Zanussi & Cybertec Meeting

1. Zanussi & Cybertec Meeting Susegana, 2/3/1999

2. Meeting Agenda • About Cybertec • The CyberPlan Planning & Scheduling Suite • Cybertec Projects at Electrolux Zanussi Cold Division in Susegana CYBERTEC - The Planning and Scheduling Company

3. About Cybertec • Company • Vision • Technology • Products • Services • Customers • Partners CYBERTEC - The Planning and Scheduling Company

4. Cybertec: The Planning & Scheduling Company • Mission: Help industrial Customers to increase resource utilization and service level and reducing stocks, product cost and human efforts • Established in 1992 • Average Annual grow > 50% • 40 focused people; 90% graduated or PHD; • Most consultants APICS CPIM certified CYBERTEC - The Planning and Scheduling Company

5. Vision • Planning & Scheduling is an Hard Problem • High improvement available through resource optimization and process synchronization • The Computing Power has increased by orders of magnitude while the complexity of the planning problem only few times CYBERTEC - The Planning and Scheduling Company

6. Cybertec Core Technology • Hardware resources • Ram based Data Bases • Cluster Of Computing Nodes • Software tools • C++, Java, Windows NT, Corba • Optimization techniques • Discrete Simulation, Constraints, LP,GA,…. + Practical Experience! CYBERTEC - The Planning and Scheduling Company

7. Products • A complete suite of products for repetitive and complex equipment industries: • Planning • Programming • Scheduling • Management Execution Systems CYBERTEC - The Planning and Scheduling Company

8. Services • Consulting • Education • Implementation • Integration • Special Projects for Hard Optimization CYBERTEC - The Planning and Scheduling Company

9. Customers Logo CYBERTEC - The Planning and Scheduling Company

10. Automotive Clothing Electric Electronic Food & Beverage Heavy Equipement Paper Pharmaceutical Plastics Ship building Steel Textile … Customer Industries CYBERTEC - The Planning and Scheduling Company

11. Consulting Companies ERP Vendors MES Integrators SW Houses Universities Arthur Andersen Atos Consulting IBM JDE ORACLE SAP Orsi ... Partners CYBERTEC - The Planning and Scheduling Company

12. The CyberPlan Planning & Scheduling Suite • SCD Supply Chain Designer • MPS Master Production Schedule • MRP Material Requirements Planning • CRP Capacity Requirements Planning • FCP Finite Capacity Planning • FCS Finite Capacity Scheduling CYBERTEC - The Planning and Scheduling Company

13. Planning: designing for performances! • To meet the market requested performance ( service level, lead times, costs) You have to design for them • CyberPlan Supply Chain Designer is a new, long waited, tool that allowes to design for performace • Resource planning (equipements, personnel, tools,..) • Safety stocks and all other MRP parameters • Purchasing contract conditions (due dates, qty, safety stocks, min-max deviation,...) • Same data and model used by your ERP CYBERTEC - The Planning and Scheduling Company

14. Cybertec Projects at Electrolux Zanussi Cold Division-Susegana CYBERTEC - The Planning and Scheduling Company

15. Zanussi & Cybertec Projects • Completed • Short Term FCS in the moulding dpts • Current • FAS & MPS Phase 1 • Automated Optimal Final Assembly Scheduling • Planned • FAS & MPS Phase 2 • Automated Optimized Master Production Schedule • Integration with Demand Management System CYBERTEC - The Planning and Scheduling Company

16. A brief introduction It was a ‘97 project The problem was to build an automated schedule for the daily activities of the two production departments Innerliner Thermofoaming and Innerdoor Thermofoaing. We started with one department and after successful implementation we dealt with the other one. The daily scheduling activities involved very experienced employees. Short Term Finite Capacity Scheduling in the Innerliner Thermofoaming and Indoor Thermofoaming departments CYBERTEC - The Planning and Scheduling Company

17. The goals • Main goal: let not-experienced employees schedule the department by giving them a computerized scheduling system. • Other benefits required: • Updated scheduling plans. • More detailed scheduling of the production activities. • More constraints under the planner control. • More activities better organized (machine changeover, purchasing material call-out). CYBERTEC - The Planning and Scheduling Company

18. A hard set of constraints A set of production requests with hourly due - dates for the next three days (or more). Production & changeover activities. Finite number of: machine operator crews set - up crews moulds Sequence dependent changeover costs: change mould change version (slight modification of the mould) same mould (change of material color) The scheduling problem CYBERTEC - The Planning and Scheduling Company

19. Output: • A production schedule for each machine such that: • satisfies the given constraints • minimizes the changeover costs • minimizes the due dates violation CYBERTEC - The Planning and Scheduling Company

20. Problem features • Why the problem was so difficult • Several contraints (changeover crew, operator machine crew, moduls, …) • Sequence set - up optimization • System was to be able to suspend a production lot and continue with a more urgent lot • Very strict lots due dates • Moreover…. • Easy to use and fast response system (few seconds…) • Very low level interaction with the computerized system CYBERTEC - The Planning and Scheduling Company

