INDUSTRIAL CASE: HOMAG
Company Profile – HOMAG Group AG
U. Doll – HOMAG
Worlds Leading Manufacturer of
Machines, Plants and Systems for Wood Working
Furniture (84%)
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Structural Elements (12%)
Founded in 1960
798 Mio € Turnover (2011)
5110 Employees (2011)
9 domestic Producing Companies
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timber frame house
construction (4%)
6 International Production Sites
21 Directly Owned Sales and
Servicing Companies
130 Sales Partners
Slide 2
Company Profile – HOMAG GmbH
U. Doll – HOMAG
• Machine classes produced at
HOMAG GmbH, Schopfloch
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single-sided edge-banding
double-sided edge-banding
double-end-tenoner
CNC machining center
• Very heterogeneous requirements regarding
work pieces (dimensions, material, features),
productivity and flexibility
• Machines are individually configured using a
construction kit with “machine units” to fulfill
customer requirements
• For higher productivity machines are
combined with handling and automation
equipment to automated production lines
• Offers services in factory and production
planning
Slide 3
AS-IS situation
U. Doll – HOMAG
Requirement of HOMAG to support of the Production Planning procedure with
the four main Planning Phases:
Slide 4
Factory
Operation
Management
of KPIs and
requirements
Simulation
Production
Design
Current weakness/needs
U. Doll – HOMAG
Main Weaknesses of the current Factory Planning Procedure
• Heterogeneous planning tools
• Some planning steps are not supported by tools (e.g. requirements)
• Simultaneous/collaborative planning using the same data is not possible
• Missing feedback from planning results
• Limited re-use of experience from previous projects
Slide 5
HOMAG Scenario
U. Doll – HOMAG
Slide 6
TO-BE Situation
U. Doll – HOMAG
HOMAG Next Factory Scenario:
• Planning of a new furniture production
Line, consisting of HOMAG machine
units
• Performance indicators, customer
requirements on capacity and further
planning constraints
• Support and improvement of the HOMAG
factory planning procedure:
• Use of new and integrated VFF
modules and their functionalities
• Integration with the Virtual Factory
Framework
Slide 7
HOMAG Scenario - Overview
U. Doll – HOMAG
Requirements
Management and KPI
Planning
RMP (ETHZ & NOVA)
HIL Simulation
(Factory Operation)
PAD (Tecnalia)
Requirements
Management
KPI
Planning
Discrete Event
Simulation
EUVEDES
(Tecnalia)
Production
Resource Planning
Simulation
Control Station for
Production Fine
Planning
FPS (PSI)
Knowledge
Association
Engine KAE
(LMS)
VF Manager
Assignment of
Customer
Orders
Factory
Performance
Factory
Performance and
Process Planning
FP³ (FhG-IPA)
VFF functional modules
Planning steps
Slide 8
Pilot Case
U. Doll – HOMAG
• Produce order specific office furniture (e.g. cabinets, tables, separating walls,
from 300x230x10 up to 2810x1010x25) in batch size one production
• Edge and finish processing
• Requirements on production line: To produce approx. 900000 parts per year
• First implementation of pilot case with the use of new and integrated VFF
modules and their functionalities
Slide 9
U. Doll – HOMAG
Slide 10
HOMAG Scenario - Speakers
U. Doll – HOMAG
HOMAG
HIL Simulation
(Factory Operation)
PAD (Tecnalia)
Requirements Management
and KPI Planning
RMP (ETHZ & NOVA)
Requirements
Management
KPI
Planning
Tecnalia – Simulation Team
Discrete Event
Simulation
EUVEDES
(Tecnalia)
Production
Resource Planning
Simulation
Control Station for
Production Fine
Planning
FPS (PSI)
VFF functional modules
Planning steps
Knowledge
Association Engine
KAE (LMS)
VF Manager
Assignment of
Customer
Orders
Factory
Performance
Factory
Performance and
Process Planning
FP³ (FhG-IPA)
FhG-IPA – Production
Planning Team
Slide 11
Conclusion
U. Doll – HOMAG
HOMAG Next Factory Scenario Planning
Results and Conclusion:
• New and optimized Furniture Production
Line for HOMAG
(Designed Production Resources consists of
2 edge banding machines and their machine
units, feedings with an integrated buffer
station, 2 turning stations, one angular transfer
all connected by conveyors)
• Fulfilled Customer Requirements on Line
Capacity and other Planning Constraints
M05_KFL610
• Application of new planning
functionalities of VFF modules
• Enhanced planning performance
due data storage and transfer via
VFF Repository
M06_Rotating
M07_Handover
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12
Shape
Milling
Shape
milling
11
Cutting
10
9
Bending Trimming
15
output
input
14
Rotating
90°
8
Handover
1
2
Handover
3
Rotating
Handover
Trimming
90°
M01_Handover
4
5
Bending
Cutting
6
7
Shape
milling
Shape
Milling
M04_Dual_Angle_Transfer
M02_Rotating
M03_KFL610
Slide 12
Benefits
U. Doll – HOMAG
Benefits:
Improvement of planning performance (Planning
time, Planning effort)
• Integrated planning framework
• Optimized tools for the different planning tasks
Improvement of planning quality (Fulfillment of
customer requirements)
• Direct propagation of planning results to all other
planning instances  Collaborative planning
• Closed control loop between requirements and
planning results
Improvement of standardization (Past and
alternative solutions)
• Offering best practice knowledge
• Reuse past similar manufacturing line
and configurations
Slide 13
U. Doll – HOMAG
HOMAG Next Factory Scenario - Storyline
HOMAG Next Factory Scenario – Actions
1. Collecting the Requirements and setup of the Performance Measurement System. Map
and align KPIs, to set target values and also to define constraints in a structured way.
