LeanMES Harri Nieminen, Fastems Oy Ab
Challenge Predictable world? We are working with operation control and decision-making systems based on stand-alone concepts highly optimized for achieving its goals in a stable predictably behaving environment. Real life! When we look at the bigger entities, in real life only predictable thing is unpredictability. A stable, predictably behaving environment do not exist.
Important problems Poor competiveness Lack of visibility Local optimization One facility One system One organization block Compexity Lack of proper tools Motivation Communication gaps Time gaps Information quality Chain of forecasts Information security
Needs from the Field Increase the productivity and efficiency in all levels Lower the costs generated from the non-value adding processes Competiveness Enabling the efficiency of networks Operational flexibility, rapid reaction and adaptation to changes Support the human worker in different ways
LeanMES mission The ultimate goal of the project is to provide lean, scalable and extendable concept for new type of MES that supports the human operator in a dynamically changing environment
LeanMES -project and consortium Project s run time 08/2013-12/2017 Budget: 6663 keur Workload: active period 60 man-years
Aims for LeanMES From local optimization to understanding cause and effects of a complex system Achieve more efficient and continuously evolving processes and systems Combine best of soft methods and hard technology Efficient networks, SME perspective
Objectives and novelty of LeanMES Research objective 1: Web of Knowledge Transparency of actions and knowledge Flow of information Standardized Interfaces Modularity Research Objective 2: Human-Machine Cooperation Lean as a guideline Human-centered but process oriented Guiding yet not constraining Interactive systems and system intelligence High level UX Research Objective 3: Competitive MES concept Lean, fast to install and easy to learn Traceable and Sustainable KPIs True support for networked manufacturing
LeanMES - scientific goals Goal 1: Study and plan various methods to implement LEAN principles in MES system. The study serves as the state-of-the-art document for the Lean MES Roadmap. Goal 2: Definition of best of breed interfaces that are implementable now and in near future as well as definition of gaps that are most critical now. Goal 3: Definition of new types of Lean KPIs that are traceable and reliable throughout the network. Goal 4: Define and test (proof of concept) feasibly of MES concept for managing networked, global production chain especially within OEM and in subcontracting context. Goal 5: Definition of Machine level MES software toolset (view) that has different user roles for office and machine control in factory floor and possibility to test/select different optimization methods for given cases (such as integrated automatic nesting). Goal 6: Understanding of how automated material handling and related information gathering can be used to improve productivity and flexibility of small series production especially in small to medium size companies in manufacturing segment. Goal 7: Provide ideal selection tracking methods that support both MES and automatic material handling and definition of gaps that are most critical now and possible solutions for those. Goal 8: Provide concepts that support information visibility and rapid reaction to changes for SMEs that are looking production from the supplier and customer perspectives. Goal 9: Provide solid business plan for SMEs that need to update their way of operation to be more lean and agile in future. This requires understanding the business transactions, to operation schemes and best of breed ICT solutions for given case.
LeanMES scope Enterprice scheduling & management ERP Others LeanMES -layer Network There might be... / What if... Sometimes there is... It always features... Humans Devices Systems Others
Examples of LeanMES enablers Visibility Inhouse Suppliers Customers Project data structure Simulations Manufacturing data Material data Order data Views Sourcing Manufacturing Quality Customer R&D Information security Technical solutions Cloud services WEB technologies Novel HMI -technologies Databases LeanMES Status information Online status for Manufacturing Storages Changes / modifications Automatic reminders Optimization models Time Costs Quality Foot print
What could LeanMES mean in my factory? Tracking and monitoring performance and key figures: humans, machines, storages and systems Transparency for manufacturing and material balance data for supply chain partners Human in the loop Engineering change management for progressing orders Tracking, monitoring and estimating production resources - tools, fixtures, programs, materials Real-time tracking, monitoring and verifying humans and parts in manufacturing, storage Support for various work schemes Optimizing and scheduling work orders Network wide change management Enabling independently to choose control scheme part-processes, resource groups Benifits from the socio-technical systems
LeanMES -project tasks 1. Important needs and state of the art in the field 2. LeanMES concept definition 3. Lean KPIs and human friendly information exchange in evolving environment 4. LeanMES control and optimization schemes in human centric operations 5. Material logistics in LeanMES 6. Implementation, testing and demonstrations 7. Dissemination
Thank You!