Overview of Web Based Production Planning

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Overview ofWeb Based Production Planning

• By Dave Sly, PEIMSE PhD Candidate
• President, www.proplanner.net

www.aiag.org
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Opening

• Software as we know it - is Dead!
• The impact that the Internet will have on
  integrated engineering has barely begun.
• Production Planning is an oxymoron!

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Who am I

• Education PhD IE candidate at ISU. PE, MBA.
• Experience Worked in large consumer product,
  semiconductor and automotive industries in
  software for facilities planning and design 15
  years.
• Goal Design and deploy an internet enabled
  protocol for production planning. The foundation
  for the next generation CAPP environment.

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What is Production Planning

• Production Planning, or manufacturing process
  planning as it is commonly referred to, deals
  with the task of defining how a new product is
  made.
• This collection of engineering tasks involves
• work assignment and resource requirements
• time and cost estimation
• layout planning
• ergonomics assessment
• quality engineering
• line balancing
• shop floor documentation
• Workflow documentation and charting

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Why is it important?

• Weve improved product design and manufacturing
  execution without improving how to bring new
  designs to the shop floor.
• Weve outsourced design and production globally,
  thus this production planning task has become
  much more difficult to perform and coordinate.
• The goal of the 12 month car drastically
  reduces the time available to create efficient
  and coordinated designs.

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Survey Results

• Manufacturing facilities studied (each with over
  250 employees) perform less than 10 major new
  product introductions annually and over 100 minor
  product modifications annually.
• Nearly all applications in use today are
  developed in-house and involve spreadsheets, word
  processors and CAD/Graphics systems. This was
  clearly validated by the focus group meetings.

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Survey Results

• Manufacturers desire a low-cost, easy-to-use and
  deploy production planning system with integrated
  functionality.
• Internet security of data is a key concern with
  the respondents.
• Manufacturing Engineers have access to the
  Internet. This access appears to be unrestricted
  with a high bandwidth capability

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Survey Results

• A significant confusion exists regarding
  terminology for process planning and its
  associated applications.
• This is especially true in relation to how
  process and production planning relates to
  enterprise resource planning (ERP) and
  manufacturing resources planning (MRP) systems.

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Survey Results

• The priorities for each of the production
  planning applications studied were reasonably
  consistent.
• Each of the planning applications studied were
  desired.
• Integration benefits became increasingly
  important with education.

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Survey Results
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Survey Results

• OEMs are key candidates for production planning
  applications, whereas job shops are not.

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Survey Results

• From the phone surveys it was observed that, on
  average, users needing to view data outnumber
  those needing to author it by a factor of between
  two and three times.
• It is also expected that the average number of
  authoring users and viewing users, within the
  types and sizes of production facilities studied,
  is around 50 and 150 respectively.

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The Impact of the Internet

• Software is a Service
• E-commerce II
• www.salesforce.com
• Outsourced IT
• Security
• Performance
• Licensing/Pricing
• Collaboration

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E-Commerce II

• Rebirth of an Internet Business Model
• Focus on Communications and Collaboration versus
  Commerce
• Applications Oriented (Movies, Music, Software
  and Books)
• Focus on B2B
• Focus on profitability and solid advantages
  available via Internet Leverage
• Focus on Service and Support

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Salesforce.Com

• Software as a service
• 0 to 70,000 customers in 24 months
• 0-100M in revenue in 24 months
• Low cost alternative - 64 to 128 per month.
• Internet collaboration
• Internet training and support

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Outsourced IT via the web

• Advantages
• Low cost for small to medium installs
• Faster uptime (economic incentive)
• Higher domain expertise
• Security
• Disadvantages
• Dependent on external firm (stability,
  availability, quality)
• Support options
• Possible higher cost for large installs
• Security

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Security Issues

• 128 bit SSL Encryption
• Server Redundancy/Access
• Password Protection
• Current Security
• Staff skill set
• E-Mail
• Floppy/CD-ROM/Zip Disk
• Suppliers

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Performance

• Thick versus Thin Client
• Data set size and filtering/segmentation
• Internet Data Speeds
• Local memory, processor, OS
• Graphics
• XML as a possible solution
• Java versus .NET

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Licensing/Pricing

• 250 to 500 per month (concurrent user)
• External or Internal Server options
• Training (webinars, tutorials, on-site)
• Support (on-line, phone, in-house)
• Maintenance Fees (included, additional)
• Distribution (internet only, CD-ROM)
• Documentation (on-line, additional book)

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Collaboration

• Application Sharing
• Data Sharing
• Document Sharing
• Account Sharing

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Commercial Applications

• Time Estimation
• Quality Management
• Cost Estimation
• Line Balancing
• Charting/Flow Analysis
• Workplace Design/Factory Visualization
• Ergonomics Assessment
• Work Instructions/Shop Floor Documentation
• Integrated Planning

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Time Estimation

• HB Maynard MOST
• ACSCO

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Quality Management

• Quality Management

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Commercial Applications

• Cost Estimation

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Commercial Applications

• Line Balancing

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Commercial Applications

• Charting/Flow Analysis

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Commercial Applications

• Workplace Design/Factory Visualization

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Commercial Applications

• Ergonomics Assessment

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Commercial Applications

• Work Instructions/Shop Floor Dox

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Audience Action Item
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Related AIAG

• APQP for the Web

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Closing

• Production Planning is new growth area for
  productivity improvement.
• Internet based solutions are the primary medium
  for feasible deployment
• XML data standards will play a major role in
  integrated planning over the web.

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Q A

• Thank You!

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Thank You!
Check it out www.aiag.org/autotech/speakers/inde
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• By Dave Sly, PEIMSE PhD Candidate
• President, www.proplanner.net

www.aiag.org