Manufacturing Systems Research Chris Hicks C Hicks University

Manufacturing Systems Research Chris Hicks © C. Hicks, University of Newcastle

Computer Aided Production Management Systems in Engineer to Order Companies • ACME grant in collaboration with NEI Objectives • Identify the characteristics of companies in ETO/MTO sector • Evaluate the status of CAPM • Identify common CAPM problems • Develop methods for modelling CAPM systems in ETO/MTO environments • Apply modelling methods to identify solutions to CAPM problems © C. Hicks, University of Newcastle

Identification of Company Characteristics and CAPM problems • Nine one day visits • Three long visits (3 days - 1 month) • Developed semi-structured “audit” methodology • Developed methods for company classification © C. Hicks, University of Newcastle

Audit • • • Markets Products Processes Manufacturing Systems CAPM Systems © C. Hicks, University of Newcastle

Manufacturing Process Company Classification Jobbing Company Type “A” Main product Batch Spares Subcontract Flow Shallow Deep Product Structure © C. Hicks, University of Newcastle

Manufacturing Process Company Type “B” Jobbing Batch Valves & Pumps Motors Cabs Flow Shallow Deep Product Structure © C. Hicks, University of Newcastle

Manufacturing Process Control Approaches Project Management Jobbing MRP + JIT Batch JIT Flow Shallow Deep Product Structure © C. Hicks, University of Newcastle

Audit Conclusions • Markets - demand highly variable and lumpy • Products - complex, highly customised, mix of products • Processes - wide range yet all areas tend to be controlled in same way • Manufacturing systems - mainly functional layouts, high capital employed • CAPM systems - poor integration, wide variety of subsystems, incorrect data structures, poor operational procedures, generally unsuccessful © C. Hicks, University of Newcastle

Systems Modelling • Functional models decompose complex systems using a hierarchical top-down approach. They provide a means of understanding activities and interrelationships • Information models enable structure of information to be described • Dynamic models show changing behaviour over time. © C. Hicks, University of Newcastle

Company X - Context Diagram a Customer ITT Contract Awarded Progress Report Tender Company X ITT Quote b Supplier © C. Hicks, University of Newcastle Order b Supplier

© C. Hicks, University of Newcastle

© C. Hicks, University of Newcastle

Method Limitations • Audit, systems analysis and data modelling provide static “snapshot” views. Longitudinal studies are a series of snapshots. No model of system dynamics. • At best enable “best practice” or potential solutions to be described and documented. • Not possible to perform experiments to examine alternative configurations and evaluate them in terms of specified performance criteria © C. Hicks, University of Newcastle

Simulation • Allows modelling of system dynamics • Very expensive in terms of model building and computational resources • Validation often a problem • Predominantly used for either small scale models or rough-cut high level models © C. Hicks, University of Newcastle

Simulation Model CAPM Modules © C. Hicks, University of Newcastle

© C. Hicks, University of Newcastle

Key Features • Large scale model allows whole manufacturing facilities to be represented • Models facilities, products, processes and planning and control systems • Many product families can be represented with shallow, medium or deep product structure • Data structures match ETO/MTO requirements • Allows variety of planning and control methods to meet local requirements • May be used as a research tool or for planning and simulation. © C. Hicks, University of Newcastle

Simulation Case Study • Heavy Machine Shop used for case study • Static configuration used layout and other resource constraint information • BOM information obtained for products • Process data and planning data obtained for 18 month period. © C. Hicks, University of Newcastle

Experimental Design • Series of full factorial experiments Factors • Process - assembly lead time, minimum set-up, machining and transfer • CAPM, scheduling methods, BOMs, dispatching rules, capacity planning • Product mix / load • Operational - data update period © C. Hicks, University of Newcastle

Conclusions • Assembly planning and capacity planning important CAPM subsystems • “Dispatching” rules not very significant • Manufacturing performance sensitive to transfer times. • Significant advantages gained through having close control of key resources • Real time data recording led to improved manufacturing performance © C. Hicks, University of Newcastle

Consequent research topics • Manufacturing Layout (Hinrichs, Wall) • Capacity planning (Tay, Holmes, Hines, Pongcharoen) • Assembly planning (Sullivan. . ) • Planning of product development activities • Planning under uncertainty (Wall, Brand, Song) • Integration of project planning methods with MRP type approaches (EPSRC proposal) • Plan Optimisation through Genetic Algorithms © C. Hicks, University of Newcastle

Manufacturing Layout • All data required for layout analysis, clustering and generation in simulation data structures • Work started with Chris Lee who was interested in improving the layout of Vickers’ Scotswood Road factory • Much work in layout has focused on moving from functional layout to cellular layouts © C. Hicks, University of Newcastle

Methods • Clustering – Matrix based methods – Similarity coefficient methods • Layout generation – Starting with some candidate solution generate new layout that minimises (maximises) some objective function – Simulated annealing – Genetic algorithms © C. Hicks, University of Newcastle

Capacity Planning • • • Finite / infinite loading Re-planning rules (Tay) Finite loading rules (Holmes) Interactive tools (Hines, Poncharoen) Schedule “optimisation” (Poncharoen) © C. Hicks, University of Newcastle

Supply Chain Management • ETO companies moving towards buy rather than make • Business process analysis approach (Mc. Govern, Earl, Harrison, Hamilton) • Agent based modelling of supply chains (Harvey, Mc. Leay, Hines) © C. Hicks, University of Newcastle

IT Implementation • Embodies audit, business process analysis and requirements definition • Transfer of computing expertise • 3 Teaching Company Schemes © C. Hicks, University of Newcastle

Layout design & effect on benchmarks • Tony Wells Siemens Semiconductors • Data from North Tyneside, US, Germany, Taiwan. • Pareto analysis of costs • Identification of cost drivers • Relating cost drivers to plant design configurations • Results so far: potential cost reduction of 50% on £ 30 m/annum -pity the plant has closed! © C. Hicks, University of Newcastle

Management of Knowledge • Data modelling / systems analysis based upon thematic knowledge that is formal, explicit and easily shared • Knowledge management requires knowledge of product and process structure • “Tacit” or embedded knowledge that is disorganised, informal, context dependent and relatively inaccessible often important. • Interested in developing methodologies for systems integration that include both thematic and tacit knowledge • LABS Proposal with Paul Braiden © C. Hicks, University of Newcastle

Other Activities • £ 180 k EDF grant with ISRU to develop distance learning material (Dave Stewardson & Mark Gary) • TCS with House of Hardy aimed at improving manufacturing efficiency (Rob Davidson & Paul Braiden) © C. Hicks, University of Newcastle

Summary • Wide portfolio of manufacturing systems research • Various types of research undertaken from theoretical through to applied. • “Market led” rather than “product led” © C. Hicks, University of Newcastle