Factory control system

Factory Control System

A demonstration of the ArchimateSystem Architect Plugin utilization for

Enterprise Modeling

Foreword

It is assumed that the reader is familiar with the manufacturing environment, the concept of Enterprise Architecture, the concept of Business Process, and the use of Enterprise Architecture tools such as IBM Rational System Architect that has been used – in conjuction with the Archimate plug-in – to model thisdemonstration. Every figure in this presentation hasbeen created using one of the several diagrammingnotations provided by System Architect, notpowerpoint.

CONCEPTUAL LAYER

The 4Ms of Manufacturing

4 Ms

Manufacturing

Information FlowIntegration

Material FlowOptimization

.Methods.Material

.Machinery.Manpower

uses

usesuses

uses

supports

supports

The Factory Management Concept

Possible StatesLeve l What isMonitored

Piece

Processing

Running

Machine Step

Processing

Running

IdleLoadingIdle

Setting-upQueued

MovingWaitingQueued

StoredCompleteIn-WorkHeld

DeliveredBeing MadeOrdered

Routing Step

Part / Lot

Product

Work Center

Job Shop

Production

Machine

Factory

monitors

monitors

monitors

monitors

monitors

makes

makes

makes

makes

Product Aggregation

ManufacturingEngineering

ManufacturingUnit

Work CenterJob ShopFactory

Part PieceProcessing

Routing

Assembly

Routing Step Process Plan

Product

createscreates

monitors

performs

makes

monitorsperforms

makes

performs

makesmonitors

Business Collaboration

Job

Part Processing

Mfg. Unit

ManufacturingUnit

MachineOperato

r

Factory Level of Control

RawMaterial

ProductRequirementsfrom Planning

Parts / LotsRequirements

(Parts/Lots/RoutingStep Execution)

Work Orders to JobShops

Feedback fromJob Shops

CompletedProducts

Factory

Factory Locations Map

Factory Locations

Suppliers

(Cold)

GoodsWarehouse

Job Shop CJob Shop B

Customers

(Cold)

ProductsWarehouse

Job Shop A

AssemblyJob Shop

Job Shop Level of Control

Completed Detailed Components

(Parts/Lots/Routing Step Execution)

Work Orders toWork

Center

Raw Material Detail

Feedback fromWork

Centers


WorkOrders

fromFactory

RoutingSteps

Job Shop

Job Shop Location Map

Job Shop Work Centers

Job Shop Services

Work Centers Control Office

ServicesControl Office

Work Center 1 Work Center 2

Stores

Work Center 3

InspectionDepartment

TransportationDepartment

MaintenanceDepartment

ToolCrib

Work Center Level of Control

(Job/Process Step Execution)

Work Orders toMachine

Feedback fromMachine


Work Ordersfrom Job

Shop

ProcessingSteps

Work Center

Next Work CenterLast Work Center

Work Center Location Map

Work Center Locations

Work CenterBuffer

Machine 1 Machine 2Machine 3

Conveyor

Manufacturing Unit Level

Work Ordersfrom

Work Center

ProcessingInstructions

ManufacturingUnit

Work Center Buffer

(Pickup)

Work Center Buffer

(Storage)

Semi-finished / Finished PartsRaw-material / Semi-finished Parts

Functional Organization

Transportations

ProductionManager

ManufacturingEngineering

Manufacturing ManufacturingCosts Control

Maintenance

Inspections

WorkCenter

Operations

Mfg UnitOperations

Machine

ProductionPlanning& Control

Job ShopServices

Factory

ProductionPlanning

ProductionControl

ToolCrib

Job ShopStores

WorkCenter

AssemblyShop Floor

Job Shop

Operator

Work Order Flow

Work Order

Maintenance

Control

Inspection

ControlTransport

Control

Production

Control

Stores

Control

Tool Crib

Control

Machine

Control

Buffer

Control

Work

Center

Control

Job Shop

Control

Factory

Control

translates product

reqm't

into part reqm't and

issues WO to job shop

splits factory WO

into

workcenter WO for

specific part reqm't

translates jobshop WO

into jobs to be

assigned

to specific machines

issues to factory

with

product reqm't

Process Plan Flow

Process Plan

Maintenance

Control

Inspection

ControlTransport

Control

Production

ControlFactory

Control

Job Shop

Control

Work

Center

Control

Buffer

ControlMachine

Control

Tool Crib

ControlStores

Control

deviations from PP may occur during jobexecution.

