CPM in CPM4 Production planning and execution system
CPM4 Collaborative Production Management What is CPM? CPM stands for Collaborative Production Management and is a family of solutions from ABB for information sharing, production planning and execution, reporting, asset monitoring, and process optimization (mathematical models) covering all processes from steel production, hot rolling, cold rolling to finishing and treatment in processing lines. Typical features: production plan optimization plant-wide sharing of information between business systems and the shop floor production execution (dispatch of production order data/collection of process data) paperless production management (online information, less misprinted data, availability of instructions) visualization of real-time production and equipment status (line stops, operating time, etc.) production performance analysis (time-based and individual-based reporting). CPM allows users in the organization to increase the efficiency of working by making the right decisions at the right time with fewer mistakes.this information is up-to-date and quickly accessible to users. This allows them to collaborate in a more informed way to ensure maximum productivity and quality. Hardware and software CPM4 is the common software framework for production planning and execution systems within ABB s business. The framework forms the basis for the different applications and is used for adapting base functionality to customer-specific requirements. The CPM4 framework is very flexible and adaptable to different process-specific demands, which means that the system can appear in different roles such as Level 3, MES and Level 2. The software package is object-oriented and is based on the MS.NET framework. The application software operates in Windows environments using standard hardware and software components. What and why in your production Do you have optimized production schedules and information at your fingertips? Is your production integrated with your planning? Can you back-trace your production? Do you know the what and why of your plant downtime? Are you managing your line set-up parameters optimally? Do you monitor material quality during production? 2
ABB s CPM4 provides the solution This application is engineered around ABB s CPM4 Framework and provides a suite of modules, which will be tailored to your needs: Production planning and scheduling Plant-wide production planning and short-term production scheduling for your production line, based on optimized production plans Production data historian Data repository with long-term storage of production data for the mill output Production performance analysis Production reports and statistics and online production data feedback Line stop/downtime monitoring Recording and analysis of line stops/downtime detailing when, what and why Equipment monitoring Recording of equipment operating time and cycles for planning and maintenance Quality management Inspection, material rejection, recording and analysis of quality set-points versus measured process values Roll management Keeps track of the rolls, monitors the roll wear and supports roll change Set-up models and recipes Calculation of pass schedule and set-up values based on mathematical models or storage in fixed tables Material identity tracking Tracking of individuals (pieces) along the production line. Your benefits access to online information giving higher operational efficiency (paperless work) filter/search capabilities for quick access to stored information optimized equipment set-up for less scrapping, uniform quality and potential energy savings powerful tool for process and production improvement knowing plant availability gives improved plant utilization direct feedback on production and quality characteristics supports quick and correct decision-making, immediate action and correction. Roll management Line stop/downtime monitoring 3
Plant unit. Application package for production execution Production planning and scheduling The production planning is optimized at a plant-wide level from the melt shop to the finished products. The schedules are distributed to the local execution systems allowing local adjustments for unexpected situations in production. The main production plan is maintained in the CPM/Level 3 system and a sub-set of production data relevant for the actual production line is downloaded to the CPM/Level 2 system. The list/schedule shows production orders for the coming hour(s) and day(s). The production of the material follows a defined process route along the production line from entry equipment to exit equipment. When the material in a production order advances along the production line, it passes through defined states. These states reflect the progress in production, providing a clear view of the order situation. Production data historian and production performance analysis Production- and process-related data is collected from different data sources (e.g. Level 1 process control system, lab systems, furnace control systems, etc.). The data is stored in the history database on a time and individual (material) basis. The production performance analysis provides the means to follow up production performance in periodic reports (shift, daily, weekly, etc.) and individual reports (coil, plate, beam, heat, etc.). Management of line stops/delay handling Line Stop Management allows you to handle and classify disruptions in the plant and identify critical reasons for downtime using statistics. Production planning and scheduling Management of line stops/delay handling 4
