Advanced Scheduler for Wonderware
MES
Chris Mollison
Scheduling Solutions
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Background to the Project
► This presentation shows how the Preactor
scheduling functionality has been integrated with
Wonderware Operations 3.4
► It discusses the benefits of using finite scheduling
functionality.
► It reviews the results obtained at Aquacolor
where Wonderware Operations and Preactor are
integrated
Background to the Project
Receive
Preparation
Make Unit
Batching
Packaging
Ship
Manufacturing Order Management
Enterprise Integration
Finite Scheduling
Dispatching
Material Management/ Formula
Manufacturing Performance Management
Manufacturing Reporting/ Analysis/ Dashboard
In Line Product Quality Compliance
Equipment Condition Monitoring
Production Capacity Management (OEE, TEEP)
Deviation/ Yield Management/ Scrap Rework
Material Management
Material Receivables
Pre-Weighing/
Dispensing
Inventory Material Management
Material Quality
Inspection
Food and beverage solution map
Manufacturing Operations Execution
WIP Status Management
Production Practices Enforcement (multi Unit)
Product Traceability
Brand Integrity/ Quality Sample Plan Management
Container Management (Tote bin management)
Regulative Compliance (HACCP)
Batch/ Process Execution
Batch/ Unit Execution
Process Automation Control
Final Inventory
Secondary Production Execution
Production Order Execution
Discrete Automation Control
Bar Code Printing
RFID Coding
Shipping Execution
Project Goals
► To create a certified integration between
Wonderware Operations 3.4 and Preactor.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Where does APS fit?
ERP
APS
MES
System Control
Automation
Jurgen Kletti, 2008
APS Role in MES
Fills the MESA function group for detailed
planning:
Sequence and time optimization of the orders
finely tuned to the performance of the
machines, including their finite capacity and
relationship to other resources
Why is scheduling different from
planning?
► Planning systems are bucketed (monthly, weekly, daily)
and cannot preserve operation sequences within the time
bucket
► True scheduling systems are bucketless, preserving
sequencing, and capable of generating work-to or
dispatch lists.
► Assignment of operation to resource is a key function to
achieve operational efficiency and optimizing performance
SAP APO
► APO is a global Supply Chain solution
► APO is made up of several modules :
►Collaborative Planning (CP)
►Supply Chain Cockpit (SCP)
►Demand Planning (DP)
►Supply Network Planning (SNP)
►Production Planning & Detailed Scheduling (PP/DS)
►Global Available-to-Promise
► Preactor does not compete with APO, but only with the
“Production Planning & Detailed Scheduling” (PP/DS)
module of APO
Limitations PP/DS for MES
► PP uses an MRP calculation with infinite capacity and
large planning and scheduling ‘bucket’ sizes (typically a
week) and mid/long term vision
▪ Hence a planning system with all the limitations
► DS does not link dependent WOs (pegging), it uses
launch date data,
▪ No synchronization of materials between dependent WOs or WOs
to WOs
► APO uses heuristics technology
▪ Very difficult to parameterize
▪ Solver cycle long and not repeatable
▪ Very difficult for users to understand
► Limited, rigid rule set
Where does APO fit?
SNP
SCP
DP
ERP/PPS
GATP
CP
APS
MES
Why Preactor?
► Founded in 1993 – 15 years of experience
in developing and implementing scheduling
solutions
► Microsoft Gold Partner
► International coverage across 5 continents
► Over 10 000 licenses sold
Why Preactor?
Preactor’s Install Base
Since its first release in 1993 more than 10,000 Preactor scheduling
systems have been installed in the broadest range of verticals…..
Data Flow
ERP
SYSTEM
Wonderware
Operations 3.4
APS
Production Order
• item
• qty
• date
Operations management
• production process
• recipe management
• inspection
• tracking
Sequencing
• sequencing logic
• dates & times
• resources to use
Integration with Wonderware
Operations
Work
Order
Wonderware Ops
(MES)
Data Sent per Op
Initial Scheduled Resource
Required Finish Time
Priority
Route constraints
Actual Start Time
Data Sent per Op
Scheduled Start Time
Target Scheduled Resource
Preactor
APS
Integration structure
Links with Operations 3.4
Checklist
Checklist
Wonderware's Operation Modules
(Factelligence)
Supply Chain Connector
Clients
• Demand passed from
Operations 3.4 to Preactor
APS
• Schedule is released from
Preactor APS to Operations
3.4
• Context sensitive windows
in Preactor shows data from
WIS
• Resource calendar
exceptions sent from
Operations 3.4
• Shop floor data updates
Preactor APS
• Static data synchronized
from Entities
• Preactor Gantt charts
available though WIS
Integration Example
Flash Demo of Preactor
Aquacolor
► Aquacolor is also heavily involved in the development of
applied nanotechnology for textiles finishing and works
with leading fashion brands including Levi Strauss,
Burberry, Hugo Boss and Trussardi
► The ability to respond to this and consistently deliver high
levels of customer service depends on a solid yet flexible
manufacturing approach
► Different orders may require different levels of dyeing,
washing and finishing yet challenges exist for some
orders may require repeat operations – typically washing with some processes – typically dying – involving
correction and adjustments during the actual process
▪ Every order may be different
Aquacolor
► Aquacolor are a Wonderware user and they
wanted improved management over shop floor
operations.
► They selected Wonderware Operations (originally
Factivity) to provide the required functionality.
► Factivity does not have inbuilt scheduling
functionality so Aquacolor selected Preactor to
provide this capability.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Wonderware Operations - benefits
► Benefits achieved from Wonderware Operations
implementations
▪ Improved control of operations
▪ Improved recipe management
▪ Improved traceability
Preactor - benefits
► Benefits achieved from Preactor implementations
▪ VISIBILITY
• Decision support
▪ Improved customer service
• Improved delivery date promising
• Improved delivery performance
▪ Improved productivity
• Better machine utilization
▪ Reduced inventories
Aquacolor Benefits




Operational improvement at recipe
management, operations information and
traceability levels, with a direct impact on
costs.
50% reduction in the time spent to build a new
work order
Saves 70% time required to give a delivery date
Scheduling overhead reduced 35%
Benefits / Goals Achieved
► Were the initial goals achieved?
▪ Yes – an integration has been developed
► Is the customer happy with the project?
▪ Wonderware and Preactor are happy with the
integration.
▪ The interface has been certified.
► What benefits (business, technical & other) were
gained
▪ A certified solution is now available to Wonderware
Operations users to role out scheduling functionality
with minimal effort.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Lessons Learned
► This is possible to integrate Wonderware
Operations 3.4 and the Preactor scheduling
functionality.
▪ Wonderware has certified the interface.
► Linking Wonderware Operations and Preactor
delivers measurable benefits.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Conclusions
► The certified interface shows that it is possible to
easily transfer data between Wonderware
Operations and Preactor.
► Wonderware Operations users can feel secure in
knowing that world class scheduling functionality
is available to them when required.
► Wonderware Operations users can benefit from
implementing the scheduling functionality now
available to them.
….any questions?