ANALYSIS OF PRODUCTION
SYSTEM
R.ŞİRİN UYAN
ELVAN EROĞLU
G.HAZAL KOCAHIDIR
NERİMAN NUR CAYMAZ
GROUP
OUTLINE
Introduction
Macro System Analysis
Micro System Analysis
2
INTRODUCTION
French based multinational corporation
Many facilities distributed all over the world
3
INTRODUCTION
Home automation
Integrated building and
automation
Fields of
Activity
Industrial automation
and control
Electrical distribution
and control
4
MACRO SYSTEM ANALYSIS
PRODUCTS
5
MACRO SYSTEM ANALYSIS
6
MACRO SYSTEM ANALYSIS
Sales by geography
billion sales
% of sales in new economies
people in 100+ countries
in Fortune 500 ranking
of sales devoted to R&D
North
America
27%
Eastern
Western Europe
Europe 6%
35%
Asia
Pacific
RoW
21%
11%
Sales by End markets
Energy & Infrastructure
16%
Industry
Data centres & Networks 17%
Buildings
Residential
10%
26%
31%
Listed at the Paris
Stock Market– CAC40
77
MACRO SYSTEM ANALYSIS
SCHNEIDER ELECTRIC TURKEY (SET)
1,795 employees, 200 dealers and partners
18 sales offices, 2 production plants
8
MACRO SYSTEM ANALYSIS
PRODUCTION PLANT MANİSA
Spreads over 72,350 m2 in total with a plant area of 25,340 m2
470 employee
9
MACRO SYSTEM ANALYSIS
PRODUCTS OF MANISA PLANT
Medium Voltage Distribution Products
Low Voltage Distribution Products
10
MACRO SYSTEM ANALYSIS
9 Main Types of Products
8 Assembly Lines
PREMSET
Line
No Manufacturing Processes
11
MICRO ANALYSIS
OF SYSTEM
12
SCOPE OF THE PROJECT
PREMSET
Operational Efficiency of Manufacturing
Processes
13
DEFINITION OF SYSTEM
Main
Product
Parts
Epoxy
Processes
Metallization
Processes
PD
Test
Helium &
Magnetron
Processes
Assembly
Main Process Groups (WorkStations)
Optional
Accessories
14
DEFINITION OF SYSTEM
Main Process Groups
(Workstations)
Epoxy
Processes
Process
No
# of
M/C
1
1
2
Metallization
Processes
# of
Parts
Process
No
# of
M/C
# of
Parts
1
1
1
1
1
1
2
1
1
3
1
2
3
1
1
4
6
4
4
1
1
5
2
4
5
1
1
6
1
1
6
3
1
7
3
1
7
6
4
8
4
1
8
6
4
9
5
1
9
1
1
10
1
1
Helium &
Magnetron
Processes
PD
Test
Process
No
# of
M/C
1
6
# of
Parts
2
Process
No
# of
M/C
1
5
# of
Parts
36
15
DEFINITION OF SYSTEM
Process Routes by Parts
Epoxy
Processes
Metallization
Processes
Helium&
Magnetron
Processes
PD
Test
SUB PROCESSES OF EPOXY WORKSTATION
PARTS
VI
Tank
Cover
ILB
C3
STD CAP
C1
VPIS CAP
1
√
2
√
3
√
4
√
5
√
6
√
√
√
√
√
√
√
√
√
√
√
√
√
7
√
√
√
√
8
√
9
√
√
√
√
√
√
√
√
√
16
DEFINITION OF SYSTEM
Process Routes by Parts
Metallization
Processes
Epoxy
Processes
Helium&
Magnetron
Processes
PD
Test
SUB PROCESSES OF METALLIZATION
WORKSTATION
PARTS
VI
Tank
Cover
ILB
C3
STD CAP
C1
VPIS CAP
1
√
√
√
2
√
√
√
3
√
√
√
4
√
√
√
5
√
√
√
6
√
√
√
7
√
√
√
8
√
√
√
9
√
√
√
10
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
17
DEFINITION OF SYSTEM
Process Routes by Parts
Epoxy
Processes
PARTS
VI
Tank
Cover
ILB
C3
STD CAP
C1
VPIS CAP
Metallization
Processes
PD TEST
√
√
√
√
√
√
√
√
PD
Test
HELIUM
√
Helium&
Magnetron
Processes
MAGNETRON
√
18
DEFINITION OF SYSTEM - BOM
Parts
Main
Product
SD1
Vacuum
Interrupter
SD2
Insulated Lınk
Body
SD3
Tank
SD4
Cover
Switching
Device (SD)
SD5
Standard Cap
VPIS Cap
End
Products
C3
C1
19
DEFINITION OF SYSTEM - BOM
Parts
Vacuum
Interrupter
Insulated Lınk
Body
Accessories
Tank
End
Products
Cover
Standard Cap
Metering
Std Cap
1,2,3
VPIS Cap
C3
Metering
1,2
Cap Kit
C1
Kit
VPIS Cap
