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Manufacturing Execution System in Automotive Supply Chain

Analytical Framework for Data Integration Oleg Gusikhin Ford Scientific Research Lab e-Technology Research
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Ford Research Laboratory

e-Technology Research (Information Science, Operations Research, Data-mining, Neural Nets, Statistics)
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Presentation Outline
Background Manufacturing Execution System (MES) Data Integration Issues Data Integration Analytical Framework MES Functional Diagram Review Summary

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Automotive Supply Chain


AP1 APN
tier 2 suppliers Stamping tier 2 suppliers tier 1 suppliers Paint Shop Final Assembly Dealers

Body Shop

tier 1 suppliers

AP15

tier 2 suppliers

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Environment
Business
First-tier automotive supplier with established business practices Mixed-volume commodity products Over 100 End Items supplied to several dozens customers

IT Infrastructure
TCP/IP Network Interface to corporate MRPII Numerous Plant Floor Automation Systems of different types and vendors evolved over time
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Production System for 1st Tier Supplier


Area A Supply Area B Assembly Distribution

Uncertainties: Rate, Yield, Downtime

Demand variability

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Distribution

Truck

Rail

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Premium Freight
Air

Truck

Rail

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Cost Savings Opportunities


Premium Freight Inventory Overtime Excessive Material Handling

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Manufacturing Execution Cycle


Customer Requirements

Resource Allocation and Scheduling

Dispatching

Monitoring

Balance on Hand, Work in Process

Plant Floor Resource Status

Production Rate, Downtime, Yield

Plant Floor Data

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IT Infrastructure
Manufacturing Execution
Raw Material Work in Process End Items

MRP
End Items

In Transit Receiving Processing Plant Inventory Final Assembly Shipping

Customer

Plant Floor Automation


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IT Infrastructure
Manufacturing Execution
Raw Material Work in Process End Items

MRP
End Items

In Transit Receiving Processing Plant Inventory Final Assembly Shipping

Customer

Plant Floor Automation


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Data Integration Environment


MRPII

Plant HUB

AS/RS

PLC ICEIS 2002

Bar code Scanner

AGV Robot

Special-purpose software system

Data Integration Issues


Asynchronies in Snapshot Data Retrieval Transactional Data Only Disjointed Data Inaccurate and/or Incomplete Data Lack of Data Information System Failures

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Asynchronies in Snapshot Data Retrieval


Missed Counts
System A System B

Production Status Snapshot


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Asynchronies in Snapshot Data Retrieval


Double Counts
System A System B

Production Status Snapshot


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Transactional Data Only

Work In Process ?

Work In Process ?

Bar Code Reader Cycle Count Cycle Count

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Disjointed Data

Part-C Part-AA Part-B Part-A

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Inaccurate Data
Incomplete container Incomplete container Complete container

Container Scan

Part Count: 4

Part Count: 4

Part Count: 4

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Incomplete Data (No Part Number)


Batch C Batch B Batch A

Reader Batch Number

Part 1

Part 2

Part 3

Batch C

Batch B

Batch A

Part 1

Part 2

Part 3

Style and Paint Codes


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Lack of Data

Workstation A

AGV

Workstation B

AGV

Shipping Dock

No Data Available
PLC AGV Control AGV Control Scanner

Data Collection

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MES Functionality Hierarchy


Execution Control Decision Support

Managerial Information

Integration and Interpretation

MRP Data

Plant Floor Data


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Operation Management vs. Information Technology

What information is needed, When, and By Whom

How to get the information

Operations Management

Information Technology

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Integrated Approach

What information is needed, When, and By Whom

How to get the information

Operations Management

MES

Information Technology

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Data Integration Framework


1. Design Material Flow Model (MFM) 2. Map Data Sources
a. Snapshot b. Transaction

3. Design Internal Logic

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Petri Net Model of Material Flow


p1

t1

p3 p4

p2

Notation

Element

Interpretation Buffer Event Part, Tool, Container

P T M
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Place Transition Marking

