Zanussi & Cybertec Meeting

Zanussi & Cybertec Meeting

CYBERTEC - The Planning and Scheduling Company

Meeting Agenda

• About Cybertec• The CyberPlan Planning & Scheduling

Suite• Cybertec Projects at Electrolux Zanussi

Cold Division in Susegana


About Cybertec

• Company• Vision• Technology• Products• Services• Customers• Partners


Cybertec: The Planning & Scheduling Company

• Mission: Help industrial Customers to increase resource utilization and service level and reducing stocks, product cost and human efforts

• Established in 1992• Average Annual grow > 50%• 40 focused people; 90% graduated or PHD;• Most consultants APICS CPIM certified


Vision• Planning & Scheduling is

an Hard Problem• High improvement

available through resource optimization and process synchronization

• The Computing Power has increased by orders of magnitude while the complexity of the planning problem only few times

1

10

100

1000

10000

1970 1980 1990 2000 2010

Comp power

ProblemComplexity


Cybertec Core Technology• Hardware resources

– Ram based Data Bases– Cluster Of Computing Nodes

• Software tools– C++, Java, Windows NT, Corba

• Optimization techniques– Discrete Simulation, Constraints, LP,GA,….

+ Practical Experience!


Products

• A complete suite of products for repetitive and complex equipment industries:– Planning– Programming– Scheduling– Management Execution Systems


Services

• Consulting• Education• Implementation• Integration• Special Projects for Hard Optimization


Customers Logo


Customer Industries

• Automotive• Clothing• Electric• Electronic• Food & Beverage• Heavy Equipement• Paper• Pharmaceutical

• Plastics• Ship building• Steel• Textile• …


Partners

• Consulting Companies• ERP Vendors• MES Integrators• SW Houses• Universities

• Arthur Andersen• Atos Consulting• IBM• JDE• ORACLE• SAP• Orsi• ...


The CyberPlan Planning & Scheduling Suite

• SCD Supply Chain Designer• MPS Master Production Schedule• MRP Material Requirements Planning• CRP Capacity Requirements Planning• FCP Finite Capacity Planning• FCS Finite Capacity Scheduling


Planning: designing for performances!• To meet the market requested performance ( service

level, lead times, costs) You have to design for them• CyberPlan Supply Chain Designer is a new, long

waited, tool that allowes to design for performace– Resource planning (equipements, personnel, tools,..)– Safety stocks and all other MRP parameters– Purchasing contract conditions (due dates, qty, safety

stocks, min-max deviation,...)• Same data and model used by your ERP


Cybertec Projects at Electrolux Zanussi Cold Division-Susegana


Zanussi & Cybertec Projects• Completed

– Short Term FCS in the moulding dpts• Current

– FAS & MPS Phase 1• Automated Optimal Final Assembly Scheduling

• Planned– FAS & MPS Phase 2

• Automated Optimized Master Production Schedule• Integration with Demand Management System


• A brief introduction– It was a ‘97 project– The problem was to build an automated schedule for the

daily activities of the two production departments Innerliner Thermofoaming and Innerdoor Thermofoaing.

– We started with one department and after successful implementation we dealt with the other one.

– The daily scheduling activities involved very experienced employees.

Short Term Finite Capacity Scheduling in the Innerliner Thermofoaming and Indoor

Thermofoaming departments


The goals

• Main goal: let not-experienced employees schedule the department by giving them a computerized scheduling system.

• Other benefits required:– Updated scheduling plans.– More detailed scheduling of the production activities.– More constraints under the planner control.– More activities better organized (machine changeover,

purchasing material call-out).


The scheduling problem

• A hard set of constraints– A set of production requests

with hourly due - dates for the next three days (or more).

– Production & changeover activities.

