Oracle Flow Manufacturing Sid Perera

Transcription

1 Oracle Flow Manufacturing Sid Perera Principal Consultant

2 Oracle Manufacturing Solution Integrated Intelligence Cost Analysis Planning Flow CTO ETO MTS Planned Orders Schedule Changes Component Substitutes Resources Substitutes Process Sample Product Lifecycle Mgmt Real-Time WIP Visibility Mixed Mode Discrete Productivity Model Shop Floor Lot-Based Analyze Adjust Warehousing / Transportatio n Contract Mfgrs Suppliers Asset Maintenance Quality Management Service Lot / Serial Genealogy Tracking Demand Schedules Sequencing Configured Order MES APIs, Direct Access Production Status Material Availability Mfg Capacity Schedules/Changes Ship Notices Invoices/Payments Partner Collaboration Customer Enterprise Shop Floor Contract Mfgrs Suppliers

3 What is Flow Manufacturing? More than a module - its a new way of life Dedicated assembly lines supporting product families Mixed model production - lot size of one Balanced line ensures smooth flow and optimum resource utilization Demand driven line and cell schedules Pull manufacturing Point-of-use kanban replenishment

4 Oracle Flow Manufacturing Solution Enables you to: 1. Plan for Customer Demand (Configured Products) 2. Design for Balanced Operations 3. Schedule and Sequence for Efficiency 4. Communicate and Complete Production 5. Plan for and Execute Kanban Management

6 Plan for Customer Demand Techniques used Complete Integration with Oracle Planning Products, Planning Workbench Product Family Definition and Planning Model Definition Option Class with Planning Percent Optional Items with Planning Percent Two-level Master Scheduling

7 Production Planning Forecasts at family level Explode family forecasts to members OR - plan based on unconsumed family forecast Consume family forecast with member demand Check ATP by product family or individual item Product Family Laptops Forecast & Consume Sales Orders Envoy Sentinel 20% Envoy Presidential 30% Envoy Multimedia 50%

9 Design for Balanced Operations Install Red Capacitor Int\Ext Qty Dynamic / Static Labor Task Machine Seq. Value Add? Setup Machine Labor (sec) Sequence of Events Document 0 Move to Chip Dept 600 Install Yellow Chip Move to Insp/Test Inspect - Test Move to FGI Warehouse Machine Time 1 Move Description To Chip Dept Ensure snap to board To Inspection Right of Red Cap To FGI Warehouse To Shipping = 1800 Sec or 30 Min. Labor Time = 1803 Sec or Min. Elapsed Time = 1803 Sec or Min. Work Content = Quality Info. 3 Sec!!! Compare Order to Product

10 Design for Balanced Operations Example Processes, Sequence of Events, & Operations PROCESSES > SEQUENCE OF EVENTS > LINE OPERATIONS > Welding Assembly mount surface s weld edges Op 10 Op 20 bolt moto r seal end s attach legs Op 30 Production line Painting clean surfac e Op 40 paint polish surfac surfac e e Op 50

11 Design for Balanced Operations Other Objectives Flat BOM Complex Bill - high maintenance Concurrent Process Engineering Visual Network Routings Design without considering the factory process

12 Design for Balanced Operations How Oracle Supports Them Graphical Line Designer Network Routings Sequence of work events Network of operations Alternate Paths Feeder Lines Drag and Drop

13 Example

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16 Design for Balanced Operations Graphical Line Designer Primary, Alternates, Rework, Subassembly Feeder, Etc.

17 Design for Balanced Operations Graphical Line Designer Sequence of Events

18 Design for Balanced Operations How do I balance the line? How Oracle Supports It Mixed Model Map Workbench Analyze Different Scenarios New Product Introduction Changes in Demand Process Improvement Bottleneck Resolution

19 Design for Balanced Operations How do I balance the line? Example Processes, Sequence of Events, & Operations PROCESSES > SEQUENCE OF EVENTS > LINE OPERATIONS > Welding Assembly mount surface s weld edges Op 10 Op 20 bolt moto r seal end s attach legs Op 30 Production line Painting clean surfac e Op 40 paint polish surfac surfac e e Op 50

20 Mixed Model Map

21 Mixed Model Map

22 Design for Balanced Operations How do I balance the line? Line Balancing Mixed Model Map Workbench

23 Design for Balanced Operations How do I balance the line? Mixed Model Map Workbench Bottleneck resolution

24 Mixed Model Calculations Line Takt Time = ((Mts/Day)x No of Dem Days))/Total Demand Machines Needed= MC Wtd Time/Opn Takt Time MC Assigned=Tot No of MC (In the dept) Labor Needed= Lbr Wtd Time/Opn Takt Time Labor Assigned=Tot Av (In the dept)

26 Line Scheduling

27 Line Scheduling Objectives Schedule production based on customer orders (or planned orders) Sequence production based on model mix to maximize line utilization Smooth demand fluctuations using demand fences Review material and resource availability for product family schedule