Petri Net Data Mapping


Snapshot

Plant Floor Transactions

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Modeling Example
Input Buffer Reader A Workstation Reader B Output Buffer

t1 p1 p2

t2 p3

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Model Execution
p1 t1 p2 t2 p3

Message From Reader A

t1

t2

Message From Reader B

t1

t2

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Firing Rule
p1 t1 p2 t2 p3

Message From Reader A

t1

t2

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Attribute Mapping
Attribute Mapping Attribute Mapping

Part

Msg

<Color>

</Color>

Msg

Part

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Information Mapping Example


AS/RS
Work Center Shipping

Scrap Assembly Plant


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Material Flow Model


WC P1 P2 Shipping P3 In Transit

Assembly Demand P4

Rework

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Initial State Mapping


WC P1 P2 BOH P3 In Transit

AS/RS
Rework

Physical Counts MRP

Assembly Demand P4

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Transaction Mapping
WC P1 P2 BOH P3 In Transit

AGV Control

PLC
Rework

Scanner

Assembly Demand P4

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Data Sources Mapping


BOH P2 P3 Assembly Demand P4 Rework

WC P1

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Internal Logic Design Using Time Parameters

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Timing Parameters
Timer
Current Time

Token Time Stamp

Input Arc Delay

<16:54:12>

<16:32:08>

00:40:00

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Availability Delay Illustration


Parts tracked by the model Parts not tracked by the model Area A
A C B C B A

Reader

Area B

6 parts 3 parts

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Modeling without delay

6 parts 3 parts

3 parts

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Modeling with delay


Availability Delay

6 parts

3 parts

4 parts

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Token Clean Up
Area A
C B C

Reader

Area B

Scrap
t3 t2

t1
Clean Up Time

tc
Current Time - t1 = Clean Up Time t3 t2
Clean Up Time

tc
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Place Status
Timer
Current Time

Token Time Stamp Place Status {up, down}


<16:54:12> <16:32:08>

Input Arc Delay

00:40:00

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Place Status Trigger


(Direct Information)
Status: Up Status: Down Status: Up

t1
Machine Up

t2
Machine Down

t1

t2

t1

t2

<Msg> Machine Down</Msg>

<Msg>Machine Up</Msg>

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Place Status Trigger


(Indirect Information)
T2 T1 >ST
Current Time <T1> Current Time <T2> Current Time <T3>

p1

t1

Timestamp <T1>

p1

t1 Timestamp
<T1>

p1

t1
<Msg>

Timestamp <T3>

<Msg>

ST

t2 p2

t2
ST

t2
ST

p2

p2

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Workstation Model
w1
1200

t1

p2
7200

t2

source=AGV transfer_type=RECEIVE transfer_to=IM100

c1

source=PLCI M100 operation=COMPLETE

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Final Model
w1 t1
P1
7200 1200

p2
600

t2

BOH P3

t3 In Transit

c1
Scrap

Assembly Demand P4

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Actual Inventory vs. Model

Inventory

Actual Model
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Time

Use of the Framework


System Specification Implementation Tool
(example: G2 with Petri Nets libraries)

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MES Architecture
MRP Interface WWW Real-Time Status Display Scheduling

MES Database

page Event Management E-mail

Plant Floor Data Integration

Dispatching

Plant Floor Automation


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Summary
Increase in dynamics and complexity of manufacturing environment creates the need to bridge the gap between corporate planning systems and plant floor process controls The success of MESs depends on the availability of accurate, consistent and timely data.

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Summary (Cont.)
The data integration function is often overlooked: this is a primary source of MES projects failures The design of MES information support requires integral analysis of material and information flow

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Summary (Cont.)
The proposed analytical framework
1. Provides a systematic approach to analyze and integrate the critical sources of data for manufacturing (supply chain) execution 2. Emphasizes the possibilities and benefits of incorporating the knowledge of production process to compensate for incomplete and/or inaccurate data

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