21. The solution Based on CyberPlan Standard Scheduling Technology: • This was the best technology availiable to solve the problem due to the number of production lots (hundreds) to be scheduled, the variety of the constraints, and the response time required. CYBERTEC - The Planning and Scheduling Company

22. Goals reached • CyberPlan is now scheduling the production of both departments • For more than one year CyberPlan has been helping to better organize the production in the Innerliner Thermofoaming and Innerdoor Thermofoaming departments • The scheduling of the activities in both departments are managed now by “no - guru guys” CYBERTEC - The Planning and Scheduling Company

23. What could be done New Cybertec Advanced Scheduling Technology could be applied to reach an even better performance in the production department What will be done Cybertec Advanced Scheduling Technology to optimize the MasterProduction Schedule & Final Assembly Scheduling Next steps CYBERTEC - The Planning and Scheduling Company

24. Automated Final Assembly Scheduling (FAS) CYBERTEC - The Planning and Scheduling Company

25. FAS: a brief introduction • Building a FAS follows the choice and qty of finished products to be produced in a given week. • The FAS consists in building a feasible and optimized schedule for finished products on the assembly lines. • It is the heart of the factory as it drives the production and purchaising (call out) flows of the factory. • FAS gives the “drum beat” to all of the activities in the factory. • As Zanussi-Susegana is a real Synchronous Manufacturing Environment, the FAS defines the feasible and optimal production flow of all production departments CYBERTEC - The Planning and Scheduling Company

26. The goal of FAS project: • There are a lot of critical aspects the planner has to deal with to get a feasible and optimized FAS • The goal is to give the FAS planner a computerized system that can help him in building and maintaining a feasible and optimized schedule. • Moreover, with the support of this system the user will be able to control more constraints and optimization aspects of the production process. CYBERTEC - The Planning and Scheduling Company

27. Two different technological areas with different scheduling problems • There is a substantial difference between the two main areas of the assembly process • Traditional Assembly Lines • Scheduling Problem: • Find a feasible and optimal schedule of production lots • Automatic Assembly Lines • Load Balancing & Scheduling problem • Find a production daily rate and optimal schedule of production lots CYBERTEC - The Planning and Scheduling Company

28. The FAS Scheduling Problem • Due dates of the production lots • Sequencing rules that are used to optimize the chenge over costs in the production flow • At present, more seven sequence optimization rules must be taken simultaneously in count when building a schedule! • Critical constraints that must be satisfied • Foaming Moulds • Welding Machine • Critical resources that must be highlighted • “Round Door” production CYBERTEC - The Planning and Scheduling Company

29. The Loading Problem • Definine the optimal daily production rate for each automatic assembly line under • Capacity constraints • no more than x items can be produced in a given “ring” • Optimization criteria • a given efficiency must be guarantee CYBERTEC - The Planning and Scheduling Company

30. The FAS System Schedule Assembly Line Scheduling CYBERTEC - The Planning and Scheduling Company

31. The FAS critical resources load Overload! CYBERTEC - The Planning and Scheduling Company

32. The New Automated MPS System CYBERTEC - The Planning and Scheduling Company

33. Automated Optimized Master Production Scheduling System • The problem is to define which finished products have to be produced in each week of the planning period • Problem data: • a customer priority class • a minimum level of customer service for each class of priority • a minimum level of resourcce utilization • a set of customer’s requests for each week • the assembly lines capacity and the capacity of other critical resources • the bill of critical resources of each product • a set of production constraints (min production lot for model plant or pnc, max …) CYBERTEC - The Planning and Scheduling Company

34. Quality optimization measures • A feasible master production plan • defines what to produce (which finished products) and how much (how much for each PNC) under respect of the capacity constraints • Customer Service level • for each priority class the customer service level is defined: • (number of satisfied customers’ demands)/(number of customers’demands) CYBERTEC - The Planning and Scheduling Company

35. The goal • Find an automated feasible master production plan which: 1. guarantees a minimum level of customer service 2. the remaining capacity is allocated to satisfy the customers’ demands according to the priority class defined CYBERTEC - The Planning and Scheduling Company

36. Output • The amount of each PNC (finished product) that must be produced on week_i • The list of customers’ demands which will be satisfied • The list of customers’ demands which will not be satisfied • The level of customer service • The level of resources utilization • Alarms CYBERTEC - The Planning and Scheduling Company

37. Input Customer Priority Class Customer Requests CYBERTEC - The Planning and Scheduling Company

38. Fast & Easy Execution Executing Command CYBERTEC - The Planning and Scheduling Company

39. Unsatisfied constraints Unsatisfied Customer Requests CYBERTEC - The Planning and Scheduling Company

40. Results Control Panel showing the customer satisfaction level Master Production Schedule Workbench CYBERTEC - The Planning and Scheduling Company