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Information Engineering. Enhancing Information Quality for Effective Decision-Making in Textiles. for. The 2000 Massachusetts Institute of Technology Conference on Information Quality. October 21, 2000 Cambridge, Massachusetts. Presented By Mr. Neil Cahill Vice President

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slide1

Information Engineering

Enhancing Information Quality

for

Effective Decision-Making in Textiles

for

The 2000 Massachusetts Institute of Technology

Conference on Information Quality

October 21, 2000

Cambridge, Massachusetts

Presented By

Mr. Neil Cahill

Vice President

Institute of Textile Technology

Charlottesville, Virginia

with

Dr. George Hodge

North Carolina State University

Dr. William Oxenham

North Carolina State University

Mr. Yatin Karpe

North Carolina State University

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide2

. . . plant having Performance Capability a traditional plant does not have, and, therefore, cannot match performance,

no matter how modern or well managed.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide3

ONE NEW CAPABILITY NEEDED

. . . High proportion of current manufacturing performance losses are due to slow response

to production problems.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide4

PERFORMANCE DEGRADATION CURVE

Point of Degradation

X

Normal

Point of Malfunction

Process

X

Performance

Point of Failure

X

Poor

Response Delay Time

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide5

SLOW RESPONSE CONTROL

Good

X

Performance

Loss

X

Performance

Measures

Reaction

Point

X

Poor

Short

Long

Response Delay Time

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide6

FAST RESPONSE CONTROL

Good

X

Loss

Reaction

Point

X

Performance

Measures

X

Poor

Short

Long

Response Delay Time

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide7

TIME VALUE

OF

INFORMATION

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide8

. . . Value of Information decays

rapidly with elapse time after need

to know.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide9

TIME VALUE OF INFORMATION

Use

Value

of

Information

Need to

Know

TIME

Info

Available

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide10

. . . Finding and Diagnosing information

takes 80% of total time needed to complete

a decision!

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide11

DECISION RESPONSE TIME

Decision

Action

Slow

Reaction

Find

&

Diagnose

10%

10%

80%

100%

Fast

Reaction

Fd

Diag

Dec

Act

5%

10%

10%

10%

35%

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide12

Measuring Decision Effectiveness

(Manufacturing Problem Solving)

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide13

BASIC DETERMINANTS

OF

MANUFACTURING DECISION EFFECTIVENESS

1. Number of process malfunctions.

2. Delay in responding to problems.

3. Effectiveness of corrective action taken.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide14

DECISION EFFECTIVENESS EQUATION

(

(

)

)

(

)

(

)

(

)

+

Malfunction

Frequency

Defects/

Hr

Response

Delay

Defects/

Hr

Elapse

Time

=

Decision

Effectiveness

1.0-R.E.

Failure Rate

Reaction Delay

Action Effectiveness

R.E. = % Response Effectiveness

slide15

TWO CONCEPTS

OF AN

INFORMATION SYSTEM

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide16

INFORMATION DELIVERY SYSTEMS

1. Information Distribution System.

2. Decision Message System.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide17

O

O

O

O

Information

Generator

Users

Information Flow Pipe

General

Report

Traditional Information System

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide18

WHAT DO USERS REALLY WANT?

Information in Reports?

OR

Meaning in Information?

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide19

. . . it is Meaning which allows people

to understand situations and make

appropriate decisions

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide20

MESSAGES

. . . Intended meaning to be conveyed by

the information to the user.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide21

. . . I told him 10 times (Information),

but he still doesn’t understand what’s

happening (Message)!

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide22

O

O

O

Information

Generator

Users

Customized

Report

Expected

Decision

Message

Interface

Information Flow Pipe

Decision Message System

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide23

O

O

Tap

Tap

Technician

Manager

Customer

Message Interface

Information

Flow

Customized Message Interface For User

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide24

INFORMATION ENGINEERING

. . . method to extract the Meaning Content

from information before sending to user.

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slide25

. . . information needs are Decision-Driven

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slide26

DATA TO DECISION CYCLE

. . . sense an event

Detection

. . . identify and quantify event

Data

. . . relationship of different events

Information

. . . meaning of relationships

Diagnosis

. . . understanding relationship

Message

. . . choice of response

Decision

. . . implement change

Action

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide27

DATA TO DECISION CYCLE

Detection

Data

Information

Reporting

Information

Diagnosis

Message

Decision

Action

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide28

DATA/INFORMATION REPORT

Weaving Computer Monitoring Report

MCH

% EFF

STY

WVR

S/RLH

WS

FS

OS

0049

0052

0051

0053

0054

0055

0037

0038

0039

0040

0561

0562

0563

0564

0565

0001

0002

0003

0004

0005

0572

0573

Avg.

