Optimal Intelligent Scheduling
When Machines Decide Improving Manufacturing Productivity with Data Analytics Vasu Netrakanti Optessa Inc.
Third Industrial Revolution: Digitisation of Manufacturing (The Economist) Perspective of optimization solutions provider Predictive analytics Decision support Integrated with plant infrastructure Real-time decisions: routing (what next), selection (which order) … In an automated manufacturing environment, computers can help machines decide.
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Case: Tier 1 On-demand Scheduling OEM
VEHICLE ASSEMBLY PLANT 1
VEHICLE ASSEMBLY PLANT 2
METEOR
COMET
400K 2 DOOR
500K 4 DOOR
2 DOOR
300K 4 DOOR
2 DOOR
SUNROOF
NON SUNROOF
SUNROOF
NON SUNROOF
SUNROOF
NON SUNROOF
SUNROOF
NON SUNROOF
SUNROOF
NON SUNROOF
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
RED WHITE BLACK BLUE SILVER
PRESS LINE MA1
PRESS LINE MA2
Optessa SUPPLIER ROOF LINER DIVISION
High complexity – 50 variants High volume for a small manufacturer – 25K parts/month “Broadcast” response (3)
1St Set of Inputs: Demand Feature
Data
Examples / Note
Vehicle models
COMET (300K): 2 DOOR METEOR (400K, 500K): 2 DOOR, 4 DOOR
Trim
COMET: GR5 – GR6, XR5 – XR7, ZR6 METEOR: GT0 – GT9, XT1 – XT9
Color
RED,WHITE,BLACK,BLUE, SILVER
Other features/Attributes
Part #, Priority Date, Priority Time, Part Required Quantity etc.
Demand
22,798 units MONTHLY
Due Dates
(Priority Date Time – 14 hours)
Logistics lead time
BoM
BoM
Vehicle configuration to part
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2nd Set of Inputs: Production Capacity and Rules Feature
Data
Examples / Note
Lines
2
Window
1 Month
Flexibility required
Shift Pattern
Line 1: Day shift, Line 2: Day and Afternoon
Defines line capacity
Cycle time
COMET ~ 83 seconds (based on 43/hour) and METEOR ~ 72 seconds (based on 50 per hour)
Cycle times can differ based on model, features and lines
Tool Setup / Changeover
Tool change: 0.75 hours Color change: 10 minutes
Demand – Capacity mismatch
Smoothing of overtime / idleness required
Line capacity
Hard constraint
On Time Delivery
High priority
Minimize Changeovers
Medium Priority
Door – Roof – Color changeovers
Line Restriction
High Priority
COMET model parts imited to line 1
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Results: Current and Optimized Scenarios
Current Follow OEM sequence
• • • •
Total Orders: 22,798 On Time: 5,653 Late: 13,324 Unscheduled: 3,821
Optimized Smoothed OT: 2 hours/day Minimize changeovers
• • • •
Total Orders: 22,798 On Time: 22,798 Late: 0 Unscheduled: 0
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Case: SC Fab Real-time Yield Management
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Case: Auto OEM ASRS Real-time Decisions The flow of painted bodies from the Paint Shop to the ASRS, and then to TCF can be represented through a flow diagram indicating the key vertices and arcs. R30/31: R30/31 is the set of readers on the two lane buffer at the exit of paint (post polish stage). After painted bodies cross the R30/R31 readers, there is no divergence until they reach the next node BT1100. All orders between R30/31 and BT1100 are the look-ahead available for RTS. BT1100: BT1100 is the skid exchange station where the painted body is transferred from Paint skid to Logistics skid. At this point, the decision of storing/bypassing/wax/set out of a painted body is conveyed to the further PLCs. PTT01: PTT01 is the turntable at the entrance of the ASRS. The orders diverge into Lane 1 or Lane 2 of the ASRS after PTT01. PTT02: PTT02 is the turntable at the exit of the ASRS. Orders retrieved from the ASRS converge at this turntable before being passed to the TCF. TT02: This is the turntable which routes LTVs to the LTV TCF buffer. The U202 and W201 bodies continue past TT02. TT03: This is the turntable which routes U202s to the U202 TCF buffer. The W201 bodies continue past TT03. TT04: Turntable routing W201 to W201 TCF buffer
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At 60 jph, 3 decisions required every minute Routing: which ASRS cell to store painted body Selection: sequence outgoing job Assignment: which sales order for painted body (8)
Challenges ďƒ˜Reliable, accessible, timely data ďƒ˜Complement or supplement existing business processes?
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