they must be reported back for PP adjustment

despatches the PP toworkcenter accordingto operations routing

selects the PP needed bythe work orders and make

them available to jobshop

recives PP from mfg.engineering and

makesthem iavailable to

factory control

despatches PP steps tomachines according to

the assigned jobs

Routing Flow

Routing

Maintenance

Control

Inspection

ControlTransport

Control

Production

Control

Stores

Control

Tool Crib

Control

Machine

Control

Buffer

Control

Work

Center

Control

Job Shop

Control

Factory

Control

deviations from routings may be neededto cope with manufacturing constraintsthey must be reported back for routingadjustment

assigns routing steps tothe workcenters

assigns routing steps tothe jobshops

defines the sequence ofoperation to be executed

to produce a product

Service Request Flow

Service Request

Maintenance

Control

Inspection

ControlTransport

Control

Production

ControlFactory

Control

Job Shop

Control

Work

Center

Control

Buffer

ControlMachine

Control

Tool Crib

ControlStores

Control

Inspection

Request

Tool Crib

RequestTransport

Request

Maintenance

RequestStores Request

fulfills the request

issues a request toworkcenter control

fulfills the requestfulfills the request

issues a request toworkcenter control

dispatches the requests frommachine and buffer to

jobshop

dispatches the request tothe relevant service

fulfills the request fulfills the request

Material Flow

Material

Maintenance

ControlInspection

Control

Transport

Control

Production

Control

ConsumableLot Part Raw Material

Stores

ControlTool Crib

Control

Machine

Control

Buffer

Control

Work

Center

Control

Job Shop

Control

Factory

Control

Tool Flow

Tool

Maintenance

Control

Inspection

ControlTransport

Control

Production

ControlFactory

Control

Job Shop

Control

Work

Center

Control

Buffer

ControlMachine

Control

Tool Crib

ControlStores

Control

Equipment Flow

Equipment

Maintenance

Control

Inspection

ControlTransport

Control

Production

Control

Stores

Control

Tool Crib

Control

Machine

Control

Buffer

Control

Work

Center

Control

Job Shop

Control

Factory

Control

BUSINESS LAYER

An Enterprise Architecture is decomposed into three layers:

• Business Layer

• Application Layer

• Infrastructure Layer

Shop Floor Process DiagramShop Floor

Work Center

Machine

Job Shop

ProductionControl

Factory

Product

Part / Lot

Machine Step

Routing Step

Factory Process Diagram

OrderExecution

Des ign &SimulateRoutings

Update JobShops Load

Plan

Issue JobShops Orders

IssueOutsourc ing

Order

UpdateEmpirical Data

AnalyzePerformance

Monitor OrdersRate of Flow

Design Lots &Routings

Monitor JobShops

Requests

Del iverProducts

Make FactoryDec is ions

Request MPSChange

Work OrderRate of Flow

Job ShopsLoad Plan

Job ShopPerformance

FactoryInformation

FactoryEmpirical Data

Factory RoutingJob ShopCapac ity

Make or BuyData

Process Plan

Job ShopCapac ity

Work Orders

MPS

Batch Lot

Bill of Material

ProductProduct Status OrderExecuted

Production Order

MPS

Change

Outsourc ing

Upon Order

Completion

Job Shops

Feedback

Job Shop

Overload

Job Shop

Overload

Job Shop Service Diagram

Job Shop

Job ShopServices

(input)

Raw Material Detail

(output)

Completed DetailedComponents


Work Orders fromFactory

Feedback from WorkCenters


Work Orders to WorkCenter

Routing Steps

Job Shop Services

Job ShopServices

MaintenanceInspection TransportStores

InspectionProcess

Tool Crib

MaintenanceProcess

StoresProcess

TransportProcess

Tool CribProcess

Inspection Process Diagram

Inspection

Rescheduling

Inspection

Completed

Inspections

PlanningRandom

Patterns

Generation

Inspection

Results

Reporting

In Process

Inspection

Inspection

Sequences

Planning

Inspection

Exception

Reporting

Allocatie

ResourcesImpact Analysis Parts/Lot

Receiving

Inspection

Execution

Lot Releasing Equipment

ReleasingInspector

Engagement

Inspection Tasks

Equipment Status

Part Status

Lot Statistics

Inspection

Exception

Inspection

Resource

Allocation

Inspection

Impact

Inspections Plan Random

Pattern

Upon InspectionRequest

Lot Inspected

Exception

APPLICATION LAYER

An Enterprise Architecture is decomposed into three layers:

• Business Layer

• Application Layer

• Infrastructure Layer

Inter-layer Relations

Report InvalidInspection

Item

ReportInspected

Part Status

ReportInspection In-

process

RecordEquipmentAss ignment

ReportReady

Machine

DisplayInspection

Plan

Report Itemsto be Moved

Record LotsReady

ReportReady

Equipment

EquipmentReleas ing

LotReleas ing

InspectionExecution

Parts /LotReceiving

AllocatieResources

InspectionExceptionReporting

In ProcessInspection

InspectionsPlanning

Application Service Realization

Log-off

Inspector

Record

Special

Inspection

Charge

Record Lots

Ready

Report Items

to be Moved

Display

Inspection

Plan

Report Ready

Machine

Record

Equipment

Assignment

Report

Inspection In-

process

Report

Inspected

Part Status

Report Invalid

Inspection

Item

Report Ready

Equipment

Log-on

Inspector

Inspection

Control

Inspection

Control

Component

Inspection Control Application Service

Inspection

Process

Log-off

Inspector

Record

Special

Inspection

Charge

Record Lots

Ready

Report Items

to be Moved

Display

Inspection

Plan

Report Ready

Machine

Record

Equipment

Assignment

Report

Inspection in-

Process

Report

Inspected

Part Status

Report Invalid

Inspection

Item

Report Ready

Equipment

Log-on

Inspector

Inspection

Control

Shop Floor Application Services

Shop FloorControl

MaintenanceControl

InspectionControl

Job ShopServices

TransportControl

Production

Control

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

MaintenanceControl

Component

Stores ControlComponent

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

Work CenterControl

Component

Buffer ControlComponent

Business and Data Objects

Equipment StatusInspection

Exception

Lot StatisticsInspection TaskPart StatusResources

Allocation

Random

Selection

Patterns

Inspection Plan

Inspection

Exception

Lot StatisticsPart Status Equipment StatusInspection TasksInspection

Resource

Allocation

Inspections Plan Random Pattern

Inspection Data Objects

Inspection Plan

Inspection Order

Inspection Job

Resources

Inspection

Request

Inspection

Empirical Data

Inspection Trend

Data

Inspection Store

Inspection

Dynamic

Inspection Data

Inspection

Shared Data

Entity Relation Diagram

Inspection_Empirical_DataNon-Key Attributes

DelaysResources_UtilizationResponse_TimeEquipment_UsageQuality_Standards

Inspection

Primary Key

Identification[PK1]

Inspection_JobPrimary Key

Identification [PK1]Non-Key Attributes

StatusCompletion_DateDurationPerformance

Inspection_OrderPrimary Key


Resources

Inspection_Trend_DataNon-Key Attributes

Order_FrequencyManpower_PerformanceQuality_Trend

Inspection_ExeptionNon-Key Attributes

"What Plan"Type

Inspection_PlanPrimary Key


Random_PatternsStart_DateEnd_Date

Inspection_RequestPrimary Key


RequestorStatusLot

Inspection_StoreNon-Key Attributes

SoreEquipment

ResourcePrimary Key

Type [PK1]

Inspection_TaskPrimary Key


Sequence

monitors

fulfills

requires /uses

issues

executes

generates

receives

creates /updates composed of

INFRASTRUCTURE LAYER

Inter-layer Relations

Work CenterServer

Work CenterControl

Component

MaintenanceControl

Component

MaintenanceServer

StoresServer

TransportServer

FactoryServer

Job ShopServer

Job ShopControl

Application

FactoryControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

BufferControl

Component

InspectionServer

Tool CribServer

Shop Floor Control Network

LAN

Work CenterIntranet

Work CenterServer

Job ShopIntranet

Work CenterPC

FactoryIntranet

FactoryPC

MaintenancePC

Job ShopPC

MaintenanceServer

MacjineController

Inspection PC

ProductionHost

InspectionServer

FactoryServer

TransportPC

Tool CribPC

StoresServer

TransportServer

Tool CribServer

Job ShopServer

StoresPC

MaintenanceHub

Inspection Hub

FactoryHub

Job ShopHub

Tool CribHub

Stores Hub

TransportHub

MachineHub

WorkCenter Hub

Infrastructure Services

Production

Supplier

Production Host

Unix Server Farm

Database Service Fi le Service Network Service

Intranet

Admin Server

Fi le Server

MessageQueuing

Mfg EngineeringServer

DBMS

PlanningServer

CICS

Supplier LAN

LAN Firewall

Supplier Firewall