Theme. What is a factory and what are the data factors?. Planning. What to measure?. Requirements Important, effective, necessary, Random Tradeoff between 100% quality and infinite time KPI ISO standard: ISO 22400
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Process cycle time, process yield, resource time between failure, resource time to repair, process cycle times, process setup and paused times, resource/process energy consumption
Statistical inference of plant behavior
The primary goal of a MES is to provide an information system that can be used for optimizing production activities in a manufacturing facility with the focus on quick response to changing conditions.
A MES is a system that consists of a set of integratedsoftware and hardware components that provide functions for managing production activities from job order launch to finished products.
Key Business Drivers
Key business drivers are the areas of performance that are most critical to an organization's success
Available To Promise
Requires detailed knowledge of available capacity
Reduced Cycle Time
Major performance indicator with a direct impact on corporate profitability
Supply Chain Optimization
Optimizing the manufacturing link in the supply chain –agile & responsive
Requires detailed knowledge of actual use
Requires ability to quickly synchronize planning and production
Track Production Units and Resources
Provide the information on where any production unit is at all times and its disposition. Also provide the product genealogical information, such as who worked on it, current production information, component materials by supplier, lot number, serial number, any rework, measured data, or other exceptions related to the product.
ISA-95 - Operations Schedule
What actions to perform
– Materials to make
– Priority and/or dates
– What materials to use
– What equipment to use
– What personnel to use
– Production parameters (e.g. Color, Options,…)
• Per Segment (step in production)
• Per location (Site, Area, …)
• Per week day shift order
Measuring shop-floor data for LCA analysis using MTConnect is feasible
Efficient – quick turnaround for performing Kaizen Energy Consumption and Event archiving
Best for non-real-time data analysis
Cost-effective for smaller operations
Actual shop floor data helped understand LCA energy consumption during production
Machine tools are relatively efficient
Energy consumption results compare well to related energy consumption work performed at NIST
Lanz, M, Mani, M. Lyons K. Ranta, A., Ikkala, K and Bengtsson, N. 2010, “Impact of energy measurements in machining operations”. In 2010 ASME Design and Engineering Technical Conference (DETC), Proceedings of 2010 International Computers and Information in Engineering Conference, ASME.
Sensitivity and Trending analysis
Future plans are for examining quality relationship between process and energy consumption. For example, an unexpected rise in energy consumption could indicate an underlying process error.