MES8610
Information Systems
of
Production Management
Roman Zahharov
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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Agenda
• Rules
• Introduction
• Get to know each other / student list + contacts
• Course program
• Course schedule
• Communication
• Introductory lecture
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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Course program
• Lectures
• Practical lessons
• Homework
• Lecture materials to be distributed
• Visiting companies
• Exam = practical part + [questionnaire +
discussion]
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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Agenda
• Rules
• Introduction
• Get to know each other / student list + contacts
• Course program
• Course schedule
• Communication
• Introductory lecture
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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13 May 2012
Introductory lecture
THIS COURSE WILL NOT
REQUIRE YOU TO
BECOME AN IT/IS
SPECIALIST
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Introductory lecture
IT DOES REQUIRE YOU
TO KNOW WHAT
PRODUCTION IS AND
HOW TO MANAGE IT
WITH HELP OF IS
SYSTEMS
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INTEROPERABILITY
TOGAF (The Open Group Architecture Framework)
• the ability of two or more systems or components to
exchange and use shared information;
• ability of systems to provide and receive services from
other systems and to use the services so interchanged to
enable them to operate effectively together.
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INTEROPERABILITY
IEEE (Institute of Electrical and Electronics Engineers)
• ability of two or more systems or components to
exchange information and to use the information that
has been exchanged.
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INTEROPERABILITY
IDABC (Interoperable Delivery of European eGovernment Services to public
Administrations, Businesses and Citizens) European Interoperability Framework
• ability of information and communication technology
(ICT) systems, as well as, of the business rocesses they
support in order to exchange data and enable the
sharing of information and knowledge.
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INTEROPERABILITY
DARPA (Defense Advanced Research Projects Agency, US)
• the ability of systems, units, or forces to provide services to and
accept services from other systems, units or forces and to use the
services so exchanged to enable them to operate effectively
together;
• condition achieved among communications-electronics systems
or items of communications electronics equipment when
information or services can be exchanged directly and
satisfactorily between them and/or their users.
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INTEROPERABILITY
ability of enterprise software and applications to interact
…in Europe between 30-40% of
total IT budgets is spent on issues
tied to interoperability*
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Introductory lecture
How many
Information Systems
a company may need
to run it’s business?
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Introductory lecture
Pharmadule
case study:
PRODUCT
Pharmadule Production Site – Jüri, Estonia
Pharmadule Production Site – Jüri, Estonia
• Production hall
• Warehouse
• Product delivery
• Engineering systems
Pharmadule Production Site – Jüri, Estonia
• Production hall
• Warehouse
• Product delivery
• Engineering systems
Production / main hall
Control of material flow
Control of production operations
Up to 32 designated locations for modules (depends on module size)
Production / main hall
Clean production – controlled environment
Designated locations for material and instrument storage
Continuous improvement in all activities
Production / workshops
In-place checking of welding quality with X-ray for clean piping
Full documentation of work operations
100% transparency over clean piping works
Certainty – guarantee against errors
Pharmadule Production Site – Jüri, Estonia
• Production hall
• Warehouse
• Product delivery
• Engineering systems
Warehouse and production logistics
Designated storage locations for each material type and tools
Controlled environment
Quarantine zone for critical equipment receipt verification
Kanban principle in material planning and handling
Pharmadule Production Site – Jüri, Estonia
• Production hall
• Warehouse
• Product delivery
• Engineering systems
Product delivery
module steel frame production at subcontractors workshop
Product delivery
Module painting
Module roof and bottom insulation
Product delivery
Prefabrication and pre-assembly
Product delivery
Architectural outfitting
Systems and equipment installation
Product delivery
Architectural outfitting
Systems and equipment installation
45
Pharmadule – 3D model, mechanical module
Full-scale biotech facility (130 modules)
• 60 000 components to be assembled
Width
:
4,45m
•
Height :
4,10m
5 000 unique components
• 10 000 installation drawings
Length : 13,35m
•
Weight : 10 ... 35 tons
7 500 assembly operations
Product delivery
Transportation to cargo harbour
Product delivery
Loading onto the cargo ship
Product delivery
Module installation onto foundation
Product delivery
Module installation onto foundation
Largest modular biotech facility, USA
Largest modular biotech facility, USA
300 modules / approx. 18000m² / 6 levels / building footprint approx.