1,2
C1 Kit
20
OBSERVATIONS AND DATA
Monthly sales forecasts till the end of 2018
MONTHS
PRODUCTS
Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14
SD1
SD2
SD3
SD4
SD5
MT1
MT2
SC1
SC2
SC3
VC1
VC2
CK1
114
45
68
13
31
20
0
29
174
116
255
6
14
108
43
65
17
39
21
0
30
180
120
264
6
15
106
42
63
23
54
23
0
32
192
128
282
6
16
105
42
63
26
62
24
0
33
198
132
290
7
17
105
42
63
26
62
24
0
33
198
132
290
7
17
109
44
65
26
62
24
0
34
204
136
299
7
17
Jul-14
…
122
49
73
33
77
26
0
36
216
144
317
7
18
…
…
…
…
…
…
…
…
…
…
…
…
…
21
OBSERVATIONS AND DATA–SALES FORECASTS
250
600
500
200
400
150
300
100
200
50
100
0
0
1 6 11 16 21 26 31 36 41 46 51 56
1 6 11 16 21 26 31 36 41 46 51 56
SD1
SD2
200
350
300
150
250
200
100
150
100
50
50
0
0
1 6 11 16 21 26 31 36 41 46 51 56
SD3
1 6 11 16 21 26 31 36 41 46 51 56
SD4
22
OBSERVATIONS AND DATA
PARTS
Process times
PROCESSES
17 out of 22
VI
LOADING
68
SAVE DATA
-
OTHER
-
MASKING
504
CONVEYOR
40
STD CAP
VPIS
TANK COVER
CAP
C1
C3
200
200
40
40
18
147
147
420
22
9
488
40
40
40
40
CAMERA DEVICE
97
97
97
97
97
97
97
SANDBLASTING
402
314
380
371
350
246
425
CONVEYOR
14
14
14
14
14
14
14
MANUEL CLEANING
0
0
0
0
0
0
0
PAINTING
580
550
584
315
260
270
285
CONVEYOR
14
14
14
14
14
14
14
FLASHOVER
162
162
162
162
162
162
162
CONVEYOR
8
8
8
8
8
8
8
OVEN
1200
1200
1200
1200
1200
1200
1200
COOLING
26
26
26
26
26
26
26
CONVEYOR
32
32
32
32
32
32
32
DISCHARGE
100
91
90
316
248
414
250
23
SYMPTOMS
Epoxy
Processes
Metallization
Processes
PD
Test
Helium&
Magnetron
Processes
Parts are accumulating in queues before METALLIZATION workstation
Parts are accumulating in queues before M/C #5 in EPOXY workstation
Idle times in other workstations
Bottleneck in Metallization and
M/C #5 in EPOXY workstation
Suffering tardiness frequently
24
PROBLEM DEFINITION
3 stages
•
1
Modifying the configuration of
Metallization Workstation to increase
its efficiency
2
Generating monthly production
schedule for parts with higher overall
production rate
•
•
•3
•
Managing Capacity Expansion
(Number of Shifts, Overtime,
Number of Machines)
25
PROBLEM DEFINITION
Metallization workstation
Carousel Structure
Chariots driven by non-accumulating conveyor
26
PROBLEM DEFINITION AND
SUCCESS CRITERIA
STAGE-1
Configuration of Metallization
Workstation
•
•
•
•
10 job stations
Each part has different processing times on stations
Each part is processed on a spesific chariot type
Total number of chariots in carousel is constrained
Decision Variables : numbers and sequence of chariots types on carousel
Objective
: maximize the number of tours of carousel
27
PROBLEM DEFINITION AND
SUCCESS CRITERIA
STAGE-2
Generating monthly production schedule
Decision Variables : numbers and timing of parts to be processed in each
workstation
Objective
: maximize overall production rate while ensuring to
meet monthly demands for end products
28
PROBLEM DEFINITION AND
SUCCESS CRITERIA
STAGE-3
Managing Capacity Expansion
• Forecasts :
orders will be ramped up through months to come
• Capacity will not be sufficient
Decision Variables : - timing of additional shifts for each workstation
- timing and number of additional machines
Objective
: minimizing additional number of machines and
shifts while ensuring to meet monthly demands
29
THANK YOU FOR LISTENING
30