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SAIL. A Daily Scheduling and Performance Measurement System for Flexible Machining Systems. SAIL Overview. A Plan for Machine Productivity Challenges Build to Order High Product Mix Daily Quantities Shared Tools and Fixtures. Unique Features. Simulation based forward schedule

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Presentation Transcript
slide1

SAIL

A Daily Scheduling and Performance Measurement System for Flexible Machining Systems

sail overview
SAIL Overview
  • A Plan for Machine Productivity
  • Challenges
    • Build to Order
    • High Product Mix
    • Daily Quantities
    • Shared Tools and Fixtures
unique features
Unique Features
  • Simulation based forward schedule
  • Download Schedule to Cell Control
  • Monitor/Broadcast Cell Performance
  • Cost per Part Tracking
unique feature 1 simulation based forward schedule
Unique Feature #1Simulation Based Forward Schedule
  • Plans Shift-by-Shift Quantities
  • Plans Days or Weeks in Advance
  • Targets schedule at a planned level of machine utilization
  • Sequences Part Numbers Through…
    • Shared fixtures/pallets
    • Tools Groups
    • Schedules Setups
unique feature 2 download schedule to cell control
Unique Feature #2Download Schedule to Cell Control
  • Instructions from Daily Schedule
  • Rolls out as operation progresses
  • Routing Instructions
    • Pallet Active
    • Pallet Cycles
    • Part Program to Run
    • Machine List
    • Load Station List
unique feature 3 monitor broadcast cell performance
Unique Feature #3Monitor/Broadcast Cell Performance
  • Records Production by Part Number
  • Fills in Daily Schedule Grid
  • Calculates Actual Machine Use
  • Provides Daily,Weekly,Monthly Totals
  • Web Page Formats
  • Access via Factory Network or Internet
unique feature 4 cost per part tracking
Unique Feature #4Cost Per Part Tracking
  • Based on the MAST Cost Model
    • Machine Depreciation Per Year
    • Hourly wage plus benefits
    • Overhead cost applied annually
  • Uses actual production to apply cost
  • Details efficiency and burden costs
sail data flow diagram
SAIL Data Flow Diagram

Job Management System

Factory

Communications

Daily / Weekly Scheduling

Performance Monitoring

Cell Controller

CNC Controls

Load Station Control

slide9
Cell Management from scheduling to shop floor through synchronized execution of software and hardware systems.
sail data flow diagram10
SAILData Flow Diagram

Job Management System

Factory

Communications

Daily / Weekly Scheduling

Performance Monitoring

Cell Controller

CNC Controls

Load Station Control

daily weekly scheduling
Daily / Weekly Scheduling
  • Planned Hours of Operation
    • Number of Hours per Day
    • Number of Days per Week
    • Shift Start and End Times
optimal daily operational plan
“Optimal” Daily Operational Plan
  • List of Parts with Production Quantity
  • Shift-by-Shift Quantity to Produce
  • Pallet – Fixture Required
  • Considers Tool Conflicts
  • Considers Pallet / Fixture Conflicts
  • Balances Work over all Machines
  • Fills Schedule to Planned Machine Use
sail data flow diagram15
SAILData Flow Diagram

Job Management System

Factory

Communications

Daily / Weekly Scheduling

Performance Monitoring

Cell Controller

CNC Controls

Load Station Control

download routing instructions
Download Routing Instructions
  • Pallet Routing Instructions
    • Pallet Number
    • Part Number
    • Number of Cycles
    • Part Program Number
    • List of Machines to Use
    • List of Load Stations to Use
sail data flow diagram18
SAILData Flow Diagram

Job Management System

Factory

Communications

Daily / Weekly Scheduling

Performance Monitoring

Cell Controller

CNC Controls

Load Station Control

performance monitoring
Performance Monitoring
  • Production Counts
    • Records actual production completed against planned quantities
    • Maintains history of Actual Production
performance monitoring21
Performance Monitoring
  • Weekly – Monthly Totals
    • Daily Totals Summarized Weekly or Monthly
    • Machine Use Averaged
performance monitoring23
Performance Monitoring
  • Machine Use by Shift
    • Records Elapsed Time
    • Uses Current Production
    • Determines Actual Use
performance monitoring25
Performance Monitoring
  • Pallet Flow Time
    • The pallet flow time monitor displays the elapsed time from when a pallet leaves the load station until it leaves the load station its next time. This elapsed time includes the transport time, machine cycle time, waiting in machine queue or buffer stand, and the load – unload time. All time that it takes to cycle the pallet is captured and reported.
performance monitoring27
Performance Monitoring
  • Machine Cycle Time
    • The Machine Cycle Time is a display of the observed cycle times at the machines. These cycles are the elapsed time from a cycle start to cycle end.
sail data flow diagram29
SAILData Flow Diagram

Job Management System

Factory

Communications

Daily / Weekly Scheduling

Performance Monitoring

Cell Controller

CNC Controls

Load Station Control

web page broadcast of performance
Web Page Broadcast of Performance
  • Monitor Current Schedule of Work
  • Monitor Expected Completion Times of Jobs
  • Monitor Machine Productivity
  • Monitor Cost per Part
case study team industry
Case StudyTEAM Industry

Problem

  • Their machine utilization and throughput were not running at full potential.

Results of SAIL

  • Increase machine utilization and throughput from 60% to 80%
  • Add 1000 hours of machine hours per man per year.
case study large midwestern corporation
Case StudyLarge Midwestern Corporation

Problem

  • They wanted to determine the impact of unallocated burden on manufacturing cost.

Results of SAIL

  • SAIL’s cost model allowed for a planned cost that is adjusted using efficiency to determine an actual manufacturing cost
case study thermoking corporation
Case StudyThermoking Corporation

Problem

  • Machine utilization and Throughput was not at maximum level.

Results of SAIL

  • Operators who were used to 50-70 parts per shift were now producing 400 parts per shift.
  • Machine utilization was now at 85%.
case study southern manufacturer
Case StudySouthern Manufacturer

Problem

  • Had a two machine system, with room for expansion, but hesitated because of low machine utilization.

Results of SAIL

  • Machine utilization reached 85%
  • They now could easily justify the third machine expansion.
a management system that
A Management System that
  • Starts with the Factory Order System
  • To Generate an Optimal Shift-by-Shift Schedule
  • That downloads Instructions to the Cell Control
  • For Execution and Operation
  • While Monitoring and Broadcasting Performance
target users applications
Target Users/Applications
  • SAIL is a tool designed for manufacturers with flexible machining systems, automated machine cells, and automated handling systems.
  • Three days of training are recommended for use of this software. Additional training is required to integrate SAIL to other computer systems such as factory systems and cell control computers.
slide39

CMS Research, Inc.

1610 S. Main Street

Oshkosh, WI 54902

Tel: 920.235.3356

Fax: 920.235.3816

cms@cmsres.com