Zanussi & Cybertec Meeting Susegana, 2/3/1999 CYBERTEC - The Planning and Scheduling Company
Meeting Agenda • About Cybertec • The Cyber. Planning & Scheduling Suite • Cybertec Projects at Electrolux Zanussi Cold Division in Susegana CYBERTEC - The Planning and Scheduling Company
About Cybertec • • Company Vision Technology Products Services Customers Partners CYBERTEC - The Planning and Scheduling Company
Cybertec: The Planning & Scheduling Company • Mission: Help industrial Customers to increase resource utilization and service level and reducing stocks, product cost and human efforts • Established in 1992 • Average Annual grow > 50% • 40 focused people; 90% graduated or PHD; • Most consultants APICS CPIM certified CYBERTEC - The Planning and Scheduling Company
Vision • Planning & Scheduling is an Hard Problem • High improvement available through resource optimization and process synchronization • The Computing Power has increased by orders of magnitude while the complexity of the planning problem only few times CYBERTEC - The Planning and Scheduling Company
Cybertec Core Technology • Hardware resources – Ram based Data Bases – Cluster Of Computing Nodes • Software tools – C++, Java, Windows NT, Corba • Optimization techniques – Discrete Simulation, Constraints, LP, GA, …. + Practical Experience! CYBERTEC - The Planning and Scheduling Company
Products • A complete suite of products for repetitive and complex equipment industries: – Planning – Programming – Scheduling – Management Execution Systems CYBERTEC - The Planning and Scheduling Company
Services • • • Consulting Education Implementation Integration Special Projects for Hard Optimization CYBERTEC - The Planning and Scheduling Company
Customers Logo CYBERTEC - The Planning and Scheduling Company
Customer Industries • • Automotive Clothing Electric Electronic Food & Beverage Heavy Equipement Paper Pharmaceutical • • • Plastics Ship building Steel Textile … CYBERTEC - The Planning and Scheduling Company
Partners • • • Consulting Companies ERP Vendors MES Integrators SW Houses Universities • • Arthur Andersen Atos Consulting IBM JDE ORACLE SAP Orsi. . . CYBERTEC - The Planning and Scheduling Company
The Cyber. Planning & Scheduling Suite • • • SCD Supply Chain Designer MPS Master Production Schedule MRP Material Requirements Planning CRP Capacity Requirements Planning FCP Finite Capacity Planning FCS Finite Capacity Scheduling CYBERTEC - The Planning and Scheduling Company
Planning: designing for performances! • To meet the market requested performance ( service level, lead times, costs) You have to design for them • Cyber. Plan Supply Chain Designer is a new, long waited, tool that allowes to design for performace – Resource planning (equipements, personnel, tools, . . ) – Safety stocks and all other MRP parameters – Purchasing contract conditions (due dates, qty, safety stocks, min-max deviation, . . . ) • Same data and model used by your ERP CYBERTEC - The Planning and Scheduling Company
Cybertec Projects at Electrolux Zanussi Cold Division-Susegana CYBERTEC - The Planning and Scheduling Company
Zanussi & Cybertec Projects • Completed – Short Term FCS in the moulding dpts • Current – FAS & MPS Phase 1 • Automated Optimal Final Assembly Scheduling • Planned – FAS & MPS Phase 2 • Automated Optimized Master Production Schedule • Integration with Demand Management System CYBERTEC - The Planning and Scheduling Company
Short Term Finite Capacity Scheduling in the Innerliner Thermofoaming and Indoor Thermofoaming departments • A brief introduction – It was a ‘ 97 project – The problem was to build an automated schedule for the daily activities of the two production departments Innerliner Thermofoaming and Innerdoor Thermofoaing. – We started with one department and after successful implementation we dealt with the other one. – The daily scheduling activities involved very experienced employees. CYBERTEC - The Planning and Scheduling Company
The goals • Main goal: let not-experienced employees schedule the department by giving them a computerized scheduling system. • Other benefits required: – – Updated scheduling plans. More detailed scheduling of the production activities. More constraints under the planner control. More activities better organized (machine changeover, purchasing material call-out). CYBERTEC - The Planning and Scheduling Company
The scheduling problem • A hard set of constraints – A set of production requests with hourly due - dates for the next three days (or more). – Production & changeover activities. – Finite number of: • machine operator crews • set - up crews • moulds • Sequence dependent changeover costs: • change mould • change version (slight modification of the mould) • same mould (change of material color) CYBERTEC - The Planning and Scheduling Company
Output: • A production schedule for each machine such that: – satisfies the given constraints – minimizes the changeover costs – minimizes the due dates violation CYBERTEC - The Planning and Scheduling Company
Problem features • Why the problem was so difficult – Several contraints (changeover crew, operator machine crew, moduls, …) – Sequence set - up optimization – System was to be able to suspend a production lot and continue with a more urgent lot – Very strict lots due dates • Moreover…. – Easy to use and fast response system (few seconds…) – Very low level interaction with the computerized system CYBERTEC - The Planning and Scheduling Company
The solution Based on Cyber. Plan Standard Scheduling Technology: – This was the best technology availiable to solve the problem due to the number of production lots (hundreds) to be scheduled, the variety of the constraints, and the response time required. CYBERTEC - The Planning and Scheduling Company
