Enactment Servicebased Production Planning System for Electronicpart Industry

1
Enactment Service-based Production Planning
System for Electronic-part Industry
Hoyeoul, LEE Byoung K. CHOI Virtual
Manufacturing System LaboratoryDept. of
Industrial EngineeringKAIST (Korea Advanced
Institute of Science and Technology)
Aug. 31. 2007 TU/e, Eindhoven Netherlands
2
Contents

• Introduction
• SCM (Supply chain management) / APS (Advanced
  planning scheduling)
• Requirement for production planning of the
  high-tech electronic part industry
• Approach for Change-Adaptive Information System
  Architecture
• EIM (Enterprise information management) reference
  architecture Gartners view
• ESA (Enterprise Service Architecture) SAPs
  SOA-based ERP concept
• System concept for change-adaptive production
  planning system
• System Design
• System architecture
• Architectural requirement of the production
  planning system and comparison with existing
  system
• System features
• Case study System Implementation
• Implementation example for TFT-LCD glass
  fabrication factory
• Conclusion
• Summary and conclusion
• Further research

3
Introduction (1/2)

• Manufacturing flow management process 1)
• One of the main SCM processes
• Composed of production and resource management
• Making a compromise between demand sides
  requirements (market) and resource management
  (supplier and facility) sides
• APS(Advanced Planning Scheduling) System
  Architecture 2)
• Target Module Production planning system
• Input Master production schedule
• Output Lot sizing (factory plan)

1) Keely Croxton, Sebastian Garcia-Dastugue,
Douglas M. Lambert and Dale S. Rogers, 2001, The
Supply Chain Management Processes,
International Journal of Logistics Management.
V12, no. 22, pp. 13-362) Stadtler, H., Kilger,
C. Supply Chain Management and Advanced
Planning, 2nd ed., Springer, Berlin, 2002
4
Introduction (2/2)

• High-tech electronic part industry TFT-LCD
  Semiconductor industries requirement for
  production planning
• What is now TFT-LCD Semiconductor companys
  dilemma
• Production planning systems are not catching up
  with environmental changes
• 1) Developing in-house application or system
  outsourcing low ROI, continuous maintenance cost
  required.
• 2) Using package software manual amendment
  after systems output causes too many office works

Table 1. Requirement of the production planning
process for high-tech electronic part industry
1) Berry, William L. and Martha C. Cooper,
Manufacturing Flexibility Methods for Measuring
the Impact of Product Variety on Performance in
Process Industries, Journal of Operations
Management, Vol. 17, No. 2 (1999), p.177.2) Lin
J.T., et al., A hierarchy planning model for
TFT-LCD production chain. International Journal
of Electronic Business Management, Vol. 2, No.
1, pp.5968, 2004
5
Approach (1/3) Gartners View

• EIM (Enterprise information management) reference
  architecture 1)
• SOA(Service Oriented Architecture)-based
  enterprise information model
• Separation between business process / business
  application ? (BPMS)
• Separation between application / Data Management
  ? (MDM)
• From existing custom/package application-based
  architecture, To Composite-based application
  architecture

1) Gartner Research Report, The Essential
Building Blocks for Enterprise Information
Management, 2005.
6
Approach (2/3) SAPs SOA-based ERP Concept

• ESA (Enterprise Service Architecture) 1,2)
• SOA-based application architecture architecture
  of the next generation ERP (R/3)
• Existing client/server-based ERP module ? Service
  composition platform (SAP NetWeaverTM)
• Corresponding with business processes, assemble
  services on the ESA to implement ERP System

Composite Applications
User Interface
Business Process Model
Enterprise Service Repository
Service Composition Platform (ESA)
Business Logic
Existing Systems
Data Repository
ERP
1) Lars Lindberg, SOA as a paradigm shift, SAP
Whitepaper, 2005
2) Delivering Operational Excellence with
Innovation, SAP Whitepaper, 2006
7
Approach (3/3) Change-adaptive Production
Planning System

• Change-adaptive production planning system
  concept
• Make workflow model reflecting topology and
  production process of the factory
• Implement services from algorithm reflecting
  behavior of the target system (equipment,
  materials)
• Use WfMS as a service composition platform

Production Planning System
Workflow ProcessModeling
Application ProcessCorresponding with
Production Process
Job Releasing
Best PracticeProduction ProcessBehavior
Service CompositionPlatform (WfMS)
JobFinishing
Planning ServiceRepository
Production Process of the Factory
Physical Spec
Production Master Data
Table 2. How to make workflow models from the
material flow
8
System Design (1/3)

• System architecture of the enactment
  service-based production planning system

Workflow Enactment Service


Application Services
Planning Services
Planning Service Repository
Service DataStorage
Service Data Storage
Master data client
Data Infrastructure
Master Data Server
9
System Design (2/3)

• Architectural requirements for production
  planning systemand how to be achieved in the
  system (Compared to existing systems)

Table 3. 7 architectural requirements and how to
be achieved in the system
10
System Design (3/3)

• System features
• You do not Develop but Design production
  planning system New system offers systematic
  features on which, without additional
  programming, users are able to construct or
  modify information system easily and quickly
  corresponding with 1) Manufacturing system
  (production process) or 2) Operation policy
  (business process)This can be possible with
  (1. Flexible workflow model - Flexible model
  that can reflect any types of mfg. system and
  business process) and (2. SOA - Assembling
  linking minimum-sized planning logic services
  accord to workflow model so that whole production
  system is constructed)
• This feature can be categorized as follows
• (System structure features) Business process
  managers view - Façade pattern 1)
• New system could be assembled to higher-level
  business process as a unit service
• Process manager can deliver processs information
  to lower-level planning system with considering
  planning system as a black box
• Workflow enactment service can be seen as a kind
  of System interface from business processs
  view
• (System behavior features) Production planning
  managers view - Strategy pattern
• System models and linked services are
  interchangeable with the others related to
  users requirement or target systems alteration
• We dont need system engineer or expert during
  interchanging system models or linked services

