Zanussi & Cybertec
Meeting
Meeting Agenda
• About Cybertec
• The CyberPlan Planning & Scheduling
Suite
• Cybertec Projects at Electrolux Zanussi
Cold Division in Susegana
CYBERTEC - The Planning and
Scheduling Company
About Cybertec
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Company
Vision
Technology
Products
Services
Customers
Partners
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
Vision
10000
1000
Comp power
100
Problem
Complexity
10
1
1970 1980
1990 2000 2010
• 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
CYBERTEC - The Planning and
Scheduling Company
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!
CYBERTEC - The Planning and
Scheduling Company
Products
• A complete suite of products for repetitive
and complex equipment industries:
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Planning
Programming
Scheduling
Management Execution Systems
CYBERTEC - The Planning and
Scheduling Company
Services
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Consulting
Education
Implementation
Integration
Special Projects for Hard Optimization
CYBERTEC - The Planning and
Scheduling Company
Customers Logo
CYBERTEC - The Planning and
Scheduling Company
Customer Industries
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Automotive
Clothing
Electric
Electronic
Food & Beverage
Heavy Equipement
Paper
Pharmaceutical
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Plastics
Ship building
Steel
Textile
…
CYBERTEC - The Planning and
Scheduling Company
Partners
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Consulting Companies
ERP Vendors
MES Integrators
SW Houses
Universities
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Arthur Andersen
Atos Consulting
IBM
JDE
ORACLE
SAP
Orsi
...
CYBERTEC - The Planning and
Scheduling Company
The CyberPlan
Planning & Scheduling Suite
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SCD Supply Chain Designer
MPS Master Production Schedule
MRP Material Requirements Planning
CRP Capacity Requirements Planning
FCP Finite Capacity Planning
FCS Finite Capacity Scheduling
CYBERTEC - The Planning and
Scheduling Company
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 - The Planning and
Scheduling Company
Cybertec Projects at Electrolux
Zanussi Cold Division-Susegana
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
Short Term Finite Capacity Scheduling in
the Innerliner Thermofoaming and Indoor
Thermofoaming departments
• 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.
CYBERTEC - The Planning and
Scheduling Company
The goals
• Main goal: let not-experienced employees
schedule the department by giving them a
computerized scheduling system.
• Other benefits required:
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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).
CYBERTEC - The Planning and
Scheduling Company
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)
CYBERTEC - The Planning and
Scheduling Company
Output:
• A production schedule for each machine
such that:
– satisfies the given constraints
– minimizes the changeover costs
– minimizes the due dates violation
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
The solution
Based 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.
CYBERTEC - The Planning and
Scheduling Company
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”
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
Automated Final Assembly
Scheduling (FAS)
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
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.
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
The FAS System Schedule
Assembly Line
Scheduling
CYBERTEC - The Planning and
Scheduling Company
The FAS critical resources load
Overload!
CYBERTEC - The Planning and
Scheduling Company
The New
Automated
MPS System
CYBERTEC - The Planning and
Scheduling Company
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:
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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 …)
CYBERTEC - The Planning and
Scheduling Company
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)
CYBERTEC - The Planning and
Scheduling Company
The goal
• Find an automated feasible master production plan
which:
1. guarantees a minimum level of customer service
2. the remaining capacity is allocated to satisfy the
customers’ demands according to the priority class
defined
CYBERTEC - The Planning and
Scheduling Company
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
CYBERTEC - The Planning and
Scheduling Company
Input
Customer
Priority
Class
Customer
Requests
CYBERTEC - The Planning and
Scheduling Company
Fast & Easy Execution
Executing
Command
CYBERTEC - The Planning and
Scheduling Company
Unsatisfied constraints
Unsatisfied
Customer
Requests
CYBERTEC - The Planning and
Scheduling Company
Results
Control
Panel
showing the
customer
satisfaction
level
Master
Production
Schedule
Workbench
CYBERTEC - The Planning and
Scheduling Company