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SIMATIC IT Preactor APS Advanced Planning and Scheduling

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Presentation on theme: "SIMATIC IT Preactor APS Advanced Planning and Scheduling"— Presentation transcript:

1 SIMATIC IT Preactor APS Advanced Planning and Scheduling
© Siemens AG 2016 siemens.com/mom

2 Siemens Manufacturing Operations Management
Siemens MOM represents a holistic solution to improve manufacturing operations performance. Plant model BoM, BoP/Recipes NPI (new products) Automation PLM Siemens Manufacturing Operations Management ERP Order/Supply chain data As-built data Manufacturing Operations Management (MOM) consolidate the management of several production processes, such as quality management, sequencing, non conformance management, asset management, and so on, within one platform. Manufacturing Execution Data collection MOM is the core element to link PLM, ERP & Automation and to provide a real-time Industry Software layer. Manufacturing Operations Management has extensive capability for supporting multiple key business processes and systems.

3 Manufacturing Operations Management
Siemens is expanding its portfolio towards a Manufacturing Operations Management (MOM). Replicate improvement across all plants and integrate intelligence from the shop floor to the top floor, maximizing efficiency and quality across production operations are the goals of manufacturing companies. PLM SCM - ERP MOM QMS R&D EMI APS MES Siemens MOM standardize and optimize manufacturing processes, minimizing lead-times, optimizing asset utilization, reduce global Time-to-Market improving response time and increasing production visibility. This is critical to gaining the full benefits of further investments in manufacturing operations management solutions covering the whole enterprise. Production Management ISA-95 HMI-SW / SCADA Automation NC PLC DCS HMI Sensors, Drives, Field Instrumentation, … Batch

4 DF PL DER - Manufacturing Operations Management
Industry key steps to success: Choose technology capabilities that are integrated through a common solution platform and support all aspects of manufacturing operations Automate data collection Standardize processes Guarantee higher quality Provide visibility to decision makers investing in Manufacturing intelligence Complete Connected Industrial Portfolio PLM SCM - ERP PLM Transactional SIMATIC IT Preactor AP/AS QSYS SIMATIC IT R&D Suite SIMATIC IT Intelligence Suite MES SIMATIC IT Production Suite ISA-95 SIMATIC Win-CC Only Siemens is able to offer a Complete & Connected Industrial Portfolio with strong Industrial Software Layer Automation - Simatic NC PLC DCS HMI Sensors, Drives, Field Instrumentation, … Batch Realtime

5 Global presence of the Siemens MOM Team – R&D and Delivery Hubs Siemens has probably the largest Manufacturing IT organization in the world Great Britain Quick facts: HQ in Genoa, Italy Core R&D sites in Germany, Italy, UK, India, Austria & US Global Delivery Hubs in Key Regions Organization of approx people Considerable Portfolio covering Vertical knowledge in key processes 500+ in R&D – significant investment Global and worldwide partners network Strong growth - Faster growth than market Germany Chippenham Höhr-Grenzhausen Belgium Karlsruhe Huizingen Nuremberg Lindau Eisenstadt France Austria Italy Genova Toulouse Detroit Portsmouth Beijing Chicago Boston Bangalore Plano Shanghai Mumbai São Paulo

6 DF PL DER Manufacturing Operations Management portfolio: Five strong software offerings
WinCC – HMI SW The Number 1 HMI-SW Complete and powerful HMI-SW functionality for all industry sectors Engineering Efficiency & TIA Portal Integration Highest Availability Openness & Scalability SIMATIC IT - MES WinCC OA - SCADA Open & High End SCADA Open Architecture for flexible usage Platform neutral Large scale distributed applications possible Highest safety IBS - QMS Quality Management Compliance Management Complete PDCA Cycle for Quality & Production SIMATIC IT Preactor A complete range of solutions for Detailed Production Scheduling Capacity Planning Graphical MPS Used in all Manufacturing Sectors The Leading MES Full featured MES with model based architecture Industry features built in for optimized portfolio in: Process Industries Discrete Industries Life Science Industries 5 strong building blocks as foundation for an integrated & complete Manufacturing Operation Management Software Portfolio

7 Introducing SIMATIC IT Preactor Advanced Planning and Scheduling software
Global competition forces companies to find ways to optimize production operations by reducing or eliminating non-value-added activities such as setup or waiting time. Highlighting potential problems allows action to be taken to balance demand and capacity. SIMATIC IT Preactor products have been developed to meet this need. SIMATIC IT Preactor is a range of advanced planning and scheduling (APS) software for the manufacturing industry.