BPMS
System boundary
New production process
Enactment service
Planning Logic A
Planning Logic B
Alternative logic
System boundary
1) Erich Gamma, Richard Helm, Ralph Johnson, John
Vlissides, Design Patterns Elements of Reusable
Object-Oriented Software, Addison Wesley,
Reading, Massachusetts, January 1995
11
System Implementation (1/4)

• Target System TFT Fab. (Fabrication factory) of
  the TFT-LCD mfg. system
• Composed of 5 main steps and more than 150
  equipments
• Each step is organized corresponding with
  bottleneck processes (photo-lithography
  equipment)

12
System Implementation (2/4)

• Production workflow modeling model reflects
  System architecture
• Step 1 Build workflow model reflecting
  production process and additional logical
  activities
• Step 2 Link each workflow models activity to
  planning services implementing planning algorithm
  1)
• Step 3 Describe data source (data format and
  location) that will be used by services
• If needed, you can connect workflow model to
  business process (See next slide)

1) Byoung K. Choi, Jeong C. Seo,
Capacity-Filtering Algorithm for Finite-Capacity
Planning of a Flexible Flow Line, International
Journal of Production Research (To be appeared)
13
System Implementation (3/4)
Dynamic web service link
Production planning process (office level) And
application model reflecting production process
Define master production data
14
System Implementation (4/4)

• System evaluation and restriction
• System evaluation
• Firstly, we disassemble production planning
  modules (that had been implemented before as a
  previous research) into minimum-sized web
  services.
• We implemented (actually, designed) production
  planning system for LCD-TFT fabrication factory
  for LCD production process without programming.
• We analyzed and verified the results (factory
  input/output plan) generated from production
  planning system, and confirmed systems logical
  structures worked valid.
• We successfully apply new production process to
  the system without any programming efforts. (from
  previous 5 mask process to new developed 4
  mask process)
• We connected production planning system to
  business process using sub flow function. On the
  business process, user defines production
  planning options and input data which are
  delivered to production planning system.
• Restriction
• So far, implemented system architecture supports
  only sequential workflow that has no transition
  branching or merging, loop node and other types.
• The production processes of TFT fabrication
  factory can be modeled only with sequential
  workflow sufficiently, but we have to develop
  additional features and functions to support
  another production processes.

System evaluation procedure
Sequential flow
Merged / branched flow(not supported)
15
Summary and Conclusion

• Summary
• Core requirements for production planning system
• To be adapted easily and quickly for production
  processes
• Workflow enactment service-based production
  planning system
• EIM(Gartner) and ESA(SAP) concept represents the
  system architectures support high reusability
  and change-adaptiveness
• We designed change-adaptive system architecture
  corresponding with production processes rather
  business processes
• On the proposed system architecture, We could
  successfully construct / modify production
  planning system reflecting target production
  process(TFT-LCD) without any programming efforts
• Conclusion
• Proposed system architecture offers users a
  systematic approach that could sufficiently
  reflect not only manufacturing system that varies
  for every companies, but also alteration of
  evolving production processes quickly and easily.
• With proposed approach, we expected that many
  companies will be able to save a lot of expenses
  on S/W development cost, maintenance cost, and
  cost caused by unnecessary office works related
  to production planning.

16
Further research

• Further research
• Improving systems modeling power to support
  general production system
• Proposed system now supports only sequential
  flow, for example, TFT-LCD manufacturing flow
  line.
• Implement additional features to support general
  production system including flow shop, job shop,
  etc.
• Expanding proposed concept to whole SCM processes
• Production planning system could be starting
  point to implement
• Enactment service-based production scheduler (or
  production simulator)
• Enactment service-based master planning system
  (or supply chain planner)
• Integration issues between applications
  (hierarchical BPMS/workflow)
• The long-term objectivePropose information
  system architecture supporting SCM (corresponding
  with exiting APS) on which users or domain
  consultants can construct /modify system without
  system programmer or expert
• Discussion

17
References

• Market research report, http//www.displaysearch.c
  om/, 2007
• Market research report, http//www.isupply.com/,
  2007
• Gartner Research Report, Service Oriented
  Architectures - Part 1, 1996
• Gartner Research Report, The Essential Building
  Blocks for Enterprise Information Management,
  2005.
• Keely Croxton, Sebastian Garcia-Dastugue, Douglas
  M. Lambert and Dale S. Rogers, 2001, The Supply
  Chain Management Processes, International
  Journal of Logistics Management. V12, no. 22, pp.
  13-36
• Sung-Won Kim, MDM Strategy for Next Generation
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  Berlin, 2002
• N. Jasmine, BPM and SOA Better Together, IBM
  White Paper, 2005, pp. 1-12.
• Byoung K. Choi, Jeong C. Seo, Capacity-Filtering
  Algorithm for Finite-Capacity Planning of a
  Flexible Flow Line, International Journal of
  Production Research (To be appeared)
• Frank Buschmann , Regine Meunier , Hans Rohnert ,
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• Erich Gamma, Richard Helm, Ralph Johnson, John
  Vlissides, Design Patterns Elements of Reusable
  Object-Oriented Software, Addison Wesley,
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  planning model for TFT-LCD production chain.
  International Journal of Electronic Business
  Management, Vol. 2, No. 1, pp.5968, 2004
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  Architecture for Order Adaptive Business Process
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• Lars Lindberg, SOA as a paradigm shift, SAP
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• Delivering Operational Excellence with
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