Tài liệu Fab 09 production planning and control 2

Sustainable Manufacturing and Factory Planning Production Planning and Control (PPC) II 13.04.2017 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl © IWF TU Berlin Page 1 Content  Production Principles and Production Types  PPC Best Practices  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 2 Aim of production control  The task of Production Control is to organize that the right product with the right specification (quality) and right quantity will reach the customer at the right time  The tasks becomes increasingly difficult because of increased variants and short time delivery expectations and globally distributed production sites and suppliers Customer orders a product Customer receives product Production control Supplier Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Production Page 3 Three level concept and control loop Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 4 Levels of Production Planning and Control Planning:  Determination of General Data  Network Scheduling  Order Network Management ERP System Order Network Product Planning Level Control: Detailed Planning and Implementation  Scheduling and Load-In  Progress Control  Deviation Control Order Key Features Work Schedules Condensed Feedback Data Manuf. Exec. System Control Area 1 Process: Execution  Processing  Manufacturing Progress  Fault Value  Process Data Control Area 2 AFO Release Control Area 3 AFO Release FDA MDA Shop Floor Manufacturing Area 1 Manufacturing Area 2 Manufacturing Area FDA Factory data acquisition MDA Machine data acquisition AFO Work Sequence Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 5 Control Circuit Model of Production Control Corporate Goals Planning System (medium-term) Planning System (long-term) MODEL SYSTEM Target Values KPIs Planning System (short-term) FDA REAL SYSTEM Shop Floor Information Flow Material Flow Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Disturbances KPI Key Performance Indicator FDA Factory Data Acquisition Page 6 Examples of order sheets Documents to be handled during Production Control:  Request by customer  Offer by producer using BOM Bill of Material  Order by customer  Internal Worksheet (production steps, duration and machines/workplaces)  Internal manufacturing orders  Accompanying papers  Quality documents and  delivery slip and invoice Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 7 Production Principles I Production Principle Workbench Principle Organizational Criterion Example  Manual Work Centers Human  Assembly Tasks S1 P1 S2 P2 S3 P1 W Interaction Material Flow P Product S Station (Assembly work place, Machine tool) Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl W Worker Source: [Löd-13] Page 8 Production Principles II Production Principle On-site Principle Organizational Criterion Example  Heavy machine construction Product  Shipyard S1 Raw Material, Components S2 S3 P (Work Object) Interaction Material Flow P Product S Station (Assembly work place, Machine tool) Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl W W Worker Source: [Löd-13] Page 9 Production Principles III Production Principle Organizational Criterion Work Shop Principle (or Function Principle) Example  Turnery Manufacturing Technology  Grindery P2 Turnery S5 S6 P2 P2 Drilling P2 S3 S4 Material Flow Grindery P1 P1 S1 S2 P1 P2 P Product S Station (Assembly work place, Machine tool) P1 P2 P1 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Löd-13] Page 10 Production Principles IV Production Principle Organizational Criterion Group Principle (or Cellular Principle) (Typically U-Shape) Example  Manufacturing Cell Material Flow of Part Family  Assembly Cell Material Flow S3 S4 P1 P1 P2 S1 S2 P1 P1 P Product P2 P2 S Station (Assembly work place, Machine tool) P1 P1 P2 P2 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Löd-13] Page 11 Production Principles V Production Principle Flow Principle P1 Organizational Criterion  Production Line Material Flow of defined Variants S1 P1 S2 P1 S3 Example  Assembly Line P1 S4 P1 P1 Material Flow P Product S Station (Assembly work place, Machine tool) Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Löd-13] Page 12 Lot size in manufacturing costs Storage costs Set up costs Total costs Lot size Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [VNL-ol] Page 13 Production Types I Criteria:  Average size of the manufacturing run (lot size)  Average number of repetitions per year for the manufacturing runs  Small production run  No repetitions Serial production  Size of production  Size of production run < 50 run > 50  Number of  Number of Airplanes Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  Very large production runs  Continuous repetitions < 24 valc.com.vn cad-ingenieur.de repetitions < 12 Plants Mass production production Luxury cars techfleece.com Single or small series production eurocarblog.com One of a kind production Mobile phones Source: [Löd-13] Page 14 Production Types II Production types Dominating organizational principle Relation to customers‘ orders One of a kind production  On-site principle  Customized non-repetitive  Workbench principle production  Make-to-order production Single or small series production  On-site principle  Make-to-order production  Work Shop principle  Assembly-to-order production  Workbench principle Serial production Mass production Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  Work Shop principle  Make-to-order production  Cellular principle  Assembly-to-order production  Flow principle  Make-to-stock production  Flow principle  Make-to-stock production Source: [Löd-13] Page 15 Content  Production Principles and Production Types  PPC Best Practices  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 16 Design Principles of Production Systems  A company sets the production methods, based on super ordinate objectives of productions (e.g. throughput time, inventory, capacity utilization, quality)  The objectives are controlled by key performance indicators (KPIs) defined by the manufacturing execution board  Companies often create catalogues of methods and tools to improve the production process  Out of that catalogue manufacturing site managers can select appropriate methods and tools and implement them to reach the objectives  Check for more information the VDI Guideline 2870 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [VDI-2870a] Page 17 Overview Over Methods and Their Impact on Quality, Cost and Time (1/3) Principle Standardization Zero defects principle Visual management Method Quality Cost Time 5S •• • •• Process standardization ••• •• ••• 5 x why ••• • •• 8D report •• •• •• A3 method •• •• •• Autonomation ••• •• •• Ishikawa diagram •• •• •• Short control loops •• • •• Poka Yoke ••• •• •• Six Sigma ••• •• •• Statistical process control ••• • • Worker self-check ••• •• •• Andon ••• • •• Shop floor management ••• ••• ••• Further focus Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Impact on objectives: Low Medium High Source: [VDI-2870b] Page 18 Overview Over Methods and Their Impact on Quality, Cost and Time (2/3) Principle Continuous improvement Method Quality Cost Time Audit •• •• •• Benchmarking •• •• •• • ••• •• ••• ••• ••• PDCA1 •• •• •• Hancho ••• •• •• Target management •• •• •• First in first out •• • • One piece flow ••• ••• ••• Quick changeover • •• ••• Value stream planning • •• ••• U layout • • ••• Cardboard engineering Idea management Employee orientation and management by objectives Flow principle Note 1): PDCA: Plan Do Check Act Further focus Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Impact on objectives: Low Medium High Source: [VDI-2870b] Page 19 Overview Over Methods and Their Impact on Quality, Cost and Time (3/3) Principle Pull principle Avoidance of waste Method Quality Cost Time Just in time / just in sequence • •• •• Kanban • ••• ••• Milk run • •• •• Production Leveling • • •• Supermarket • •• •• Chaku Chaku • •• •• Low cost automation • ••• •• Total productive maintenance • ••• • Waste analysis • ••• ••  A detailed description of the methods is given in VDI 2870, Part 2 [VDI-2870b]. Further focus Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Impact on objectives: Low Medium High Source: [VDI-2870b] Page 20