8 Introducing Preactor Customer base
Large install base serving the manufacturing sector across the globe Customer base ranges from mid-size to some of the largest multi-national companies in the world. Operates across multiple sectors, this shows the flexibility to solve any scheduling requirement. Global, multi-sector footprint Install base by region Install base by industry

9 Planning and Scheduling
What’s the difference? Planning and Scheduling

10 Planning and Scheduling Typical Detail and Horizon
What to make When to make it How much to make Where to make it Materials Required Resources Required Low Detail Planning How best to make it Execute against plan Sequencing Synchronization Priorities, constraints and conflicts Monitoring execution Managing change Scheduling Scheduling High Detail Years Months Weeks Days Hours Minutes

11 Advanced Planning A Strategic Decision Tool
Considers forecast and long term orders to decide feasibility and set general direction of production; Dynamically sets target stock levels to meet future demand; Load balance across multiple resources considering eg constraints, materials shelf life; Supports major decisions of production capacity: Extend work force Extend resource capacity Extend factories Forecast Demand Starting Stock Orders Planning period Stock control parameters Capacity Planning ERP SIMATIC IT Preactor AP

12 Advanced Scheduling A Tactical Decision Support Tool
Forecast Demand Starting Stock Orders Planning period Stock control parameters Capacity A Tactical Decision Support Tool Considers detailed production demand to provide production sequence, work to list; Predicts effects of change in production, interruptions, machine breakdown, scrap; Reacts to real time production efficiency; Supports decisions: Overtime Order prioritization Split production batches Due Date Negotiation Order Promising (CTP/ATP) Scheduling Planning ERP SIMATIC IT Preactor AS SIMATIC IT Preactor AP Shift Patterns Detailed constraints Sequencing Rules

13 Advanced Planning SIMATIC IT Preactor AP

14 MPS Data and MPS Planning Approaches
SIMATIC IT Preactor AP MRP Target Stock Levels by SKU by Day/Week/Month Resource Capacities Process Rates Achievable Daily/Weekly/Monthly Production Load for each product Stock Sales Orders Forecast Make to Stock (Forwards) Make to Order (Backwards)

15 MPS Period Loading – Forwards (Make to Stock)
Not Capacity Constrained Capacity Capacity Constrained J F M A M J J A S O N D

16 MPS Period Loading – Backwards (Make to Order)
Not Capacity Constrained Capacity Capacity Constrained J F M A M J J A S O N D

17 Finite Capacity - Constrain Mode
Constraining multiple products 6 DOC 5.5 DOC 5.5 DOC 4 DOC 4 DOC 2 DOC 5.5 DOC 4 DOC Rank Batches based on Days of Cover (DOC) 4 DOC 4 DOC Recalculate Batch sizes to target DOC 4 DOC 4 DOC 6 DOC 4 DOC Repeat process for next Period 3.2 DOC 3.2 DOC Squeeze Batch with longest DOC by one re-order quantity 3.2 DOC 3.2 DOC 3.2 DOC 3.2 DOC 3.2 DOC 1.4 DOC 1.4 DOC 1.4 DOC 1.4 DOC 1.4 DOC Repeat Period 1 Period 2

18 Finite Capacity - Move Mode
Constraining multiple products Rank Batches based on Days of Cover 6 DOC 6 DOC 5.5 DOC 2.8 DOC Calculate overload 5.5 DOC 4 DOC 4 DOC Look for items that have additional planning resources to move overload to 3.2 DOC 3.2 DOC 3.2 DOC 3.2 DOC 3.2 DOC 5.5 DOC 3.2 DOC 1.4 DOC 1.4 DOC 1.4 DOC 1.4 DOC 1.4 DOC Repeat Planning Resource 1 Planning Resource 2 Planning Resource 3