091.0

080.4

083.1

074.1

091.6

091.6

105.2

094.1

094.5

086.0

094.6

096.6

098.0

094.0

094.1

072.1

086.8

089.5

079.5

094.1

094.8

095.0

090.0.

056

056

056

056

056

056

056

056

053

056

056

053

056

056

053

056

056

053

056

053

056

053

032

033

033

033

033

032

032

032

033

033

033

032

032

033

032

033

033

032

033

032

032

032

1.09

1.24

0.90

2.02

0.27

1.22

0.00

0.13

0.13

0.72

0.26

0.65

0.38

0.13

0.53

2.08

0.72

1.68

0.94

0.53

1.18

0.92

0.80

5

6

5

11

2

8

0

1

1

3

2

3

3

1

3

4

1

3

2

1

2

5

2

2

0

1

0

1

0

0

0

2

0

2

0

0

1

8

3

7

4

3

1

2

1

0

1

0

0

0

0

0

0

0

0

0

0

0

0

0

1

2

0

0

6

0

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide29

DATA TO DECISION CYCLE

Detection

Data

Information

Diagnosis

Meaningful

Messages

Message

Decision

Action

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slide30

MEANING/MESSAGE REPORT

o

100

o

o

o

o

o

Weaver 032

o

95

o

o

o

o

90

Machine

Efficiency

(%)

85

80

Weaver 033

75

0

2

4

6

8

10

12

14

Stops Rate

Efficiency Delay Curve

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide31

O

O

O

Information

Generator

Users

Customized

Report

Expected

Decision

Message

Interface

Information Flow Pipe

Decision Message System

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide32

Walk-through Visit

of

21st Century Textile Plant

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide33

CIM

Computer-Integrated Manufacturing

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide34

Figure 1. Automated and computerized plant with full-factory communications network (Murata CIM Mill).

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide35

. . . Future textile plants will be

highly automated!

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide36

Automated Piece Up

and

Cone Doffing

Academic\No5Class899.ppt

38

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide37

45

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slide38

PLANT COMMUNICATIONS NETWORK

. . . Local Area Network (LAN) providing

real-time bi-directional communication

between individual machines and plant

computer.

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slide39

COMMUNICATIONS CENTER

Assess Plant Performance Status

and

Broadcast Action Messages

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slide41

Broadcast Messages To Selected Personnel

O

Computer Control Center

O

Broadcast

Message

O

Factory Network

Machine-to-Man messaging

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide42

SIGNAL DISPATCHED OPERATORS

. . . Computerized monitoring system

detects Machine Service Needs and

automatically Calls appropriate personnel.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide43

O

O

Technician

Operator

O

O

Handler

Cleaner

Spinning Machine Change-Over Swat Team

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide44

So now must . . .

Put intelligence into the machine system!

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide46

AUTOMATED DECISION OF FABRIC GRADE

IF:

OR:

THEN:

IF NOT:

More than (3) Stops/50 yards

Technician Repair Required

Send AGV to Human Inspector

Send AGV to Loading Dock

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide47

ENGINEERING INFORMATION

FOR

MANUFACTURING DECISION MAKERS

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide48

INSTANTANEOUS FACT-FINDING

. . . provide a decision-maker with needed facts

in the logical order to readily understand

performance problem as soon as detected.

DECISION MAKER DRAWS THE CONCLUSIONS

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide49

TYPES OF DECISIONS

MADE IN MANUFACTURING

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide50

CLASSIFY DECISION TYPES

1. PROGRAMMABLE DECISION

. . . repetitive situations with predictable response.

2. DISCRETIONARY DECISION

. . . Situation requiring a judgment call.

3. KNOWLEDGE INTENSIVE DECISION

. . . Unique situations requiring special knowledge

for response.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide51

TYPE DECISIONS

MADE IN MANUFACTURING

100

80

60

%

Manufacturing

Decisions

40

20

0

Programmable

Discretionary

Knowledge

Intensive

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide52

. . . concentrates on Programmable Decisions

avoiding Discretionary or Knowledge-Intensive

Decisions, which are highly complex and

uncertain.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide53

DESIGNING THE MESSAGE INTERFACE

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide54

MESSAGE INTERFACE

. . . Part of communications system that

converts information into Meaningful Message

so user can make quicker and more effective

decisions.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide55

O

O

Tap

Tap

Technician

Manager

Customer

Message Interface

Information

Flow

Customized Message Interface For User

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide56

DATA TO DECISION CYCLE

Detection

Data

Information

Diagnosis

Message

Interface

to User

Message

Decision

Action

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide57

DESIGNING THE MESSAGE INTERFACE

1. Identify Machinery Layout.

2. Identify Information Sources

3. Identify Information User

4. Determine Expected Decision.

5. Determine Need-to-Know Information.

6. Develop Diagnostic Logic.

7. Design Actionable Message Format.

8. Assess Action Effectiveness.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide58

STEP 1. MACHINERY LAYOUT

. . . specific type and arrangement of

production machinery to be controlled.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide59

