SAIL / MAST Software

1. SAIL / MAST Software

2. SAIL A Daily Scheduling and Performance Measurement System for Flexible Machining Systems

3. SAIL Overview • SAIL provides benefits through the following features. • Scheduling – Order Tracking, Generation, and Download • Allocation – Balance Machine, Pallet and Priorities • Monitoring – Production Counts,Machine Cycle, OEE • Material Tracking –Serial Number, Part Marking, Paths • Quality and Part Audit –Inspection Signals by Path • Tool Planning –Schedule Tool Use, Tool Replacements • Capacity Planning –Configure Paths for future mix

4. SAIL Data Flow Diagram ERP Management System Factory Communications Web SAIL Coordinates Data Flow For Automatic Operation Robot Control Cell Control Computer CNC Controls Load Station Control

5. Benefit #1Daily Scheduling from ERP Orders • ERP/MRP Orders are imported daily • Schedule generated by allocating demand quantities into daily job quantities. • Flexibility is adjusted to “best fit” demand • Job data is downloaded automatically to control computers • “Hot Jobs” can be generated and downloaded • Report Actual Hours\Production to ERP Order

6. Benefit #2Allocate Demand to Flexible Capacity • Allocation method uses simulation to “optimize” the combination of machine assignments, active pallets, and job priority • Flexibility is adjusted daily • Sets a Target OEE for all machines • Balance work across Machines • Balance work across Pallets/Fixtures

7. Benefit #3Increased OEE through Monitoring/Reporting • Increase of 30+% OEE when compared to manual scheduled cells • Elimination of overtime due to poor scheduling • Compares Planned to Actual production counts • Control Chart for machine cycle times • Log of all event activity

8. Benefit #4Monitoring and Reporting • SAIL monitors all FMS operation • Updated every 1 minute • Report Production Counts • Report Standard and Actual Machine Hrs • Retains Multiple Year History • Control Chart for Machine and Load Cycles

9. Benefit #5Material Tracking and Serial Numbering • Each part is tracked for its specific path (combination of pallets and machines) • Serial Numbering is automatically assigned • Part markers print serial number and 2D codes • Root Cause investigation for part quality • Sort and Containment using Bar Code Reader • Release jobs based on material availability

10. Benefit #6Quality Plan for Flexible Operation • Inspection Signals defined by Quality Plan • Signals triggered by count, time or first piece • Filter path by machine, pallet, part • Close Loop inspection process • Audit actual inspection frequency

11. Benefit #7Tool Scheduling and Replacement • Establish Tool Use using current schedule • Define number of Redundant Tools • Forecast tool replacements by shift • Audit Actual vs. Planned Tool Replacements

12. Benefit #8Planning for Flexible Capacity • Use forecast demand to set hours of operation • Balance flexibility to production mix • Add / remove paths to simplify quality plan • Establish Base Model criteria for daily scheduling

13. SAIL provides the management of Flexible Capacity from scheduling to shop floor operation through synchronized execution of software and hardware systems.

14. CMS Software 1610 S. Main Street Oshkosh, WI 54902 Tel: 920.235.3356 Fax: 920.235.3816 cms@cmssail.com