Issuu on Google+

Optimal Intelligent Scheduling

When Machines Decide Improving Manufacturing Productivity with Data Analytics Vasu Netrakanti Optessa Inc.


Third Industrial Revolution: Digitisation of Manufacturing (The Economist) Perspective of optimization solutions provider Predictive analytics  Decision support Integrated with plant infrastructure Real-time decisions: routing (what next), selection (which order) … In an automated manufacturing environment, computers can help machines decide.

(2)


Case: Tier 1 On-demand Scheduling OEM

VEHICLE ASSEMBLY PLANT 1

VEHICLE ASSEMBLY PLANT 2

METEOR

COMET

400K 2 DOOR

500K 4 DOOR

2 DOOR

300K 4 DOOR

2 DOOR

SUNROOF

NON SUNROOF

SUNROOF

NON SUNROOF

SUNROOF

NON SUNROOF

SUNROOF

NON SUNROOF

SUNROOF

NON SUNROOF

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

RED WHITE BLACK BLUE SILVER

PRESS LINE MA1

PRESS LINE MA2

Optessa SUPPLIER ROOF LINER DIVISION

High complexity – 50 variants High volume for a small manufacturer – 25K parts/month “Broadcast” response (3)


1St Set of Inputs: Demand Feature

Data

Examples / Note

Vehicle models

COMET (300K): 2 DOOR METEOR (400K, 500K): 2 DOOR, 4 DOOR

Trim

COMET: GR5 – GR6, XR5 – XR7, ZR6 METEOR: GT0 – GT9, XT1 – XT9

Color

RED,WHITE,BLACK,BLUE, SILVER

Other features/Attributes

Part #, Priority Date, Priority Time, Part Required Quantity etc.

Demand

22,798 units MONTHLY

Due Dates

(Priority Date Time – 14 hours)

Logistics lead time

BoM

BoM

Vehicle configuration to part

(4)


2nd Set of Inputs: Production Capacity and Rules Feature

Data

Examples / Note

Lines

2

Window

1 Month

Flexibility required

Shift Pattern

Line 1: Day shift, Line 2: Day and Afternoon

Defines line capacity

Cycle time

COMET ~ 83 seconds (based on 43/hour) and METEOR ~ 72 seconds (based on 50 per hour)

Cycle times can differ based on model, features and lines

Tool Setup / Changeover

Tool change: 0.75 hours Color change: 10 minutes

Demand – Capacity mismatch

Smoothing of overtime / idleness required

Line capacity

Hard constraint

On Time Delivery

High priority

Minimize Changeovers

Medium Priority

Door – Roof – Color changeovers

Line Restriction

High Priority

COMET model parts imited to line 1

(5)


Results: Current and Optimized Scenarios

Current Follow OEM sequence

• • • •

Total Orders: 22,798 On Time: 5,653 Late: 13,324 Unscheduled: 3,821

Optimized Smoothed OT: 2 hours/day Minimize changeovers

• • • •

Total Orders: 22,798 On Time: 22,798 Late: 0 Unscheduled: 0

(6)


Case: SC Fab Real-time Yield Management

(7)


Case: Auto OEM ASRS Real-time Decisions The flow of painted bodies from the Paint Shop to the ASRS, and then to TCF can be represented through a flow diagram indicating the key vertices and arcs. R30/31: R30/31 is the set of readers on the two lane buffer at the exit of paint (post polish stage). After painted bodies cross the R30/R31 readers, there is no divergence until they reach the next node BT1100. All orders between R30/31 and BT1100 are the look-ahead available for RTS. BT1100: BT1100 is the skid exchange station where the painted body is transferred from Paint skid to Logistics skid. At this point, the decision of storing/bypassing/wax/set out of a painted body is conveyed to the further PLCs. PTT01: PTT01 is the turntable at the entrance of the ASRS. The orders diverge into Lane 1 or Lane 2 of the ASRS after PTT01. PTT02: PTT02 is the turntable at the exit of the ASRS. Orders retrieved from the ASRS converge at this turntable before being passed to the TCF. TT02: This is the turntable which routes LTVs to the LTV TCF buffer. The U202 and W201 bodies continue past TT02. TT03: This is the turntable which routes U202s to the U202 TCF buffer. The W201 bodies continue past TT03. TT04: Turntable routing W201 to W201 TCF buffer

.

At 60 jph, 3 decisions required every minute Routing: which ASRS cell to store painted body Selection: sequence outgoing job Assignment: which sales order for painted body (8)


Challenges ďƒ˜Reliable, accessible, timely data ďƒ˜Complement or supplement existing business processes?

(9)


Vasu Netrakanti - When Machines Decide - Improving Manufactuing Productivity with Data Analytics