Advanced Scheduler for Wonderware MES

Chris MollisonScheduling Solutions

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Background to the Project

► This presentation shows how the Preactor scheduling functionality has been integrated with Wonderware Operations 3.4

► It discusses the benefits of using finite scheduling functionality.

► It reviews the results obtained at Aquacolor where Wonderware Operations and Preactor are integrated

Background to the Project

Manufacturing Order Management Enterprise Integration

Finite Scheduling

Dispatching

Batch/ Process Execution Batch/ Unit Execution

Process Automation Control

Manufacturing Operations ExecutionWIP Status Management

Production Practices Enforcement (multi Unit)

Discrete Automation Control

Manufacturing Performance Management

In Line Product Quality Compliance Equipment Condition Monitoring

Production Capacity Management (OEE, TEEP)

Product Traceability

Secondary Production Execution Production Order Execution

Container Management (Tote bin management)

Final Inventory

Bar Code Printing RFID Coding

Shipping Execution

Receive Preparation Batching Make Unit Packaging Ship

Deviation/ Yield Management/ Scrap Rework

Brand Integrity/ Quality Sample Plan Management

Manufacturing Reporting/ Analysis/ Dashboard

Material ManagementMaterial Receivables

Pre-Weighing/ Dispensing

Inventory Material Management

Material Quality Inspection

Regulative Compliance (HACCP)

Material Management/ Formula

Food and beverage solution map

Project Goals

► To create a certified integration between Wonderware Operations 3.4 and Preactor.

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Automation

ERP

MES

APS

System Control

Jurgen Kletti, 2008

Where does APS fit?

APS Role in MES

Fills the MESA function group for detailed planning:

Sequence and time optimization of the orders finely tuned to the performance of the

machines, including their finite capacity and relationship to other resources

Why is scheduling different from planning?► Planning systems are bucketed (monthly, weekly, daily)

and cannot preserve operation sequences within the time bucket

► True scheduling systems are bucketless, preserving sequencing, and capable of generating work-to or dispatch lists.

► Assignment of operation to resource is a key function to achieve operational efficiency and optimizing performance

SAP APO

► APO is a global Supply Chain solution► APO is made up of several modules :

►Collaborative Planning (CP)►Supply Chain Cockpit (SCP)►Demand Planning (DP)►Supply Network Planning (SNP)►Production Planning & Detailed Scheduling (PP/DS)►Global Available-to-Promise

► Preactor does not compete with APO, but only with the “Production Planning & Detailed Scheduling” (PP/DS) module of APO

Limitations PP/DS for MES

► PP uses an MRP calculation with infinite capacity and large planning and scheduling ‘bucket’ sizes (typically a week) and mid/long term vision

▪ Hence a planning system with all the limitations► DS does not link dependent WOs (pegging), it uses launch

date data, ▪ No synchronization of materials between dependent WOs or WOs

to WOs► APO uses heuristics technology

▪ Very difficult to parameterize ▪ Solver cycle long and not repeatable▪ Very difficult for users to understand

► Limited, rigid rule set

Where does APO fit?E R P /P P S

ERP/PPS

MES

APS

CP

SCP DPSNP

GATP

Why Preactor?

► Founded in 1993 – 15 years of experience in developing and implementing scheduling solutions

► Microsoft Gold Partner► International coverage across 5 continents► Over 10 000 licenses sold

Since its first release in 1993 more than 10,000 Preactor scheduling systems have been installed in the broadest range of verticals…..

Preactor’s Install Base

Why Preactor?

ERP SYSTEM

Wonderware Operations 3.4

APS

Data Flow

Production Order • item• qty• date

Operations management• production process • recipe management• inspection• tracking

Sequencing• sequencing

logic • dates & times• resources to

use

Integration with Wonderware Operations

WorkOrder

Wonderware Ops(MES)

Data Sent per OpScheduled Start Time

Target Scheduled Resource

PreactorAPS

Data Sent per OpInitial Scheduled Resource

Required Finish TimePriority

Route constraintsActual Start Time

Integration structure

Links with Operations 3.4

Clients

Wonderware's Operation Modules(Factelligence)

Supply Chain Connector

Checklist

• Demand passed from Operations 3.4 to Preactor APS

• Schedule is released from Preactor APS to Operations 3.4

• Context sensitive windows in Preactor shows data from WIS

• Resource calendar exceptions sent from Operations 3.4

• Shop floor data updates Preactor APS

• Static data synchronized from Entities

• Preactor Gantt charts available though WIS

Checklist

Integration Example

Flash Demo of Preactor

WW Demo 1024x768.swf

Aquacolor

► Aquacolor is also heavily involved in the development of applied nanotechnology for textiles finishing and works with leading fashion brands including Levi Strauss, Burberry, Hugo Boss and Trussardi

► The ability to respond to this and consistently deliver high levels of customer service depends on a solid yet flexible manufacturing approach

► Different orders may require different levels of dyeing, washing and finishing yet challenges exist for some orders may require repeat operations – typically washing - with some processes – typically dying – involving correction and adjustments during the actual process

▪ Every order may be different

Aquacolor

► Aquacolor are a Wonderware user and they wanted improved management over shop floor operations.

► They selected Wonderware Operations (originally Factivity) to provide the required functionality.

► Factivity does not have inbuilt scheduling functionality so Aquacolor selected Preactor to provide this capability.

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Wonderware Operations - benefits

► Benefits achieved from Wonderware Operations implementations▪ Improved control of operations▪ Improved recipe management▪ Improved traceability

Preactor - benefits

► Benefits achieved from Preactor implementations▪ VISIBILITY

• Decision support

▪ Improved customer service• Improved delivery date promising• Improved delivery performance

▪ Improved productivity• Better machine utilization

▪ Reduced inventories

Aquacolor Benefits

Operational improvement at recipe management, operations information and traceability levels, with a direct impact on costs.

50% reduction in the time spent to build a new work order

Saves 70% time required to give a delivery date Scheduling overhead reduced 35%

Benefits / Goals Achieved

► Were the initial goals achieved? ▪ Yes – an integration has been developed

► Is the customer happy with the project?▪ Wonderware and Preactor are happy with the

integration.▪ The interface has been certified.

► What benefits (business, technical & other) were gained▪ A certified solution is now available to Wonderware

Operations users to role out scheduling functionality with minimal effort.

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Lessons Learned

► This is possible to integrate Wonderware Operations 3.4 and the Preactor scheduling functionality.▪ Wonderware has certified the interface.

► Linking Wonderware Operations and Preactor delivers measurable benefits.

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Conclusions

► The certified interface shows that it is possible to easily transfer data between Wonderware Operations and Preactor.

► Wonderware Operations users can feel secure in knowing that world class scheduling functionality is available to them when required.

► Wonderware Operations users can benefit from implementing the scheduling functionality now available to them.

….any questions?