Constant Monitoring of KPI throughout the planning project. (ETHZ)
2. Analysis of past similar resources and production line configurations. Retrieve and reuse
of past solutions based on sample past manufacturing lines. (LMS)
3. Production Resource Planning and Capacity Calculation. Further Technical and
Economical Calculations. Calculation of defined performance indicators of the
manufacturing line. (FhG-IPA)
4. Create production sequence for customer orders (planned production steps) within
HOMAG Production line. Virtual Production Sequence used in further simulations. (PSI)
5. Discrete Event Simulation of the HOMAG production line simulating the Capacity and
Energy Consumption with fine planned and optimized production sequence. (Tecnalia)
6. HIL simulation for the calculation of optimized cycle times for the production sequence
with collision detection. Calculation of KPI referred to the cycle time.
(Tecnalia)
Slide 16
HOMAG Next Factory Scenario - Storyline
HOMAG Next Factory Scenario – Conclusion
• Constant monitoring and control of Key Performance Indicators and
Performance Requirements of the HOMAG Line.
• Suitable past production line configurations used as a basis for the planning
project.
• Production Resources and Processes have been planned and the line capacity
is calculated.
Further Technical and Economical Calculations have been performed.
• Production sequence for customer orders (planned production steps) within
HOMAG Production line have been established
• Capacity and Energy Consumption has been simulated and verified with the
required line performance.
• Visualisation and optimisation of production sequence and smaller gap between
the parts to be produced.
Slide 17
Requirement Management and Planning Module
RMP HOMAG Scenario
Planning Tasks
Import:
Functional Requirements, KPIs,
target values, planning
constraints [from HOMAG
Customer].
Executed Planning Tasks:
Collecting the Requirements
and setup of the Performance
Measurement System. The
module helps to collect a rough
process idea, to map and align
KPIs, to set target values and
also to define constraints in a
structured way.
Export:
KPIs, Target values, Rough
Process Description, Planning
constraints
[to all Scenario Partners via
Virtual Factory Manager]
Figure: RMP Module - Screenshot
Knowledge Repository and Knowledge Association Engine Module
KR-KAE HOMAG Scenario
Planning Tasks
Import:
KPIs Target Values [from RMP
module via Virtual Factory
Manager].
Sample Resource Structures
and pasts solutions concerning
resource planning from
HOMAG.
Executed Planning Tasks:
Propose past similar resources/
production line configurations.
The module helps to retrieve
and reuse past solutions based
on sample past manufacturing
lines.
Figure: KR-KAE Module - Screenshot
Factory Performance and Process Planning Module
FP³ HOMAG Scenario
Planning Tasks
Import:
Customer Requirements
concerning Capacity and
required Production Processes
[from RMP Module via Virtual
Factory Manager].
Executed Planning Tasks:
Production Resource Planning
and Capacity Calculation.
Further Technical and
Economical Calculations
Export:
Process sequence and related
Resource Structure of the
planned HOMAG Line,
Calculated KPI values (e.g.
Calculated Capacity Per Year,
Loading Of Production, …)
[to all Scenario Partners via
Virtual Factory Manager]
Figure: FP³ Module - Screenshot
Fine Production Planning Module
FPS HOMAG Scenario
Planning Tasks
Import:
Process sequence and related
Resource Structure of the
planned HOMAG Line,
[from FP³ via Virtual Factory
Manager]. Planned Production
Steps [from HOMAG ERP
System and integration into the
VFF Repository]
Executed Planning Tasks:
Create production sequence for
customer orders (planned
production steps) within
HOMAG Production line.
