Unit 4
Network Systems, Manufacturing
Planning, Control and Scheduling in
CIM Environment
This Unit is About:
Network Systems
Manufacturing Planning (Forecasting)
Manufacturing Planning (Scheduling)
Manufacturing Control (Management)
Network Systems in CIM
For Connectivity and communications in:
• CAD/CAM, CAE, CAPP, and other sub-systems
• Departmental activities
• Plant-wide activities
• Company-wide activities
• Global activities
• Executive planning and managerial activities
Company-wide Networking Systems
and Activities Include:
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Planning
Scheduling
Intranet systems
Email systems
Telephone networks
Fax systems
Scanners
Servers
Workstations
Meetings
Others
Global Networking Systems and
Activities Include:
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Database
Internet
Severs
Telephone systems
Emails systems
Go-to-meeting.com
Texting
Skyping
Cloud-based systems
Bank transfers
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Teleconferencing
Postal
UPS
DHL
Supply chain
Satellite systems
GPS systems
Software issues
Other networks
Types of CIM Network Systems
Local Area Network (LAN)
Metropolitan Area Network (MAN)
Wide Area Network (WAN)
Local Area Network (LAN)
• A group of computers
and associated devices
that share a common
communications line
or wireless link to a
server within a small
geographic area such
as an office building
or home.
Sample Local Area Network
Metropolitan Area Network (MAN)
• A
network
that
interconnects users with
computer resources in a
geographic area
or
region larger than that
covered by a large local
area network (LAN) but
smaller than the area
covered by a wide area
network
Sample Metropolitan Area Network
Wide Area Network (WAN)
• A computer network
that spans a large
geographical area of two
or
more
local-area
networks.
These
computers connected are
often connected through
public networks, such as
the telephone system,
leased lines or satellites.
Sample Global CIM Network Systems
USA
Mexico
India
CIM
Japan
Ghana
China
Cloud-Based Computer Networking
The practice of using a
network of remote servers
hosted on the Internet to
store, manage, and process
data, rather than a local
server or a personal
computer.
Benefits of Cloud-Based Network Systems
1. It allows companies to avoid upfront
infrastructure costs, and focus on projects.
2. It allows enterprises to get their applications up
and running faster.
3. It allows for improved system manageability and
less maintenance.
4. It enables companies to more rapidly adjust
resources to meet fluctuating and unpredictable
business demand.
Chapter 8: Enterprise Resource
Planning and Beyond
APICS Dictionary defined enterprise
resource planning (ERP) as a method
for the effective planning and control of
all resources needed to take, make, and
account for customer orders in a
manufacturing, distribution, or service
company
Enterprise Resource Planning
(ERP)
• ERP is one of the newer system concepts that focuses
on the integration of business systems
• These integrated systems support all of the functional
departments in the enterprise: sales and order entry,
engineering, manufacturing, finance and accounting,
distribution, order planning and execution, and the
supply chain flow
• Tech 149 team project is taking advantage of this
philosophy in its systems integration approach
Enterprise Resource Planning
(ERP)
Since businesses are increasingly focusing on
customers, customer relationship management
(CRM) systems are being developed to help
companies manage the information they have
about their customers, the products these
customers buy, and the way the customers
prefer to do business
Some Related Aspects of ERP
• Product data management (PDM)
• Information technology issues (data collection issues
and system integration problems)
• The role of the Internet
• Sample ERP systems include: PeopleSoft, SAP R/3,
Oracle, Sterling, Legacy, and JBA
Network Systems is All About Communications and Connectivity
Design
Man
Prod
Eng
Sales &
Mark
Enterprise Resource Planning (ERP)
Chapter 6: Introduction to
Production/Operations Planning
The planning functions have formal interfaces
with both the design and production
departments and informal relationships with
most of the enterprise. The operations
management functions are a critical part of
the CIM implementation.
Some Planning Areas for CIM
Manufacturing planning and control
• All planning has a time horizon, e.g.
number of days, months or years
• Enterprise planning is divided into three
levels:
– Strategic plan
– Aggregate plan
– Disaggregate plan
Strategic Plan
• The strategic plan is generally long range:
one year to many years
• The strategic plan is performed at highest
level in management
Aggregate Plan
• The aggregate plan has an
intermediate-length time horizon of
about two to eight months
• The aggregate plan emphasizes levels
of employment, output, inventories,
back orders, and subcontractors
Aggregate Plan
• The goal of aggregate planning is the
generation of a production plan that utilizes
the enterprise resources efficiently to meet
customer demand
• The production plan and forecasted
customer demand provides the aggregate
information from which the disaggregate
master production schedule (MPS) is
produced
Forecasting Defined
• The process of estimation in unknown
situations
• The process of prediction
• The practice of demand planning
Forecasting Techniques
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Causal / econometric methods
Time (trend) series
Judgmental methods
Other methods
Causal/econometric methods
• Regression analysis using linear
regression or non-linear regression
• Autoregressive moving average
(ARMA)
• Autoregressive integrated moving
average (ARIMA)
• Econometrics
Time Series
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Moving average
Exponential smoothing
Extrapolation
Linear prediction
Trend estimation
Growth curve
Judgmental methods
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Composite forecasts
Surveys
Delphi method
Scenario building
Technology forecasting
Forecast by analogy
Other methods
• Simulation
• Prediction market
• Probabilistic forecasting
MPS Time-Phased Record
_______________________________________________________
Period
_______________________________________________________
1
2
3
4
5
6
7
8
9
10
_______________________________________________________________________________________________
Forecast 5
5
5
5
5
5
20
20
20
20
Available 26
32
38
44
50
56
47
38
29
20
MPS
11
11
11
11
11
11
11
11
11
11
On hand 20
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Disaggregate Plan
• The development of MPS data is the start of
disaggregate planning
• The disaggregate plan provides short-range
planning with detailed plans that include machine
loading, part routing, job sequencing, lot sizes,
safety stock, and order quantities.