28 Scheduling Algorithms No Level Loading Scheduled by Scheduling Criteria Scheduled until capacity is reached Level Daily Rate Total demand is spread evenly across scheduling horizon Mixed Model Same as Lvl Daily Rate Follows a production rule pattern for mix

29 Sequencing Criteria Sales Orders Order Entry Date Order Priority Order Promise Date Order Request Date Order Scheduled Date Planned Orders Planned Order Due Date

30 Line Scheduling Line Scheduling Workbench Sequence based on user-defined priorities Schedule to line rates Balance production lines Schedule mixed-model production Execute directly from sales order demand

31 Line Scheduling Sales Order Demand Product A Product B Product B Product A Product B Product A Product A SO 1 SO 2 SO 3 SO 4 SO 5 1-JUN 2-JUN 3-JUN 4-JUN 5-JUN Priority 2 Priority 1 Priority 3 Priority 2 Priority 1

32 Line Scheduling Algorithm = No Level Load, Criteria = Order Priority, Date Line Capacity SO 2 SO 1 SO 4 SO 5 SO 1 SO 4 SO 3 1-JUN 2-JUN 3-JUN 4-JUN Schedule only 4 days of production SO 3 Unscheduled

33 Line Scheduling Algorithm = Level Daily Rate (Spread Demand Evenly) Line Capacity Product B Product B Product B Product B Product A Product A Product A Product A 1-JUN 2-JUN 3-JUN 4-JUN Unscheduled Same criteria options to sequence orders

34 Line Scheduling Algorithm = Mixed Model Scheduling (Production Rule Pattern) Line Capacity 1-JUN 2-JUN 3-JUN 4-JUN Unscheduled

35 Schedule and Sequence for Efficiency Techniques Used Sequence Based on User-Defined Priorities Execute Directly From Sales Order Demand Schedule Mixed-Model Production Balance Production Lines Feeder Line Synchronization Supplier Synchronization What Ifs and Simulations

36 User Defined Sequencing Rules Selected data attributes applied to constraints 36

37 Constraint Sequencing for Efficiency 37

38 Schedule Sales Order or Planned Order Demand Line Scheduling Work Bench 38

39 Schedule Sales Order Demand LSWB Demand dates and Production dates 39

40 Mixed Model Schedule Summary LSWB Balanced Mixed Model Production 40

41 Mixed Model Schedule Summary LSWB Balanced Mixed Model Production 41

42 Mixed Model Schedule Summary LSWB Detailed schedules with Sales Order reference (Different Item) 42

43 Mixed Model Schedule Summary Capacity Check 43

44 Mixed Model Schedule Summary Capacity Check 44

46 Plan for and Execute Kanban Management Techniques used Define Pull Sequences Calculate #of Cards / Kanban Size Kanban Requirements Simulation Generate Non-Replenishable Kanbans Automate Transactions - Generate Requisitions

47 Plan for and Execute Kanban Management Pull Sequences Op 10 loc 1 item A inter-org i1 Op 20 raw in loc process 2 item B Op 30 Production line raw in supplier s1 loc process 3 item A supplier s2 Op 40 loc 4 item C line l1 Op 50 loc 5 item D intra-org r1 item D supplier s3

48 Replenishment Chain

49 Replenishment Chain

50 Replenishment Chain View by: Supplier, Buyer, Location

51 Plan for and Execute Kanban Management Kanban Execution Signals Replenish Internal Kanbans Stores Move (Intra-Org) Production Replenish External Kanbans Supplier Kanbans Aggregate Kanban Signals Move Order (Inter-Org) Non-replenishable Kanbans

52 Supplier Kanban Execution Purchase to Build Component demand and Production Sequence communicated to suppliers. 52

54 Communicate and Complete Production Techniques Used Flow Workstation Communicate Schedule Convey Work Instructions (OMS) Work Orderless Completion Extremely Lightweight Entity No Pre-exploded Bills and Routings Substitutions and Changes Management of Engineering Changes Serial / Lot Control, FG and Components Scrap Reporting Quality Collection Integration

55 Flow Workstation Paperless Communication of Production Schedule - work instructions, OMS, components, resources

58 Flow Workstation Paperless Communication of Production Schedule - work instructions, OMS, components, resources Attachments

59 Work Order Less Completion

60 Work Order Less Completion No Pre-exploded Bills and Routings, Management of Engineering Changes, Substitutions and Changes, Serial / Lot Control, FG and Components, Scrap, Quality Integration, Mobile Support

61 Summary

62 Oracle Flow Manufacturing Complete Flow Infrastructure Flow and ERP Data Model Integration Demand Management Line Design and Balancing Line Scheduling Production Execution Kanban Planning and Execution

63 Know More. Do More. Spend Less.