Simulation Based Scheduling Tool for Handcraft

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Simulation Based Scheduling Tool for Handcraft
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Contents

• Introduction
• Problem definition and goals
• Adaption and integration of the scheduling tool
• Data collection and data input
• Integration of technical data
• Test runs / experiments
• Benefits
• Future prospects

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Introduction

• In the last years the international competition
  and the customer's requests rose.
• The dynamic abilities (innovation readiness,
  creativity, flexibility) and the technological
  authority decide whether enterprises exist
  successfully in this competition.
• Small and medium enterprises (SME) have
  unbureaucratic organization forms, short
  information paths, flat hierarchies, close
  customer contact and high motivation
• These are the special strengths from SME.

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Introduction

• In the future the computer-aided simulation will
  become more important, because the tendencies in
  the economy like
• increasing product complexity and variant
  variety
• rising requirements of quality
• ascending requirements of flexibility with
  special wishes
• increasing requirements at service time and
  degree
• faster product changes
• smaller lot sizes
• cost minimization
• increasing integration into worldwide
  production networks
• lead to shorter development and planning cycles.

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Problem definitions and goals

• The company is a medium-sized handcraft
  enterprise which has 80 employees and exists
  since 1883. The range of products concentrates on
  the production of exhibition booths and the
  interior fittings of shops and businesses. During
  the last years due to successful business the
  company grew considerably. In this time new
  machines were purchased to offer customers
  appropriate services. The production scheduling
  should be improved and therefore a production
  scheduling tool was installed

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Problem definitions and goals

• The following goals are to be achieved by the
  commitment of the scheduling tool
• Transparency of production
• Administration of resources
• Decrease of the capital lockup
• Increase of date reliability
• Extent of utilization increase of the machines
  and employees
• Reduction of the overtime per order

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Adaption and integration of the scheduling tool

• The integration of the production scheduling tool
  is devided into the data analysis, planning,
  implementation, testing and handling-over. The
  simulation takes a special value in the field of
  production planning and control (PPS).
• The following tasks of the PPS-system are
  supported thereby
• Production Program Planning
• Quantity Planning
• Date and Capacity Planning
• Order Release
• Order Monitoring

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Data collection and data input

• A set of operational data (factory structural
  data, operating data, work plans, organization
  data and system load data) is integrated into the
  model.
• The data quality is affected by different
  characteristics of the data, for example
• Completeness and consistency
• Accuracy and plausibility
• up-to-dateness

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Data collection and data input

• In the production scheduling a detailed
  description of the manufacturing process is
  necessary. All relevant products and work plans
  must be considered.

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Data collection and data input

• In small and medium enterprises these relevant
  data is only partically available in digital
  form. For the purpose of determination of the
  appropriate data a data collection (machines,
  work places, work plans) has to be made. This
  data is transferred into the detailed scheduling
  instrument, provided with the appropriate
  parameters and stored in a data base.

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Data collection and data input

• Some problems are arisen during the
  standardisation of the products
• product name
• Lot size of the product
• Processing time on work place
• Set-up time for each work step

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Data collection and data input

• The work times and set-up times were determined
  by work time measurements on the individual
  machines and work places.
• Determined times were put down into the database.
• CNC Simulations were accomplished for the
  determination of the appropriate set-up times and
  work times. These data were then entered
  accordingly.
• After the data input some simulation runs with
  parameter variation were made. These served for
  the repeated examination of the data.

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Integration of technical data

• For an efficient use of simulation in the
  operational environment an integration of
  technical data is necessary. Computer-aided data
  exchange supports a fast creation of simulation
  models. It leads to a permanent topicality of the
  data in the models and allows the further
  processing of generated simulation results in
  other data processing systems.

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Integration of technical data

• The scheduling tool was connected to an ACCESS
  data base. For this purpose a new mask (order
  input mask) had to be designed and integrated in
  the existing data base. In addition the articles
  in the production scheduling tool were first
  standardized and entered via the appropriate
  schedules.

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Integration of technical data

• The order input mask was arranged in such a way
  that all relevant information is queried.
• Goal was the simple handling of the system for
  all users.
• In this order input mask all products and/or all
  necessary articles should be indicated.
• A delivery note can be print directly.
• The planning relevant articles were marked
  accordingly in the data base.
• Input and transfer of the orders to the
  production scheduling tool were made by the order
  input mask.

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Test runs / experiments

• In addition the different optimization goals are
  defined, e.g.
• Turn-around time
• Date reliability
• Extent of utilization increase
• Preparation time minimization
• and implemented parametrizable in the system.

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Test runs / experiments

• You can simulated the total production process
  for several days or weeks.
• The technological conditions are considered as
  well as the availability of all resources
  (operational funds, personnel, tools, material
  and other aids).
• The flexible worker assignment is supported by
  this proceeding.
• The optimization strategies and their effects on
  the individual principal of planning - e.g.
  turn-around time, utilization of capacity, date
  loyalty and existence - can be simulated and
  adjusted against each other.

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Benefits

• The problems of the date co-ordination and
  machine utilization were substantially improved
  through commitment of the scheduling tool.
• The following goals were achieved
• Increase of the date loyalty around 13 to 98
• Extent of utilization increase of resources
  around 15 to 95
• Reduction of the overtime from 15 to 5 per
  order

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Future prospects

• Small and medium Enterprises start up, because
  they
• use modern technologies
• redesigned their processes
• provide consistent data
• create a tool where other tools can be tied up
• have a basis for PDA installations in the
  future
• This reasons makes the SME attractive for the
  research and still offers large development
  potentials.