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Factory Information Systems: Background
TTE-5317 FIS 1
2
General info Course keywords: XML, XML Schema, databases, SQL,
CAMX, Web Services,
Lecturer: Corina Postelnicu Office: RL206 Email: [email protected]
Contacting lecturer : Fridays 08:00-09:50, RL206 (if the schedule
allows) Lecture breaks
All students must register in Moodle2 http://moodle2.tut.fi
Course Schedule All changes/additions will be announced via Moodle
3
Laboratories & Assignments
Labs and assignment presentation: attendance mandatory
Labs: Tuesdays 08-10, 10-12 and 12-14 Room RL201 Check lab student groups and assigned time slots in Moodle
2 assignments Assignment 2 : group assignment
Exam & Grade
Exam date(s): check pop
Grade calculation example ( weight changes possible here): Labs: 25% Assignments: 30% Exam: 45%
In order to pass the course, the student must pass the exam AND all labs AND all assignments
Material
Book: Factory Information Systems in Electronics Production, Ivan Delamer and J. Lastra
Lecture slides
Lecture 1 Outline
1. Enterprise System Architecture Intro 2. Examples ;ajor players in the electronics
production industry 3. Factory Information Systems: Background 4. XML and XSD
1/23/14
0. An Enterprise System Architecture
1/23/14
An Enterprise System Architecture
Supply Chain
Enterprise
Manufacturing Execution Systems (MES)
Factory floor:
Machines, Manufacturing Equipment
Suppliers Customers
ERP, Order Management,
Planning and Scheduling
Maintenance, Control, Quality
An Enterprise System Architecture
Supply Chain
Enterprise
Manufacturing Execution Systems (MES)
Factory floor:
Machines, Manufacturing Equipment
Suppliers Customers
ERP, Order Management,
Planning and Scheduling
Maintenance, Control, Quality
ERP MES
centralized, high-level data management: Scheduling use of materials, human resources, Dispatching work orders, Forecasting sales , Issue of materials purchases
Initiating factory activities Monitoring plant status Short-term scheduling and optimizing multiple work orders Updating assembly line control strategy Managing machine recipes
expensive software & difficult to install (need to tailor business processes during installation of supporting Management Information Systems)
usually one ERP system per company one MES per factory or factory sector (e.g. group of assembly lines).
no knowledge on how to perform operations, only on what resources the operations need
awareness of how the factory works, Capability to give commands and instructions to the correct machines at the correct time.
Different Points of View Business Systems Manufacturing Systems
Time Horizons Long-term view Real-time view
Point of View View from the boardroom View from the workcenter
Interested in Accounting reference points
Inventory value Buyers Suppliers New entrants Rivals Substitutes
Material movement reference points (Does the product stop moving? If not, dont model separately)
Suppliers Customers
Typical Enterprise Model
Product Realization Process
Order Fulfillment Process
Order Capture Process
Support Processes
Enterprise
Demand
Offer
Product Realization Process
Order Fulfillment Process
Order Capture Process
Support Processes
Enterprise Enterprise Enterprise
Product Realization
Process Cycle Time
Manufacturing
Cycle Time
Sales Cycle Time
Supply Chain Cycle Times
Supply Chain Cycle Times
Manufacturing cycle time: the time to transform an order into a deliverable product
Sales cycle time: the time it takes from the moment a customer issues a purchase order until delivery
MCT< SCT MCT>SCT Factories can build to order Factories must build to forecast Reschedule production very frequently
Schedule production over relative long periods of time
Very small inventories
Increase of inventory stocking levels
Supply Chain Cycle Times
Manufacturing cycle time: the time to transform an order into a deliverable product
Sales cycle time: the time it takes from the moment a customer issues a purchase order until delivery
16
MCT< SCT MCT>SCT Factories can build to order Factories must build to forecast Reschedule production very frequently
Schedule production over relative long periods of time
Very small inventories
Increase of inventory stocking levels
Mass Production Lean Production
Influencing MCT-SCT relationship Mass versus Lean production
Criteria Mass production Lean production
Goal Good enough Perfection (zero defects, zero
inventories) Authority to stop the
line The manager Everyone
Errors Corrected at the exit from the line
Corrected on-the-fly (zero defects)
Inventory Days to weeks Minutes (zero inventories)