3000m²
53
Product delivery
Connection of systems between modules
Architectural finishes
Product delivery
Facility interior
Product delivery
Facility exterior
Introductory lecture
Pharmadule
case study:
PROCESS
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International Society for
Pharmaceutical Engineering
Designing for Quality
Overview of integrated IS-platform for project
design and production
Pharmadule
Operations / Production / Development engineer
Roman Zahharov MSc IEM
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International Society for
Pharmaceutical Engineering
Some truth’s are eternal…
empty
“He that would perfect his work
must first sharpen his tools”
Confucius - 500 BC
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Designing for Quality
Introduction
• Introduction
– Conventional construction
• Industrialization
– Concurrent engineering
– Prefabrication
• Case study
– Information Systems overview
– Integrated systems
• Summary
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Designing for Quality
Introduction
• The 20th century has seen the
breakthrough of industrial methods
• In building however, industrial concepts have only been
partially accepted
• Industrialized building techniques have not developed
steadily but rather have evolved in a sporadic fashion
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Designing for Quality
Introduction
• In conventional construction projects
– work processes carried out in a sequential order
– majority of the work is being performed on-site
– limited use of industrial methods based on standardization
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Designing for Quality
Introduction
Conventional construction ...
50%
... of total construction costs can be reduced
by focusing on the construction company’s core business ...
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Designing for Quality
Introduction
10%
of the total conventional construction
costs and time is spent
on
waiting of materials or machinery
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Designing for Quality
Introduction
45%
of all construction work on site is an indirect
work such as handling of materials and planning
35%
20%
is an interruption in work and waiting
is categorized as direct work, which directly
generates value for the client
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Designing for Quality
Industrialization
• Introduction
– Conventional construction
• Industrialization
– Concurrent engineering
– Prefabrication
• Case study
– Information Systems overview
– Integrated systems
• Summary
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Designing for Quality
Industrialization
In 21st century industrialization is
a vital move towards a higher degree of
– efficiency
– reduced costs
– high quality products
– increased profitability
– shorter construction time
– ensured quality
– improved work environment
– improved predictability
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Designing for Quality
Industrialization
• To succeeded with cost reduction in conventional
construction engineering and design execution principles can
be drastically improved through current engineering
•
construction time shortening can be achieved
via
decrease of on-site activities and moving those to a
controlled environment, therefore increase degree of
prefabrication at off-site production factories
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Designing for Quality
Industrialization – Concurrent Engineering
Similarities are found in
both manufacturing and conventional construction:
• produce engineered products that provide a service to the user
• involved the assembly of many diverse pre-manufactured components in
the final products
• utilize repeated processes in the design and production of their products
• experience similar problems such as:
– the high cost of correcting design errors due to late changes
– poor resource utilization
– inadequate information management
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Designing for Quality
Industrialization – Concurrent Engineering
• Incitement of adapting CE in the construction industry derives
from belief that construction can be considered
as a manufacturing process
• Aligning the business processes of the construction industry to
those of the manufacturing industry would significantly
improve its competitiveness
• In comparison to sequential engineering, the
total time saving, can be as large as 40%
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Designing for Quality
Project Negotiation Manager
Project Negotiation Manager
Develop Project
Execution Site
Proposal
Negotiate
Project
Execution Site
Proposal
TG50 Start Project
Execution
Industrialization – Concurrent Engineering
Clearly defined process is a MUST!
TG55 Start Project
Execution Site
Project Manager
Project Manager
Project Manager
Project Manager
Initiate Project
Execution
Pharmadule
Monitor and
Control Project
Execution
Pharmadule
Plan Site
Assembly
Close Project
Execution
Pharmadule
Project Manager
Project Manager
Plan Project
Execution
Pharmadule
Execute Project
Management
Project
Execution
Pharmadule
Project Technical
Manager
Engineering
Before Facility
Layout Freeze
Project Design Manager
Project Technical
Manager Project Manager
Project Design
Manager
Requirements
Approval
Procedure
Engineering
After Facility
Layout Freeze
PMS50 Facility
Layout Freeze
approved by
Client
Design Before
Facility Layout
Freeze
Project Design
Manager
Project Technical
Project Design
Manager
Manager
Functional
Acceptance
Procedure
Project Design
Manager
Design After
Facility Layout
Freeze
Area Design
Area-N
CMS110-N
Area N
Released for
Detail 3D
modeling
Project
Procurement
Manager
Supply
Management
Tagged Material
Project Procurement
Manager
Supply
Management
Long Lead
Material
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Project Technical
Manager
Design
Acceptance
Procedure
Area-N
Project Design Project Design
Manager
Manager
Project Fabrication
Manager
Project Manager
Pre-Production
Engineering
Area-N
CMS120
Area-N
Released for
Pre-Production
Engineering
Project
Procurement
Manager
Supply
Management
Untagged
Material
Fabrication
Area-N
P
W
PMS60-N
Area N
Released for
Client
Walk-Dow n
Designing for Quality
Industrialization – Concurrent Engineering
• Key principles for Concurrent Engineering are
Integration and Concurrency
– concurrent and parallel scheduling
– integration of product, process and commercial information
– integration of the supply chain involved in delivering the project
–
multi-disciplinary teams from day one
• Implementation of a CE design requires a set of enablers including
tools (software applications), techniques, technologies
and support structures
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Designing for Quality
Industrialization
• Introduction
– Conventional construction
• Industrialization
– Concurrent engineering
– Prefabrication
• Case study
– Information Systems overview
– Integrated systems
• Summary
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Designing for Quality
Industrialization – Prefabrication
• A prerequisite for the industrialization of construction is the
rational use of prefabrication, with the purpose of simplifying and
streamlining on-site work
• As In CE the success of prefabrication lies within the adoption of a
manufacturing philosophy rather than a
construction philosophy and processes
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Designing for Quality
Industrialization – Prefabrication
Time
Cost
Productivity
Quality
Predictability
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
Health
Safety
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Environment
Designing for Quality
Industrialization
Prefabrication
System
Engineering
System
Engineering
System
Engineering
System
Engineering
System
Engineering
MS
G
System
Design
System
Design
System
Design
System
Design
System
Design
Production
Area 1
Batch #
1
2
3
4
Design
Area 1
Batch #
1
2
3
4
Design
Area 2
Batch #
5
6
7
8
MS
Design
Area ...
