Information Engineering
Enhancing Information Quality
for
Effective Decision-Making in Textiles
for
The 2000 Massachusetts Institute of Technology
Conference on Information Quality
October 21, 2000
Cambridge, Massachusetts
Presented By
Mr. Neil Cahill
Vice President
Institute of Textile Technology
Charlottesville, Virginia
with
Dr. George Hodge
North Carolina State University
Dr. William Oxenham
North Carolina State University
Mr. Yatin Karpe
North Carolina State University
i:\share\sandys\conferences\informationengineering-mit2.ppt
. . . plant having Performance Capability
a traditional plant does not have, and,
therefore, cannot match performance,
no matter how modern or well
managed.
i:\share\sandys\conferences\informationengineering-mit2.ppt
ONE NEW CAPABILITY NEEDED
. . . High proportion of current
manufacturing performance losses are due
to slow response
to production problems.
i:\share\sandys\conferences\informationengineering-mit2.ppt
PERFORMANCE DEGRADATION CURVE
Point of Degradation
Normal
X
Point of Malfunction
Process
Performance
X
Point of Failure
Poor
X
Response Delay Time
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SLOW RESPONSE CONTROL
Good
X
Performance
Loss
X
Performance
Measures
Reaction
Point
X
Poor
Short
Response Delay Time
Long
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FAST RESPONSE CONTROL
Good
X
Reaction
Point
Performance
Loss
X
Measures
X
Poor
Short
Response Delay Time
Long
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TIME VALUE
OF
INFORMATION
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. . . Value of Information decays
rapidly with elapse time after need
to know.
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TIME VALUE OF INFORMATION
Use
Value
of
Information
Need to
Know
TIME
Info
Available
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. . . Finding and Diagnosing information
takes 80% of total time needed to
complete
a decision!
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DECISION RESPONSE TIME
Decision Action
Find
Slow
Reaction
& Diagnose
10% 10%
80%
100%
Fast
Reaction
Fd Diag Dec
Act
5% 10% 10% 10%
35%
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Measuring Decision Effectiveness
(Manufacturing Problem Solving)
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BASIC DETERMINANTS
OF
MANUFACTURING DECISION EFFECTIVENESS
1. Number of process malfunctions.
2. Delay in responding to problems.
3. Effectiveness of corrective action taken.
i:\share\sandys\conferences\informationengineering-mit2.ppt
DECISION EFFECTIVENESS EQUATION
Decision
Effectiveness
=
Malfunction
Frequency
Failure Rate
( )(
Defects/
Hr
)+ ( )( ) ( )
Response
Delay
Reaction Delay
R.E. = % Response Effectiveness
Defects/
Hr
Elapse
Time
1.0-R.E.
Action Effectiveness
TWO CONCEPTS
OF AN
INFORMATION SYSTEM
i:\share\sandys\conferences\informationengineering-mit2.ppt
INFORMATION DELIVERY SYSTEMS
1. Information Distribution System.
2. Decision Message System.
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Users
Information
Generator
O O
Information Flow Pipe
O O
General
Report
Traditional Information System
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WHAT DO USERS REALLY WANT?
Information in Reports?
OR
Meaning in Information?
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. . . it is Meaning which allows
people
to understand situations and make
appropriate decisions
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MESSAGES
. . . Intended meaning to be conveyed by
the information to the user.
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. . . I told him 10 times (Information),
but he still doesn’t understand what’s
happening (Message)!
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Users
O
O
O
Customized
Report
Expected
Decision
Message
Interface
Information
Generator
Information Flow Pipe
Decision Message System
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Technician
O
O
Manager
Customer
Message Interface
Ta
p
Ta
p
Information
Flow
Customized Message Interface For User
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INFORMATION ENGINEERING
. . . method to extract the Meaning Content
from information before sending to user.
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. . . information needs are Decision-Driven
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DATA TO DECISION CYCLE
Detection
Data
Information
. . . sense an event
. . . identify and quantify event
. . . relationship of different events
Diagnosis
. . . meaning of relationships
Message
. . . understanding relationship
Decision
. . . choice of response
Action
. . . implement change
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DATA TO DECISION CYCLE
Detection
Data
Information
Information
Reporting
Diagnosis
Message
Decision
Action
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DATA/INFORMATION REPORT
Weaving Computer Monitoring Report
MCH
% EFF
STY
WVR
S/RLH
WS
0049
0052
0051
0053
0054
0055
0037
0038
0039
0040
0561
0562
0563
0564
0565
0001
0002
0003
0004
0005
0572
0573
Avg.
