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Network Systems, Manufacturing Planning, Control and Scheduling in CIM Environment

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Unit 4 Network Systems, Manufacturing Planning, Control and Scheduling in CIM Environment Key Aspects of Manufacturing Scheduling in a CIM Environment Operations ... – PowerPoint PPT presentation

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Title: Network Systems, Manufacturing Planning, Control and Scheduling in CIM Environment


1
Unit 4
  • Network Systems, Manufacturing Planning, Control
    and Scheduling in CIM Environment

2
This Unit is About
  • Network Systems
  • Manufacturing Planning (Forecasting)
  • Manufacturing Planning (Scheduling)
  • Manufacturing Control (Management)

3
Network Systems in CIM
  • For Connectivity and communications in
  • CAD/CAM, CAE, CAPP, and other sub-systems
  • Departmental activities
  • Plant-wide activities
  • Company-wide activities
  • Global activities
  • Executive planning and managerial activities

4
Company-wide Networking Systems and Activities
Include
  • Planning
  • Scheduling
  • Intranet systems
  • Email systems
  • Telephone networks
  • Fax systems
  • Scanners
  • Servers
  • Workstations
  • Others

5
Global Networking Systems and Activities Include
  • Database
  • Internet
  • Severs
  • Other networks
  • Telephone systems
  • Emails systems
  • Go-to-meeting.com
  • Texting
  • Skyping
  • Bank transfers
  • Teleconferencing
  • Postal
  • UPS
  • DHL
  • Supply chain
  • Satellite systems
  • GPS systems
  • Software issues

6
Chapter 8 Enterprise Resource Planning and
Beyond
  • APICS Dictionary defined enterprise resource
    planning (ERP) as a method for the effective
    planning and control of all resources needed to
    take, make, and account for customer orders in a
    manufacturing, distribution, or service company

7
Enterprise Resource Planning (ERP)
  • ERP is one of the newer system concepts that
    focuses on the integration of business systems
  • These integrated systems support all of the
    functional departments in the enterprise sales
    and order entry, engineering, manufacturing,
    finance and accounting, distribution, order
    planning and execution, and the supply chain flow
  • Tech 149 team project can take advantage of this
    philosophy in its concurrent engineering approach

8
Enterprise Resource Planning (ERP)
  • Since businesses are increasingly focusing on
    customers, customer relationship management (CRM)
    systems are being developed to help companies
    manage the information they have about their
    customers, the products these customers buy, and
    the way the customers prefer to do business

9
Some Related Aspects of ERP
  • Product data management (PDM)
  • Information technology issues (data collection
    issues and system integration problems)
  • The role of the Internet
  • Sample ERP systems include PeopleSoft, SAP R/3,
    Oracle, Sterling, Legacy, and JBA

10
Network Systems is All About Communications and
Connectivity
11
Enterprise Resource Planning (ERP)
12
Chapter 6 Introduction to Production/Operations
Planning
  • The planning functions have formal interfaces
    with both the design and production departments
    and informal relationships with most of the
    enterprise. The operations management functions
    are a critical part of the CIM implementation.

13
Some Planning Areas for CIM
14
Manufacturing planning and control
  • All planning has a time horizon, e.g. number of
    days, months or years
  • Enterprise planning is divided into three levels
  • Strategic plan
  • Aggregate plan
  • Disaggregate plan

15
Strategic Plan
  • The strategic plan is generally long range one
    year to many years
  • The strategic plan is performed at highest level
    in management

16
Aggregate Plan
  • The aggregate plan has an intermediate-length
    time horizon of about two to eight months
  • The aggregate plan emphasizes levels of
    employment, output, inventories, back orders, and
    subcontractors

17
Aggregate Plan
  • The goal of aggregate planning is the generation
    of a production plan that utilizes the enterprise
    resources efficiently to meet customer demand
  • The production plan and forecasted customer
    demand provides the aggregate information from
    which the disaggregate master production schedule
    (MPS) is produced

18
Forecasting Defined
  • The process of estimation in unknown situations
  • The process of prediction
  • The practice of demand planning

19
Forecasting Techniques
  • Causal / econometric methods
  • Time (trend) series
  • Judgmental methods
  • Other methods

20
Causal/econometric methods
  • Regression analysis using linear regression or
    non-linear regression
  • Autoregressive moving average (ARMA)
  • Autoregressive integrated moving average (ARIMA)
  • Econometrics

21
Time Series
  • Moving average
  • Exponential smoothing
  • Extrapolation
  • Linear prediction
  • Trend estimation
  • Growth curve

22
Judgmental methods
  • Composite forecasts
  • Surveys
  • Delphi method
  • Scenario building
  • Technology forecasting
  • Forecast by analogy