Export:
Planning Sequence – Fine
Planned Production Steps [to
DES module via Virtual Factory
Manager] and KPI Required
Handover Cycle Time [to RMP
module via Virtual Factory
Manager].
Figure: FPS Module - Screenshot
Resource Structure /
Machine
Configuration
Representative set
of customer orders
(Operational data)
FPS module
FPS business
logic
VFF/FPS
Connector
Planning Sequence
-Production
Steps
Average Cycle Time
for a defined
Machine Unit
Discrete Event Simulation Module
DES HOMAG Scenario Planning
Tasks
Import:
Production sequence including
parts order and machines cycle
times. [from FPS via Virtual
Factory Manager]
New Production Sequence with
updated cycle times from [from
PAD via Virtual Factory Manager]
Executed Planning Tasks:
Simulation of the HOMAG
production line simulating the
Capacity and Energy Consumption
with fine planned cycle times (from
FPS) and simulated, optimized
cycle times from PAD)
Figure: DES Module - Screenshot
Export:
Simulated Capacity and Energy
Consumption of the production line
taking into consideration machines
downtimes. [to RMP and PAD
module via Virtual Factory
Manager]
Closed Loop based on Process Automation Designer Module
Figure: PAD Module –
Screenshot
PAD HOMAG Scenario
Planning Tasks
Import:
Customer Requirements
concerning the Production
Process. Production schedule
with Fine Planned Production
Sequence Steps [from FPS via
Virtual Factory Manager]
Executed Planning Tasks:
HIL simulation for the calculation
of new optimized cycle times
with collision detection. KPI
referred to the cycle time
concerning the handover
machine.
Export:
Revised Simulation Input Data
(Optimized Production
Sequence according to the
Simulation) for the DES module
via Virtual Factory Manager.
KPI referred to the cycle time of
the handover machine [to RMP
module via Virtual Factory
Manager]
Output to VFM
• KPI cycle time
for the critical
machine.
Input from
VFM
Production
sequence ( from
virtual customer
orders)
• Optimized times
in production
sequence ( for
virtual customer
orders )
Production
Operations
Cycle Time KPI
Updated
Production
Operations
Parts Data
Import
Export
Requirement Management and Planning Module
RMP HOMAG Scenario
Planning Tasks
Import:
Functional Requirements, KPIs,
target values, planning
constraints [from HOMAG
Customer].
Executed Planning Tasks:
Collecting the Requirements
and setup of the Performance
Measurement System. The
module helps to collect a rough
process idea, to map and align
KPIs, to set target values and
also to define constraints in a
structured way.
Export:
KPIs, Target values, Rough
Process Description, Planning
constraints
[to all Scenario Partners via
Virtual Factory Manager]
Figure: RMP Module - Screenshot
HOMAG Next Factory Scenario - Storyline
FhG-IPA
HOMAG Next Factory Scenario – Subjects
o Planning of a new furniture production Line for HOMAG
o Planning Focus is the fulfillment of customer requirements on capacity and given
planning constraints.
o Support and improvement of the HOMAG factory planning procedure
Slide 25
HOMAG Next Factory Scenario - Storyline
FhG-IPA
HOMAG Next Factory Scenario – Actions
1.
Collecting the Requirements and setup of the Performance Measurement System. Map and align
KPIs, to set target values and also to define constraints in a structured way. Constant Monitoring
of KPI throughout the planning project.
2.
Analysis of past similar resources and production line configurations. Retrieve and reuse of past
solutions based on sample past manufacturing lines.
3.
Production Resource Planning and Capacity Calculation. Further Technical and Economical
Calculations. Calculation of defined performance indicators of the manufacturing line.
4.
Create production sequence for customer orders (planned production steps) within HOMAG
Production line. Virtual Production Sequence used in further simulations.
5.
Discrete Event Simulation of the HOMAG production line simulating the Capacity and Energy
Consumption with fine planned and optimized production sequence.
6.
HIL simulation for the calculation of optimized cycle times for the production sequence with
collision detection. Calculation of KPI referred to the cycle time concerning the handover machine.
Slide 26
HOMAG Next Factory Scenario - Storyline
FhG-IPA
HOMAG Next Factory Scenario – Conclusion
o
Constant monitoring and control of Key Performance Indicators and Performance Requirements of
the HOMAG Line.
o
Suitable past production line configurations used as a basis for the planning project.
o
Production Resources and Processes have been planned and the line capacity is calculated.
Further Technical and Economical Calculations have been performed.
o
Production sequence for customer orders (planned production steps) within HOMAG Production
line have been established
o
Capacity and Energy Consumption has been simulated and verified with the required line
performance.
o
Visualisation and optimisation of production sequence and smaller gap between the parts to be
produced.
Slide 27