Batch ...
Time
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Construction
Area 1
Batch #
1
2
3
4
Production
Area 2
Batch #
5
6
7
8
Production
Area ...
Batch ...
Construction
Area 2
Batch #
5
6
7
8
Construction
Area ...
Batch ...
Designing for Quality
Case study
• Introduction
– Conventional construction
• Industrialization
– Concurrent engineering
– Prefabrication
• Case study
– Information Systems overview
– Integrated systems
• Summary
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Designing for Quality
Tools – System engineering – Comos PT
• Data centric, everything in ONE database
• Object oriented
• Support for all disciplines using tagged items
• Audit trail of changes, FDA CFR 21 part 11
(Electronic Records; Electronic Signatures)
• Easy to import/export information
• Possible to interface with other systems
• Integrated work flow
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Designing for Quality
Tools – System engineering – Comos PT
Specs
Data Sheet
PFD
Loop Diagram
Engineering
Database
P&ID
DQ, IQ, OQ
Sheets
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
3D PDMS
Change
Management
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Designing for Quality
Tools – System engineering – Comos PT
Database and P&ID are the same
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Designing for Quality
Tools – System engineering – Comos PT
All documents, including P&ID, are database reports
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Designing for Quality
Tools – System engineering – Comos PT – Data export
• Data uploaded to the client’s maintenance system
• Data supplied after the walk down at factory
Recent project example:
• For each tag there is 45 fields of data:
– Tag number
– Manufacturer catalog number
– Physical location
– P&ID document number
– Ex-rating
– ...
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Designing for Quality
Tools – 3D Design – PDMS
Plant Design Management System (object-oriented database)
3D view/review
internal / external
Technical calculations
(Pipe/HVAC dimensioning/structural)
Bill Of Material
Production
operations
sequencing
Purchase data
Validation
CAM (welding robots
etc.)
Engineering control
Drawings
3D Visualization
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etc…
Designing for Quality
Tools – 3D Design – PDMS
Design review
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Designing for Quality
Tools – 3D Design – PDMS
Design review
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Designing for Quality
Tools – 3D Re-Viewer – JetStream Roamer
•
3D View for non-designers
•
3D Review, internal and external
•
Construction and validation planning
•
Almost all 3D formats (AutoCAD, PDMS, MicroStation,
SolidWorks etc.)
•
Extremely easy to use, “Doom” like interface
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Designing for Quality
Tools – 3D Re-Viewer – JetStream Roamer
Complex installation are easy to check …
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Designing for Quality
Tools – 3D Re-Viewer – JetStream Roamer
… against PDMS 3D model, directly on production floor
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Designing for Quality
Tools – Document handling – ProArc
Simplifies retrieval and reuse of existing documentation
• Full control of all projects documents
• Access restrictions fully applied
• Traceability every revision available if needed
• Time saver for both Document Control and for the project
• Forced use of templates ensure company standards
• Streamlines day-to-day work: tasks flow to the participant
• Document deliveries to and from the customer
•
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Designing for Quality
Tools – Document handling – ProArc
20112 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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Designing for Quality
Tools – Enterprise Resource Planning - Movex
… and for everything else 
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Designing for Quality
Tools – Product Data Management – DePlan
Design, Engineering and Planning
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Designing for Quality
Tools – Product Data Management – DePlan
• Material management
– article database
– object data from PDMS and Comos
– add non PDMS or Comos material manually
– a bridge between CAD and ERP systems
• System integrator
– data between Comos and PDMS
– data from Comos and PDMS to Validation (ComDB)
• Planning
– tool for making quotations
– forecast orders
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Designing for Quality
Case study
• Introduction
– Conventional construction
• Industrialization
– Concurrent engineering
– Prefabrication
• Case study
– Information Systems overview
– Integrated systems
• Summary
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Designing for Quality
Interoperability – CAD/PDM/ERP framework concept
• In new millenium further development of ERP class systems
is the integration with other functions
within the entire enterprise
• The integration enables faster delivery of quality products,
realizing intangible but significant value-addition
to the total quality image of the firm
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Designing for Quality
Interoperability – CAD/PDM/ERP framework concept
• When enterprise-wide integration is achieved
without functional barriers, speedy access to information
empowers the employees.