19 SIMATIC IT Preactor AP - General Features
You can choose to plan in finite or infinite capacity mode and your planning time periods can be days, weeks, months or a combination of all three. Parameters can be set against each of your item codes, which allow you to perform different calculations for each item. For example some of your products may be in ‘make to stock’ mode whilst others are in ‘make to order’ mode. Infinite MPS Finite MPS

20 SIMATIC IT Preactor AP - Stock Plots
When a change in demand occurs whether that be in terms of quantity or delivery dates you need to be able to quickly assess if you are able to meet the new requirements. You can import your demand changes into Preactor AP and create a new ‘what if’ plan. Your planning BoM will be exploded and Preactor AP will show you if you have any capacity issues. If there are issues you can work interactively to create an acceptable MPS.

21 Advanced Scheduling SIMATIC IT Preactor AS

22 Accurate Models Produce Feasible Schedules
Resources Constraints Processes Calendars Finite scheduling is based on a detailed model of the plant This leads to two very important benefits over other planning tools Improved utilization of resources Truly feasible schedules It can increase throughput, reduce work in process and raw material inventory. It provides a ‘crystal ball’ for the planner to use at shop floor level.

23 Higher Due Date Performance with Detail Scheduling
OVERLOAD A5 90 10 20 30 40 50 60 70 80 90 A6 80 A4 A5 70 60 A4 Planning done. All will be ok  A3 100% used capacity Would be late if we did this!!! Really???? Let’s See... 50 A3 40 A2 Setup Time 30 A2 20 A1 A1 10 Process Time Capacity Planning Detailed Scheduling

24 Increased Efficiency with Detail Scheduling
Capacity Planning Detailed Scheduling Capacity Gain A6 90 10 20 30 40 50 60 70 80 90 A6 Initial Sequence on Resource 1 A1 A2 A3 A4 A5 A6 Optimised Sequence on Resource 1 A1 A4 A3 A6 A2 A5 80 A5 Preferred Sequence is Orange, Grey, Blue For minimum setup A5 70 A4 60 A4 100% used capacity 50 A3 A3 40 Setup Time 30 A2 A2 20 A1 A1 10 Process Time Resource Resource

25 Setup Time and Multiple Constraints
If we consider due date and sequence dependent setup times then it is much more complex. Multiple Constraints Equipment Availability Labor Availability Power Constraints Tooling Constraints No Setup Reduction Some Setup Reduction Full Setup Reduction 1 2 4 3 Day 1 Day 2 Day 3 Day 4

26 Material Control and The Material Explorer
Material requirements Visibility of Shortages Inventory plots

27 What if? Comparing Multiple Scenarios

28 Impact Analysis and Schedule Repair
When things change, the tools are there to provide clear visibility of the impact. Planners can manually interact with the Gantt chart, run automated schedule repairs or even rerun entire scheduling rules.

29 Tight integration with both ERP and MES solutions allows rapid response to changes.
Analyse Generate Update Release Execute Sequence New Order Demand Constraints Schedule Order Amendments Material Availability Schedule SIMATIC IT Preactor AS Order Progress Schedule Breakdowns MES/SCADA The most successful companies are those using lean scheduling software. By connecting such systems to their ERP, MES and shop-floor data collection, they are able to monitor the state of execution against plan.

30 The benefits & Unique Selling Points
Faster and smarter, with an ROI measured in weeks. What makes SIMATIC IT Preactor different? Faster Creates plans and schedules in seconds or minutes. Smarter Management can identify potential problems (cause & effect) and fix them before they actually happen. Systematic Results Improved Customer Service +90% Inventory Reduction % Cycle Time Reduction % Productivity Increases % Family of Products, competitively priced Technically superior, available in multiple languages Customizable for any type of planning and scheduling requirement Track record, install base and availability of case studies Local support – implementation, training, post go-live

31 Thank you for your attention!
Preactor International Limited – A Siemens Company Cornbrash Park, Bumpers Way, Chippenham, Wiltshire SN14 6RA United Kingdom Tel: +44 (0) Web: siemens.com/hm16


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