MES
MES
MES
Analytical Framework for Data Integration Oleg Gusikhin Ford Scientific Research Lab e-Technology Research
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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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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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Demand variability
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Distribution
Truck
Rail
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Premium Freight
Air
Truck
Rail
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Dispatching
Monitoring
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IT Infrastructure
Manufacturing Execution
Raw Material Work in Process End Items
MRP
End Items
Customer
IT Infrastructure
Manufacturing Execution
Raw Material Work in Process End Items
MRP
End Items
Customer
Plant HUB
AS/RS
AGV Robot
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Work In Process ?
Work In Process ?
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Disjointed Data
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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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Part 1
Part 2
Part 3
Batch C
Batch B
Batch A
Part 1
Part 2
Part 3
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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Managerial Information
MRP Data
Operations Management
Information Technology
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Integrated Approach
Operations Management
MES
Information Technology
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t1
p3 p4
p2
Notation
Element
P T M
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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
t1
t2
t1
t2
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Firing Rule
p1 t1 p2 t2 p3
t1
t2
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Attribute Mapping
Attribute Mapping Attribute Mapping
Part
Msg
<Color>
</Color>
Msg
Part
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Assembly Demand P4
Rework
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AS/RS
Rework
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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WC P1
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Timing Parameters
Timer
Current Time
<16:54:12>
<16:32:08>
00:40:00
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Reader
Area B
6 parts 3 parts
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6 parts 3 parts
3 parts
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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
00:40:00
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t1
Machine Up
t2
Machine Down
t1
t2
t1
t2
<Msg>Machine Up</Msg>
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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
c1
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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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Inventory
Actual Model
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Time
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MES Architecture
MRP Interface WWW Real-Time Status Display Scheduling
MES Database
Dispatching
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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