091.0
080.4
083.1
074.1
091.6
091.6
105.2
094.1
094.5
086.0
094.6
096.6
098.0
094.0
094.1
072.1
086.8
089.5
079.5
094.1
094.8
095.0
090.0.
056
056
056
056
056
056
056
056
053
056
056
053
056
056
053
056
056
053
056
053
056
053
032
033
033
033
033
032
032
032
033
033
033
032
032
033
032
033
033
032
033
032
032
032
1.09
1.24
0.90
2.02
0.27
1.22
0.00
0.13
0.13
0.72
0.26
0.65
0.38
0.13
0.53
2.08
0.72
1.68
0.94
0.53
1.18
0.92
0.80
5
6
5
11
2
8
0
1
1
3
2
3
3
1
3
4
1
3
2
1
2
5
FS
2
2
0
1
0
1
0
0
0
2
0
2
0
0
1
8
3
7
4
3
1
2
OS
1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
1
2
0
0
6
0
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DATA TO DECISION CYCLE
Detection
Data
Information
Diagnosis
Message
Meaningful
Messages
Decision
Action
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MEANING/MESSAGE REPORT
100
o
o
o
Machine
Efficiency
(%)
o
oo
95
o
90
o o
o
Weaver 032
o
85
80
Weaver 033
75
0
2
4
6
8
10
12
14
Stops Rate
Efficiency Delay Curve
i:\share\sandys\conferences\informationengineering-mit2.ppt
Users
O
O
O
Customized
Report
Expected
Decision
Message
Interface
Information
Generator
Information Flow Pipe
Decision Message System
i:\share\sandys\conferences\informationengineering-mit2.ppt
Walk-through Visit
of
21st Century Textile Plant
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CIM
Computer-Integrated Manufacturing
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Figure 1. Automated and computerized plant with full-factory communications network (Murata CIM Mill).
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. . . Future textile plants will be
highly automated!
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Automated Piece Up
and
Cone Doffing
Academic\No5Class899.ppt
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38
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45
PLANT COMMUNICATIONS NETWORK
. . . Local Area Network (LAN) providing
real-time bi-directional communication
between individual machines and plant
computer.
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COMMUNICATIONS CENTER
Assess Plant Performance Status
and
Broadcast Action Messages
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Broadcast Messages To Selected Personnel
O
Computer Control Center
Broadcast
O
Message
O
Factory Network
Machine-to-Man messaging
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SIGNAL DISPATCHED OPERATORS
. . . Computerized monitoring system
detects Machine Service Needs and
automatically Calls appropriate personnel.
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O
O
Technician
Operator
O
Handler
Spinning Machine Change-Over Swat Team
O
Cleaner
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So now must . . .
Put intelligence into the machine system!
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AUTOMATED DECISION OF FABRIC GRADE
IF:
More than (3) Stops/50 yards
OR:
Technician Repair Required
THEN:
Send AGV to Human Inspector
IF NOT:
Send AGV to Loading Dock
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ENGINEERING INFORMATION
FOR
MANUFACTURING DECISION MAKERS
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INSTANTANEOUS FACT-FINDING
. . . provide a decision-maker with needed facts
in the logical order to readily understand
performance problem as soon as detected.
DECISION MAKER DRAWS THE CONCLUSIONS
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TYPES OF DECISIONS
MADE IN MANUFACTURING
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CLASSIFY DECISION TYPES
1. PROGRAMMABLE DECISION
. . . repetitive situations with predictable response.
2. DISCRETIONARY DECISION
. . . Situation requiring a judgment call.
3. KNOWLEDGE INTENSIVE DECISION
. . . Unique situations requiring special knowledge
for response.
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TYPE DECISIONS
MADE IN MANUFACTURING
100
80
%
Manufacturing
Decisions
60
40
20
0
Programmable
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Discretionary
Knowledge
Intensive
. . . concentrates on Programmable Decisions
avoiding Discretionary or Knowledge-Intensive
Decisions, which are highly complex and
uncertain.
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DESIGNING THE MESSAGE INTERFACE
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MESSAGE INTERFACE
. . . Part of communications system that
converts information into Meaningful Message
so user can make quicker and more effective
decisions.
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Technician
O
O
Manager
Customer
Message Interface
Ta
p
Ta
p
Information
Flow
Customized Message Interface For User
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DATA TO DECISION CYCLE
Detection
Data
Information
Diagnosis
Message
Message
Interface
to User
Decision
Action
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DESIGNING THE MESSAGE INTERFACE
1.
2.
3.
4.
5.
6.
7.
8.
Identify Machinery Layout.
Identify Information Sources
Identify Information User
Determine Expected Decision.
Determine Need-to-Know Information.
Develop Diagnostic Logic.