Goals reached • Cyber. Plan is now scheduling the production of both departments – For more than one year Cyber. Plan has been helping to better organize the production in the Innerliner Thermofoaming and Innerdoor Thermofoaming departments • The scheduling of the activities in both departments are managed now by “no - guru guys” CYBERTEC - The Planning and Scheduling Company
Next steps • What could be done – New Cybertec Advanced Scheduling Technology could be applied to reach an even better performance in the production department • What will be done – Cybertec Advanced Scheduling Technology to optimize the Master Production Schedule & Final Assembly Scheduling CYBERTEC - The Planning and Scheduling Company
Automated Final Assembly Scheduling (FAS) CYBERTEC - The Planning and Scheduling Company
FAS: a brief introduction – Building a FAS follows the choice and qty of finished products to be produced in a given week. – The FAS consists in building a feasible and optimized schedule for finished products on the assembly lines. – It is the heart of the factory as it drives the production and purchaising (call out) flows of the factory. – FAS gives the “drum beat” to all of the activities in the factory. – As Zanussi-Susegana is a real Synchronous Manufacturing Environment, the FAS defines the feasible and optimal production flow of all production departments CYBERTEC - The Planning and Scheduling Company
The goal of FAS project: • There a lot of critical aspects the planner has to deal with to get a feasible and optimized FAS • The goal is to give the FAS planner a computerized system that can help him in building and maintaining a feasible and optimized schedule. • Moreover, with the support of this system the user will be able to control more constraints and optimization aspects of the production process. CYBERTEC - The Planning and Scheduling Company
Two different technological areas with different scheduling problems • There is a substantial difference between the two main areas of the assembly process – Traditional Assembly Lines • Scheduling Problem: – Find a feasible and optimal schedule of production lots – Automatic Assembly Lines • Load Balancing & Scheduling problem – Find a production daily rate and optimal schedule of production lots CYBERTEC - The Planning and Scheduling Company
The FAS Scheduling Problem • Due dates of the production lots • Sequencing rules that are used to optimize the chenge over costs in the production flow – At present, more seven sequence optimization rules must be taken simultaneously in count when building a schedule! • Critical constraints that must be satisfied – Foaming Moulds – Welding Machine • Critical resources that must be highlighted – “Round Door” production CYBERTEC - The Planning and Scheduling Company
The Loading Problem • Definine the optimal daily production rate for each automatic assembly line under – Capacity constraints • no more than x items can be produced in a given “ring” – Optimization criteria • a given efficiency must be guarantee CYBERTEC - The Planning and Scheduling Company
The FAS System Schedule Assembly Line Scheduling CYBERTEC - The Planning and Scheduling Company
The FAS critical resources load Overload! CYBERTEC - The Planning and Scheduling Company
The New Automated MPS System CYBERTEC - The Planning and Scheduling Company
Automated Optimized Master Production Scheduling System • The problem is to define which finished products have to be produced in each week of the planning period • Problem data: – – – a customer priority class a minimum level of customer service for each class of priority a minimum level of resourcce utilization a set of customer’s requests for each week the assembly lines capacity and the capacity of other critical resources – the bill of critical resources of each product – a set of production constraints (min production lot for model plant or pnc, max …) CYBERTEC - The Planning and Scheduling Company
Quality optimization measures • A feasible master production plan – defines what to produce (which finished products) and how much (how much for each PNC) under respect of the capacity constraints • Customer Service level – for each priority class the customer service level is defined: • (number of satisfied customers’ demands)/(number of customers’demands) CYBERTEC - The Planning and Scheduling Company
The goal • Find an automated feasible master production plan which: 1. guarantees a minimum level of customer service 2. the remaining capacity is allocated to satisfy the customers’ demands according to the priority class defined CYBERTEC - The Planning and Scheduling Company
Output • The amount of each PNC (finished product) that must be produced on week_i • The list of customers’ demands which will be satisfied • The list of customers’ demands which will not be satisfied – The level of customer service – The level of resources utilization – Alarms CYBERTEC - The Planning and Scheduling Company
Input Customer Priority Class Customer Requests CYBERTEC - The Planning and Scheduling Company
Fast & Easy Execution Executing Command CYBERTEC - The Planning and Scheduling Company
Unsatisfied constraints Unsatisfied Customer Requests CYBERTEC - The Planning and Scheduling Company
Results Control Panel showing the customer satisfaction level Master Production Schedule Workbench CYBERTEC - The Planning and Scheduling Company
Скачать презентацию Zanussi Cybertec Meeting Susegana 2 3 1999 CYBERTEC —
90a2b50c114dc72b6915ad55dab5e16b.ppt