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

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This Unit is About

• Network Systems
• Manufacturing Planning (Forecasting)
• Manufacturing Planning (Scheduling)
• Manufacturing Control (Management)

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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

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Company-wide Networking Systems and Activities
Include

• Planning
• Scheduling
• Intranet systems
• Email systems
• Telephone networks
• Fax systems
• Scanners
• Servers
• Workstations
• Others

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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

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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

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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

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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

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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

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

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Some Planning Areas for CIM
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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

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Strategic Plan

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

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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

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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

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Forecasting Defined

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

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Forecasting Techniques

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

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Causal/econometric methods

• Regression analysis using linear regression or
  non-linear regression
• Autoregressive moving average (ARMA)
• Autoregressive integrated moving average (ARIMA)
• Econometrics

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Time Series

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

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Judgmental methods

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

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Other methods

• Simulation
• Prediction market
• Probabilistic forecasting

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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 ___________________________
______________________________
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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

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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

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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

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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

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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

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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

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Product Structure Diagram

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

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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

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Sample Manufacturing Scheduling
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Key Aspects of Manufacturing Scheduling in a CIM
Environment

• Operations
• Materials
• Equipment and tooling
• Facilities
• Product
• People

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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

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Sample Scheduling Software
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People Scheduling in CIM

• By job type
• By operation type
• By product type
• By shift

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Materials Scheduling in CIM

• JIT
• MRP
• Purchasing
• Networking Members
• Design
• Purchasing
• Manufacturing
• Supplier
• Warehousing
• Facilities
• Others

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Equipment Tooling Scheduling in CIM

• Process types
• Number available
• Routing issues
• Maintenance issues
• Facilities
• Others

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Facilities Scheduling in CIM

• Layout issues
• Size and space issues
• Availability issues

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Product Scheduling in CIM

• Delivery Issues
• Customer issues
• Production issues

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Chapter 9 The Revolution in Manufacturing

• Several technologies and philosophies have
  revolutionized manufacturing in recent years.
  Some of these are covered in this chapter

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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

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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
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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

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