Design Actionable Message Format.
Assess Action Effectiveness.
i:\share\sandys\conferences\informationengineering-mit2.ppt
STEP 1. MACHINERY LAYOUT
. . . specific type and arrangement of
production machinery to be controlled.
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PROCESS
NAME
MACHINE
LAYOUT
TYPE
MONITOR
Barco Sycotex
Stretch Breaker
Rebreaker
Barco Sycotex
Blender
Servo
Sliverdance
Roving
Barco Sycotex
FA.NI Monitor
Ring Spinning
Savio Elios
Linked Winding
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Loepfe Clearers
PACKING
Barco Sycotex
STEP 2. IDENTIFY INFORMATION SOURCES
. . . Determine what computer accessible
sources of information are available.
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INFORMATION SOURCE
DIAGRAM
. . . Identifies types of information and
monitoring source at each manufacturing
process.
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INFORMATION SOURCE DIAGRAM
Process
Stretch Breaker
Information Type
Production
Output Pounds
Pounds/Hour
Efficiency
Stops
Declaration (Long Stops)
Maintenance
Service
Stop Cause
Rebreaker
Production
Output Pounds
Pounds/Hour
Efficiency
Stops
Declaration (Long Stops)
Maintenance
Service
Stop Cause
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STEP 3. IDENTIFY INFORMATION
USER
. . . Specific individuals, technicians, operators,
managers, etc., who make decisions in response
to problem situations.
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. . . Target User is maintenance technician.
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STEP 4. DETERMINE EXPECTED
DECISIONS
. . . decisions routinely made by Individual
responsible for responding to a particular
problem.
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MAINTENANCE TECHNICIAN EXPECTED DECISION
PROBLEM SITUATION
EXPECTED DECISION
1. High Flag Machines
Quickly identify High Flag Machines
and take corrective action with high
First Time Success rate.
2. High Off-Quality Machines
Identify quality defects while
On-Machine and correct
immediately.
3. Meet Maintenance Schedule
Meet all maintenance schedules
and assure adequate parts
inventory.
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STEP 5. DETERMINE NEED-TO-KNOW
INFORMATION
. . . Specific information in logical order needed
by decision-maker to understand situation and
make right choice.
i:\share\sandys\conferences\informationengineering-mit2.ppt
MAINTENANCE TECHNICIAN
Need-To-Know
High Flag Machines
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Which Machine?
What Style?
How Long?
Type of Flags?
Flag History.
Maintenance Record.
Parts Replacement Records
Assigned Technicians.
Assigned Weaver.
Any Special Events
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STEP 6. DEVELOP DIAGNOSTIC LOGIC
. . . Arrange need-to-know information
into the logical order of inquiry that a
decision-maker would follow to understand
what happened and how to respond.
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TWO TYPES OF INQUIRY MADE BY COMPUTER
QUESTIONS (Q’s)
. . . information in database; go get it!
MESSAGES (M’s)
. . . information not available in database;
ask people to find it!
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COMPUTING DIAGNOSTIC LOGIC
High Flag Machine
Diagnostic
Stage
I. Problem Focus
. . . What problem to
diagnose?
II. Localize Problem
. . . Where is problem
located?
Order of
Inquiry
Q1
Who is the User?
Q2
What Malfunction triggered alarm?
Q3
Which Machine triggered alarm?
Q4
What Product being run?
Q5
How long has problem been happening?
Q6
All or some Machines?
Q7
All or some positions on
machine?
Any other alarms on this machine?
Q8
M1
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Question/Message
Statement
Message to Maintenance:
Check settings on alarm machines
STEP 7. DESIGN ACTIONABLE MEASURE
FORMAT
. . . Did report to user (1) provide needed
information, (2) explain what happened, and
(3) allow an effective decision?
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ALERT/ADVISORY MESSAGE
TO:
Bob Roberts, Maintenance Technician
ALERT:
Machine 18 classified as Malfunctioning
with Chronic High Flags.
ADVISORY:
Over past 5 days (1/1-1/5), 65% of checks out-of-limit,
including stops, efficiency, flags, and quality points.
ACTION:
Flags which average 2/day relative to
expected 0.25/day are the major source of losses.
EFFECTIVENESS LOOP
. . . System continuously assesses State of Control
in manufacturing and Effectiveness of control
action taken.
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DATA TO DECISION CYCLE
DATA
INFORMATION
EFFECTIVENESS
. . . did it work
MEANING
MESSAGES
DECISION
ACTION
i:\share\sandys\conferences\informationengineering-mit2.ppt
. . . Value of Information is its
Meaning Content!
i:\share\sandys\conferences\informationengineering-mit2.ppt