• Enterprise-wide integration will drive the company
towards global rather than local optimisation
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Designing for Quality
Interoperability – CAD/PDM/ERP
CAD
PDM
Engineering &
Design
Specs
P&ID
BOM
Drawings
3D Model
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ERP
Designing for Quality
Interoperability – CAD/PDM/ERP
CAD
PDM
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ERP
Designing for Quality
Interoperability – From Design to Delivery
• Single point of entry for all data
• Starting at the P&ID and data sheets, into the 3D model. Then on to supply,
construction and validation, where non critical systems are checked out via
handhelds (PDA’s)
• Documents created are automatically put in document management
system, where they are electronically signed.
• Digital data and documents are put in clients maintenance systems.
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Designing for Quality
Summary
• Introduction
– Conventional construction
• Industrialization
– Concurrent engineering
– Prefabrication
• Case study
– Information Systems overview
– Integrated systems
• Summary
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Designing for Quality
Summary
In conventional construction,
where project organization is scattered with barriers between
different subcontracting companies for engineering,
procurement, construction and validation,
such integration would be extremely difficult
… or not possible at all
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Designing for Quality
Summary
Information systems interoperability
is a mandatory foundation for
integration of engineering, design, supply, construction and validation
into one seamless flow, that directly impacts
quality and lead time
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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Introductory lecture
a company may need as many information
systems as many business functions there
is, or even more ...
2?
5?
10?
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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15...?
Designing for Quality
Interoperability – From Design to Delivery
Engineering
Supply
Construction
Client
Production
Articles
Master
Tagged
Objects
Master
(Engineering)
After Sales
Site
Article DB and Material management: DePlan
MC/Comm./
Validation:
ComDB
P&ID/
Data
sheets:
Comos
Operation &
Maintenance
ERP:
Movex
Industrialized
Untagged
Objects
Master
(Design)
modular production
3DCAD:
PDMS
Modules
Documents
Master
Document Handling: ProArc
2D CAD:
AutoCAD
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3D Review:
NavisWorks
Data
warehouse
with access to
all project
information.
Published &
Linked
Introductory lecture
a company may need as many information
systems as many business functions there
is, or even more ...
... this may result in dozens of systems
... and they all need integrations
2012 MARM21 MES8610 Information Systems of Production Management Roman Zahharov
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Introductory lecture
... all functions meet up in production,
where value is added to a product
... then all information crosses at
production management system
... then it becomes difficult to manage it
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Individual in a team
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Designing for Quality
References
•
•
•
•
•
•
Josephson, P.-E., and Saukkoriipi, L. (2005). Slöseri i byggprojekt – Behov av
förändrat synsätt (Waste in construction projects. Need to change approach), FoUVäst report 0507, Gothenburg, Sweden
Koskela, L. (1992). Application of the new production philosophy to construction,
Technical report no. 72, CIFE, Stanford University, Stanford, California, USA
Alinaitwe, H., Mwakali J., and Hansson B. (2005). Labour productivity in the
building construction, Proceedings of CIB 2006, W065/W055/W086 – Construction
in the XXI Century: Local and global challenges, October 2006, Rome, Italy
Azam Forsberg, A., Saukkoriipi, L. (2007). Measurement of waste and productivity
relation to lean thinking, Proceedings IGLC-15, July 2007, Michigan, USA
Yahaya Y. Yusuf, Little, D. (1998). An empirical investigation of enterprise-wide
integration of MRPII, International Journal of Operations & Production
Management, Volume 18, Page: 66 – 86
Shevstsenko, E., Zahharov, R., Karaulova, T. and Wang, Y. (2008) Developing
integrated CAD/ERP framework for industrialization of modular construction
through lean manufacturing concepts, DAAAM International Scientific Book 2008
Volume 7, Page: 759-772, Vienna.
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13 May 2012