23
Other methods
  • Simulation
  • Prediction market
  • Probabilistic forecasting

24
MPS Time-Phased Record __________________
_____________________________________ Period
_______________________________________________
________ 1 2 3 4 5 6 7 8 9 10
_________________________________________________
______________________________________________
Forecast 5 5 5 5 5 5 20 20 20 20
Available 26 32 38 44 50 56 47 38 29 20
MPS 11 11 11 11 11 11 11 11 11 11 On
hand 20 ___________________________
______________________________
25
Disaggregate Plan
  • The development of MPS data is the start of
    disaggregate planning
  • The disaggregate plan provides short-range
    planning with detailed plans that include machine
    loading, part routing, job sequencing, lot sizes,
    safety stock, and order quantities.
  • The disaggregate plan has the shortest time
    horizon

26
Disaggregate Plan
  • The term disaggregate means to separate into
    component parts
  • At disaggregate planning level, an aggregate plan
    is disaggregated into all the various models and
    options necessary to meet customer demand
  • The first step in disaggregation is the creation
    of MPS from the aggregate production plan

27
Material Requirement planning (MRP)
  • The material requirement planning (MRP) strategy
    in the manufacturing planning and control (MPC)
    system is a very useful tool at the disaggregate
    level
  • MRP system addresses the need for parts
    management of complex products and product mixes
    with high rates of production
  • MRP process starts with the MPS providing the
    quantity of each model or part required (gross
    requirement) per period

28
MRP Record
  • MRP Record
  • Period Number
  • __________________
    _____________________
  • Item tube steel 246784
  • 1 2 3 4 5 6 7
  • __________________________________________________
    ________________________________
  • Gross requirements 100
  • Scheduled receipts
  • Projected on hand 140 140 140 140 40 40 40
  • Planned order receipts
  • Planned order releases
  • __________________________________________________
    _______________________________
  • Order policy Fixed lot Order quantity
    200 Lead time 5

29
Bill of Materials (BOM)
  • The bill of materials (or BOM in the form of
    product structure diagram) and current inventory
    provide critical information for an effective MRP
    system

30
Bill of Materials (BOM)
  • The bill of materials provides the MRP system
    with the part number and quantity of all parts
    required to build and assemble the product
  • The inventory control system supplies the MRP
    system with the projected on-hand balance of all
    parts and materials listed on the BOM
  • The MRP run produces the requirements for
    purchasing and production that are needed to
    complete the master schedule

31
Product Structure Diagram
  • The product structure diagram illustrates clearly
    the sequence required to build the product, with
    the 0 level representing the finished product

32
Part Routing, Lead Times and Capacity Planning
  • The routing sheet specifies each production
    operation and the work center location
  • Lead time includes four elements run time, setup
    time, move time and queue time (setup time, move
    time and queue time add no value)
  • Capacity requirement planning (CRP) works with
    the system data to calculate the labor and
    machine time requirements needed to complete the
    master production schedule

33
Sample Manufacturing Scheduling
34
Key Aspects of Manufacturing Scheduling in a CIM
Environment
  • Operations
  • Materials
  • Equipment and tooling
  • Facilities
  • Product
  • People

35
Scheduling in CIM Environment
  • Scheduling information in CIM must be
  • Shared by all
  • Seen by all
  • Retrieved by all
  • Contained in the Database
  • Must be functional
  • Must be in real time
  • Must be self updating

36
Sample Scheduling Software
37
People Scheduling in CIM
  • By job type
  • By operation type
  • By product type
  • By shift

38
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39
Materials Scheduling in CIM
  • JIT
  • MRP
  • Purchasing
  • Networking Members
  • Design
  • Purchasing
  • Manufacturing
  • Supplier
  • Warehousing
  • Facilities
  • Others

40
Equipment Tooling Scheduling in CIM
  • Process types
  • Number available
  • Routing issues
  • Maintenance issues
  • Facilities
  • Others

41
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42
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43
Facilities Scheduling in CIM
  • Layout issues
  • Size and space issues
  • Availability issues

44
Product Scheduling in CIM
  • Delivery Issues
  • Customer issues
  • Production issues

45
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46
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47
Chapter 9 The Revolution in Manufacturing
  • Several technologies and philosophies have
    revolutionized manufacturing in recent years.
    Some of these are covered in this chapter

48
Just-In Time (JIT) Manufacturing
  • Just-In-Time manufacturing (JIT) encompasses
    every aspect of manufacturing, from design
    engineering to delivery of the finished goods,
    and includes all stages in the processing of raw
    material
  • JIT is much more than material-ordering plan that
    schedules deliveries at the time of need

49
JIT focuses on the elimination of the seven
wastes found in manufacturing practices, namely
1. Waste of overproduction 2. Waste of
waiting 3. Waste of transportation 4. Waste of
processing 5. Waste of stocks 6. Waste of
motion 7. Waste of making defective products
50
Kanban (Card)
  • Kanban is a Japanese word that means card
  • These cards in effect replace all work orders and
    inventory move tickets
  • Within the MPC system, kanban controls the flow
    of production material
  • One- and two-card kanban systems are in common
    use
  • Kanban supports a pull (JIT) system

51
Network Systems is All About Communications and
Connectivity
52
Enterprise Resource Planning (ERP)
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