TYPE

MONITOR

PROCESS

NAME

MACHINE

LAYOUT

Barco Sycotex

Stretch Breaker

Rebreaker

Barco Sycotex

Blender

Servo

Sliverdance

Roving

Barco Sycotex

FA.NI Monitor

Ring Spinning

Savio Elios

Linked Winding

Loepfe Clearers

PACKING

Barco Sycotex

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide60

STEP 2. IDENTIFY INFORMATION SOURCES

. . . Determine what computer accessible

sources of information are available.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide61

INFORMATION SOURCE DIAGRAM

. . . Identifies types of information and

monitoring source at each manufacturing

process.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide62

INFORMATION SOURCE DIAGRAM

Process

Information Type

Stretch Breaker

Production

Output Pounds

Pounds/Hour

Efficiency

Stops

Declaration (Long Stops)

Maintenance

Service

Stop Cause

Rebreaker

Production

Output Pounds

Pounds/Hour

Efficiency

Stops

Declaration (Long Stops)

Maintenance

Service

Stop Cause

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide63

STEP 3. IDENTIFY INFORMATION USER

. . . Specific individuals, technicians, operators,

managers, etc., who make decisions in response

to problem situations.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide64

. . . Target User is maintenance technician.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide65

STEP 4. DETERMINE EXPECTED DECISIONS

. . . decisions routinely made by Individual

responsible for responding to a particular

problem.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide66

MAINTENANCE TECHNICIAN EXPECTED DECISION

PROBLEM SITUATION

EXPECTED DECISION

1. High Flag Machines

Quickly identify High Flag Machines

and take corrective action with high

First Time Success rate.

2. High Off-Quality Machines

Identify quality defects while

On-Machine and correct

immediately.

3. Meet Maintenance Schedule

Meet all maintenance schedules

and assure adequate parts

inventory.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide67

STEP 5. DETERMINE NEED-TO-KNOW INFORMATION

. . . Specific information in logical order needed

by decision-maker to understand situation and

make right choice.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide68

MAINTENANCE TECHNICIAN

Need-To-Know

High Flag Machines

1. Which Machine?

2. What Style?

3. How Long?

4. Type of Flags?

5. Flag History.

6. Maintenance Record.

7. Parts Replacement Records

8. Assigned Technicians.

9. Assigned Weaver.

10. Any Special Events

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide69

STEP 6. DEVELOP DIAGNOSTIC LOGIC

. . . Arrange need-to-know information

into the logical order of inquiry that a

decision-maker would follow to understand

what happened and how to respond.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide70

TWO TYPES OF INQUIRY MADE BY COMPUTER

QUESTIONS (Q’s)

. . . information in database; go get it!

MESSAGES (M’s)

. . . information not available in database;

ask people to find it!

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide71

COMPUTING DIAGNOSTIC LOGIC

High Flag Machine

Diagnostic

Stage

Order of

Inquiry

Question/Message

Statement

I. Problem Focus

. . . What problem to

diagnose?

Q1

Who is the User?

Q2

What Malfunction triggered alarm?

Q3

Which Machine triggered alarm?

Q4

What Product being run?

II. Localize Problem

. . . Where is problem

located?

Q5

How long has problem been happening?

Q6

All or some Machines?

Q7

All or some positions on machine?

Q8

Any other alarms on this machine?

M1

Message to Maintenance:

Check settings on alarm machines

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide72

STEP 7. DESIGN ACTIONABLE MEASURE FORMAT

. . . Did report to user (1) provide needed

information, (2) explain what happened, and

(3) allow an effective decision?

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide73

ALERT/ADVISORY MESSAGE

TO:

Bob Roberts, Maintenance Technician

ALERT:

Machine 18 classified as Malfunctioning

with Chronic High Flags.

ADVISORY:

Over past 5 days (1/1-1/5), 65% of checks out-of-limit,

including stops, efficiency, flags, and quality points.

ACTION:

Flags which average 2/day relative to

expected 0.25/day are the major source of losses.

slide74

EFFECTIVENESS LOOP

. . . System continuously assesses State of Control

in manufacturing and Effectiveness of control

action taken.

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide75

DATA TO DECISION CYCLE

DATA

INFORMATION

EFFECTIVENESS

MEANING

. . . did it work

MESSAGES

DECISION

ACTION

i:\share\sandys\conferences\informationengineering-mit2.ppt

slide76

. . . Value of Information is its

Meaning Content!

i:\share\sandys\conferences\informationengineering-mit2.ppt