Set-up models The CPM/Level 2 system offers extensive packages of optimization models such as: Steel Production Scrap Mix, Energy Balance, Alloys, Slag, Melt Down Control, Oxygen, DRI, Vacuum Hot Rolling Hot Strip Mills, Plate Mills, Steckel Mills Cold Rolling Single and Multi Stand Mills, Reduction-, Temper- and Foil-Mills Management of equipment Production and quality of the plant output rely on equipment, which has to function in a safe and reliable way. Equipment Monitoring and Roll Management provides support for monitoring operating time, cycle count and rolled tonnage as well as administering maintenance, roll logistics and roll change. Management of quality defects The Quality Management allows you to effectively manage and monitor quality-related matters. This function supports the management of: quality inspection allowing the user to handle prime/non-prime material, add text remarks and follow test instructions rejecting/scrapping of material allowing the user to handle reject causes, reject location, etc. automatic monitoring of deviations in material property values versus target/nominal values. Material identity tracking An accurate identity tracking image of material movements in the production line is crucial for correct reporting, triggering other functions and ensuring the correct setup of the process equipment. Identity tracking reflects the material movement along the line based on different sensor signals and manual input. The user/operator always has the possibility to make corrections for sensor failure and when unexpected situations occur. New tracking information is shown when the situation changes and therefore provides an up-to-date image/map of the actual material positions. Material identity tracking Management of equipment Management of quality defects 5
Plant wide Plant wide Level 3 production optimization systems While Level 2 systems focus on the process optimization of one plant unit, such as one EAF or one Z-mill, CPM4-based Level 3 systems provide production optimization capabilities for one production area, e.g. steelmaking and casting or cold rolling and finishing. The main functional modules include: manufacturing order processing production scheduling schedule optimization and pacing production tracking, coordination and re-scheduling genealogy and plant-wide reporting inventory management. Manufacturing order processing Manufacturing orders are typically received from ERP/Level 4, or entered manually. Operation plans (production routes) are assigned, and production requests are generated for each plant unit included in the operation plan. Production scheduling Material allocation is done, where applicable, in collaboration with inventory management. Appropriate sequencing of production requests generates the production schedules, including scheduled start and end times. Schedule optimization and pacing The CPM4 schedule optimization modules aim at maximizing throughput, synchronizing production, reducing energy consumption and meeting order due dates. The module also takes into account planned maintenance stops and facilitates production schedule simulations ( what if scenarios). Pacing synchronizes production via schedule re-timing based on actual production events. CPM4 therefore helps the planner and production to: quickly and accurately generate production schedules; optimize the production schedule for maximum throughput (up to around 2-3%) and energy savings (up to around 5-6%); simulate various alternatives, e.g. during maintenance planning; synchronize production in real time. Production tracking, coordination re-scheduling Level 3 tracks and visualizes order progress in real time, monitors deviations from defined production schedules and quality. Re-scheduling is performed where necessary, and schedule changes are communicated to the surrounding process segments involved. Plant wide Level 3 production optimization systems Schedule optimization and pacing Level 4 / ERP / SCM Manufacturing orders Order status Manufacturing order report Production requests and production schedule Setpoints Production data and order status CPM / Level 3 Level 2 Level 2 Process data Level 1 OCS Lev 1 OCS Lev 1 OCS Production requests Level 1 OCS Production data and order status Production route 6
Production tracking Genealogy Genealogy, traceability and plant-wide reporting Consolidated production reporting for the entire production process gives the manager a quick overview of the utilization and efficiency of the plant, as well as product quality. Full product genealogy provides the foundation for plant-wide reporting, and allows for complete traceability of a product s lifecycle. Genealogy also helps you pinpoint defects upstream, and identify/isolate other potentially defective products. Inventory management This CPM4 module covers input/raw material storages, intermediate storage, and output/finished product storage and gives you full WIP visibility and control. The functionality provided includes handling of material entry, move, exit, inventory control and corrections. Inventory management also collaborates with production planning to allocate materials and to generate material request lists. The immediate benefits include reduced capital costs, improved customer satisfaction and manpower savings. ABB CPM4 helps you achieve optimal performance CPM4 conclusions CPM systems bridge the gap between the shop floor and the top floor and provide concrete improvements in terms of product quality, production output, and customer service. ABB s CPM4 systems are built on 25 years experience and feedback from more than 140 CPM systems. CPM4-based solutions help customers to continuously improve and helps them in their drive to become even more competitive. CPM4 solutions brings tangible benefits, in terms of increased revenues, reduced operating costs and lower capital employed. Throughput, Prime Yield Operating Costs, Poor Quality ROCE (ROCE = Return On Capital Employed) Revenue Expenses Capital Employed Inventories, WIP 7
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