• The disaggregate plan has the shortest time
horizon
Disaggregate Plan
• The term disaggregate means to separate into
component parts
• At disaggregate planning level, an aggregate plan is
disaggregated into all the various models and
options necessary to meet customer demand
• The first step in disaggregation is the creation of
MPS from the aggregate production plan
Material Requirement planning (MRP)
• The material requirement planning (MRP) strategy in the
manufacturing planning and control (MPC) system is a very
useful tool at the disaggregate level
• MRP system addresses the need for parts management of
complex products and product mixes with high rates of
production
• MRP process starts with the MPS providing the quantity of
each model or part required (gross requirement) per period
MRP Record
MRP Record
Period Number
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Item: tube steel #246784
1
2
3
4
5
6
7
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Gross requirements
100
Scheduled receipts
Projected on hand
140
140
140
140
40
40
40
Planned order receipts
Planned order releases
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Order policy = Fixed lot
Order quantity = 200
Lead time = 5
Bill of Materials (BOM)
The bill of materials (or BOM in the form of
product structure diagram) and current
inventory provide critical information for an
effective MRP system
Bill of Materials (BOM)
• The bill of materials provides the MRP system with the part
number and quantity of all parts required to build and
assemble the product
• The inventory control system supplies the MRP system with
the projected on-hand balance of all parts and materials
listed on the BOM
• The MRP run produces the requirements for purchasing and
production that are needed to complete the master schedule
Product Structure Diagram
The product structure diagram illustrates
clearly the sequence required to build the
product, with the 0 level representing the
finished product
Part Routing, Lead Times and
Capacity Planning
• The routing sheet specifies each production operation
and the work center location
• Lead time includes four elements: run time, setup time,
move time and queue time (setup time, move time and
queue time add no value)
• Capacity requirement planning (CRP) works with the
system data to calculate the labor and machine time
requirements needed to complete the master production
schedule
Sample Manufacturing Scheduling
People
Operations
Facilities
Product
Equipment
Processes
Materials
Tooling
Key Aspects of Manufacturing
Scheduling in a CIM Environment
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Operations
Materials
Equipment and tooling
Facilities
Product
People
People
Operations
Facilities
Product
Equipment
Processes
Materials
Tooling
Scheduling in CIM Environment
• Scheduling information in CIM must be:
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Shared by all
Seen by all
Retrieved by all
Contained in the Database
Must be functional
Must be in real time
Must be self updating
Sample Scheduling Software
People Scheduling in CIM
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By job type
By operation type
By product type
By shift
Materials Scheduling in CIM
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JIT
MRP
Purchasing
Networking Members:
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Design
Purchasing
Manufacturing
Supplier
Warehousing
Facilities
Others
Design
Purchasing
Facilities
Materials
Others
Manufacturing
Warehousing
Supplier
Equipment & Tooling Scheduling in
CIM
Process
Facilities
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Process types
Number available
Routing issues
Maintenance issues
Facilities
Others
Availability
Equipment
and Tooling
Routing
issues
Others
Maintena
nce
Facilities Scheduling in CIM
• Layout issues
• Size and space issues
• Availability issues
Product Scheduling in CIM
• Delivery Issues
– Customer issues
– Production issues
Chapter 9: The Revolution in
Manufacturing
Several technologies and philosophies
have revolutionized manufacturing in
recent years. Some of these are
covered in this chapter
Just-In Time (JIT) Manufacturing
• Just-In-Time manufacturing (JIT)
encompasses every aspect of manufacturing,
from design engineering to delivery of the
finished goods, and includes all stages in the
processing of raw material
• JIT is much more than material-ordering plan
that schedules deliveries at the time of need
JIT focuses on the elimination of the seven wastes
found in manufacturing practices, namely:
1. Waste of overproduction 2. Waste of waiting
3. Waste of transportation 4. Waste of processing
5. Waste of stocks
6. Waste of motion
7. Waste of making defective products
Kanban (Card):
• Kanban is a Japanese word that means
“card”
• These cards in effect replace all work orders
and inventory move tickets
• Within the MPC system, kanban controls the
flow of production material
• One- and two-card kanban systems are in
common use
• Kanban supports a pull (JIT) system
Network Systems is All About Communications and Connectivity
Design
Man
Prod
Eng
Sales &
Mark
Enterprise Resource Planning (ERP)