Part flow coordination
Relies on huge inventories
Just-in-time (kanban) policy
Changeover times Months Days
18
Inbound Supply Chain Outbound
Product Realization Process
Order Fulfillment Process
Order Capture Process
Support Processes
Enterprise
Product Realization Process
Order Fulfillment Process
Order Capture Process
Support Processes
Enterprise
Product Realization Process
Order Fulfillment Process
Order Capture Process
Support Processes
Enterprise
Voice of Customer Voice of Customer
Delivery Orders
Returns/Repairs
Delivery Orders
Returns/Repairs
Selling/Buying
Customer Care
Selling/Buying
Customer Care
Settlements Settlements
Supplier Relationship Processes Customer Relationship Processes
Supply Chain Enterprise Process Model
1. Example: Electronics Production.
Major Players
2. -OEM s original brand owners -- outsourcing of assembly, logistics, marketing to Electronics Manufacturing Service (EMS providers
e.g. Toshiba laptops
1 Original Electronics Manufacturer -In-house expertise - High integration level
3. Contract manufacturers /EMS
- in charge with design , not only assembly
Example Electronics Production. Major Players OEMs: previously responsible for almost every process in the supply chain Manufacturing outsourcing has enabled reduction of costs to an OEM. Initially, contract manufacturing was used by OEMs to manage the
manufacturing peaks and valleys. Nowadays, some OEMs perform little / no manufacturing of their own,
outsourcing it to Electronic Manufacturing Service (EMS) providers. An OEM is more accurately described as the original brand-name owner Through the 1990s, Electronics Manufacturing Service (EMS) providers
have increased their role, offering: Full manufacturing (many OEMs now manufacture nothing) Design services
Major Players in Electronics Production
Component, material and equipment (machines) providers: Printed Circuit Boards (PCBs), Semiconductors (chips), Passives: capacitors & resistors , Power supplies, Etc
Distributors: delivery of finished goods to customers.
Service Providers e.g. maintenance, consulting, customer support, etc. Example: Minimization of downtime of equipment
Web-enabled machines can send information to the service providers
Remote diagnostics Scheduled maintenance
2. Factory Information Systems
Background
Information system
Strong need for integration because: Various implementation levels
Various protocols ...
DATA / INFORMATION
DATA / INFORMATION
Drivers of Change in Manufacturing
Need to: Reduce costs & maximize profit
+ Improve productivity + Improve quality
Adapt to customers needs (be flexible to changes in demand) Information available everywhere, consumer make educated choices
Support faster cycles (business, manufacturing, time to market) Business cycles are getting shorter. Product life time is ever shorter. Factory Information Systems are the enabler of faster cycles
Change enablers
Supply-Chain Fission: outsourcing manufacturing, maintenance, logistics etc.
Supply-Chain Fusion: collaboration, merging of processes typically occuring in different enterprises
Fission
Fusion
FIS Implementation levels IPC/CAMX Standards
IPC Number/ Function -xxx1 Generic
-xxx2 Administ
-xxx3 Document
-xxx4 Board Fab
-xxx5 Bare Bd Test
-xxx6 Assembly Manufact
-xxx7 Assy Test/Insp.
-xxx8 Comp. & Mat'ls
IPC-2500 CAMX Framework
IPC-2501 IPC-2503
IPC-2510 GenCAM Product Data
IPC-2511 IPC-2512A IPC-2513A IPC-2514A IPC-2515A IPC-2516A IPC-2517A IPC-2518A
IPC-2520 Quality Product Data
IPC-2524
IPC-2530 SRFF Process Data
IPC-2531
IPC-2540 Shop Floor Communication (CAMX)
IPC-2541 IPC-2546(incl. Am1&2)
IPC-2547
IPC-2550 Execution Communication (MES)
IPC-2551 (Working Draft)
IPC-2554 (Working Draft)
IPC-2556 (PINS)
IPC-2560 Enterprise Communication
IPC-2570 Supply Chain Communication (PDX)
IPC-2571 IPC-2576 IPC-2577 IPC-2578
IPC-2580 Application Specific Data
IPC-2581 IPC-2582 IPC-2583 IPC-2584 IPC-2586 IPC-2588
http://webstds.ipc.org
Factory Information Systems ...various protocol stacks
IPC 2501
IPC 2541
IPC 2546
IPC 2546 FA
IPC 2547
IPC 2546 SP ...
2. XML and XSD