) SaaS service for under 30 persons production unit set-up is 850 / month. This can be used as starter package (2 APS planning named-users and 30 MES named-users). To give more accurate pricing we need to understand the use case, number of users (roles), number of sites and scale of production. For a pilot phase we can provide the SaaS service for 3 months at 250 / month Training of your experts (2-3 persons) would require 2 days basic training and 2 days additional support to get you going (1.000 /day+ VAT)

13 Steps ahead 1. Software training for Delfoi Planner (2 doctoral students) 2. Implementation of Delfoi Planner on 11T dipole line 3. Collecting data and development of KPIs and metrics of current production

14 Conclusion Key magnet assembly process metrics are identified for the 11T dipole line Based on that Delfoi Planner with MES capabilities is selected Implementation of this MES tool on the 11T line is currently being planned This study is conducted in close association with Suraj Panicker (new doctoral student) working on lean manufacturing tools