– Finite number of:• machine operator crews• set - up crews• moulds

• Sequence dependent changeover costs:

• change mould• change version (slight

modification of the mould)

• same mould (change of material color)


Output:

• A production schedule for each machine such that:– satisfies the given constraints– minimizes the changeover costs – minimizes the due dates violation


Problem features• Why the problem was so difficult

– Several contraints (changeover crew, operator machine crew, moduls, …)

– Sequence set - up optimization– System was to be able to suspend a production lot and continue

with a more urgent lot– Very strict lots due dates

• Moreover….– Easy to use and fast response system (few seconds…)– Very low level interaction with the computerized system


The solutionBased on CyberPlan

Standard Scheduling Technology:– This was the best

technology availiable to solve the problem due to the number of production lots (hundreds) to be scheduled, the variety of the constraints, and the response time required.


Goals reached

• CyberPlan is now scheduling the production of both departments– For more than one year CyberPlan has been helping to

better organize the production in the Innerliner Thermofoaming and Innerdoor Thermofoaming departments

• The scheduling of the activities in both departments are managed now by “no - guru guys”


Next steps

• What could be done– New Cybertec Advanced Scheduling Technology could

be applied to reach an even better performance in the production department

• What will be done– Cybertec Advanced Scheduling Technology to

optimize the Master Production Schedule & Final Assembly Scheduling


Automated Final Assembly Scheduling (FAS)


FAS: a brief introduction

– Building a FAS follows the choice and qty of finished products to be produced in a given week.

– The FAS consists in building a feasible and optimized schedule for finished products on the assembly lines.

– It is the heart of the factory as it drives the production and purchaising (call out) flows of the factory.

– FAS gives the “drum beat” to all of the activities in the factory.– As Zanussi-Susegana is a real Synchronous Manufacturing

Environment, the FAS defines the feasible and optimal production flow of all production departments


The goal of FAS project:

• There are a lot of critical aspects the planner has to deal with to get a feasible and optimized FAS

• The goal is to give the FAS planner a computerized system that can help him in building and maintaining a feasible and optimized schedule.

• Moreover, with the support of this system the user will be able to control more constraints and optimization aspects of the production process.


Two different technological areas with different scheduling problems

• There is a substantial difference between the two main areas of the assembly process– Traditional Assembly Lines

• Scheduling Problem:– Find a feasible and optimal schedule of production lots

– Automatic Assembly Lines• Load Balancing & Scheduling problem

– Find a production daily rate and optimal schedule of production lots


The FAS Scheduling Problem

• Due dates of the production lots• Sequencing rules that are used to optimize the chenge

over costs in the production flow– At present, more seven sequence optimization rules must be taken

simultaneously in count when building a schedule!• Critical constraints that must be satisfied

– Foaming Moulds– Welding Machine

• Critical resources that must be highlighted– “Round Door” production


The Loading Problem

• Definine the optimal daily production rate for each automatic assembly line under– Capacity constraints

• no more than x items can be produced in a given “ring”

– Optimization criteria• a given efficiency must be guarantee


The FAS System Schedule

Assembly Line Scheduling


The FAS critical resources load

Overload!


The New Automated MPS System


Automated Optimized Master Production Scheduling System

• The problem is to define which finished products have to be produced in each week of the planning period

• Problem data:– a customer priority class– a minimum level of customer service for each class of priority– a minimum level of resourcce utilization– a set of customer’s requests for each week– the assembly lines capacity and the capacity of other critical resources– the bill of critical resources of each product– a set of production constraints (min production lot for model plant or

pnc, max …)


Quality optimization measures

• A feasible master production plan– defines what to produce (which finished products) and

how much (how much for each PNC) under respect of the capacity constraints

• Customer Service level– for each priority class the customer service level is

defined:• (number of satisfied customers’ demands)/(number of

customers’demands)


The goal

• Find an automated feasible master production plan which:1. guarantees a minimum level of customer service2. the remaining capacity is allocated to satisfy the

customers’ demands according to the priority class defined


Output

• The amount of each PNC (finished product) that must be produced on week_i

• The list of customers’ demands which will be satisfied

• The list of customers’ demands which will not be satisfied– The level of customer service– The level of resources utilization– Alarms


Input

Customer Requests

Customer PriorityClass


Fast & Easy Execution

Executing Command


Unsatisfied constraints

Unsatisfied Customer Requests


Results

Control Panel

showing the customer

satisfaction level

Master Production Schedule

Workbench

Date post:	22-Feb-2016
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Zanussi & Cybertec Meeting

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