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SAIL

SAIL. A Daily Scheduling and Performance Measurement System for Flexible Machining Systems. SAIL Overview. A Plan for Machine Productivity Challenges Build to Order High Product Mix Daily Quantities Shared Tools and Fixtures. Unique Features. Simulation based forward schedule

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SAIL

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  1. SAIL A Daily Scheduling and Performance Measurement System for Flexible Machining Systems

  2. SAIL Overview • A Plan for Machine Productivity • Challenges • Build to Order • High Product Mix • Daily Quantities • Shared Tools and Fixtures

  3. Unique Features • Simulation based forward schedule • Download Schedule to Cell Control • Monitor/Broadcast Cell Performance • Cost per Part Tracking

  4. Unique Feature #1Simulation Based Forward Schedule • Plans Shift-by-Shift Quantities • Plans Days or Weeks in Advance • Targets schedule at a planned level of machine utilization • Sequences Part Numbers Through… • Shared fixtures/pallets • Tools Groups • Schedules Setups

  5. Unique Feature #2Download Schedule to Cell Control • Instructions from Daily Schedule • Rolls out as operation progresses • Routing Instructions • Pallet Active • Pallet Cycles • Part Program to Run • Machine List • Load Station List

  6. Unique Feature #3Monitor/Broadcast Cell Performance • Records Production by Part Number • Fills in Daily Schedule Grid • Calculates Actual Machine Use • Provides Daily,Weekly,Monthly Totals • Web Page Formats • Access via Factory Network or Internet

  7. Unique Feature #4Cost Per Part Tracking • Based on the MAST Cost Model • Machine Depreciation Per Year • Hourly wage plus benefits • Overhead cost applied annually • Uses actual production to apply cost • Details efficiency and burden costs

  8. SAIL Data Flow Diagram Job Management System Factory Communications Daily / Weekly Scheduling Performance Monitoring Cell Controller CNC Controls Load Station Control

  9. Cell Management from scheduling to shop floor through synchronized execution of software and hardware systems.

  10. SAILData Flow Diagram Job Management System Factory Communications Daily / Weekly Scheduling Performance Monitoring Cell Controller CNC Controls Load Station Control

  11. Daily / Weekly Scheduling • Planned Hours of Operation • Number of Hours per Day • Number of Days per Week • Shift Start and End Times

  12. Sample Planning Period Screen

  13. “Optimal” Daily Operational Plan • List of Parts with Production Quantity • Shift-by-Shift Quantity to Produce • Pallet – Fixture Required • Considers Tool Conflicts • Considers Pallet / Fixture Conflicts • Balances Work over all Machines • Fills Schedule to Planned Machine Use

  14. Sample Daily Schedule

  15. SAILData Flow Diagram Job Management System Factory Communications Daily / Weekly Scheduling Performance Monitoring Cell Controller CNC Controls Load Station Control

  16. Download Routing Instructions • Pallet Routing Instructions • Pallet Number • Part Number • Number of Cycles • Part Program Number • List of Machines to Use • List of Load Stations to Use

  17. Sample Routing Instructions Screen

  18. SAILData Flow Diagram Job Management System Factory Communications Daily / Weekly Scheduling Performance Monitoring Cell Controller CNC Controls Load Station Control

  19. Performance Monitoring • Production Counts • Records actual production completed against planned quantities • Maintains history of Actual Production

  20. Daily Schedule with Actual Production

  21. Performance Monitoring • Weekly – Monthly Totals • Daily Totals Summarized Weekly or Monthly • Machine Use Averaged

  22. Weekly Totals Screen

  23. Performance Monitoring • Machine Use by Shift • Records Elapsed Time • Uses Current Production • Determines Actual Use

  24. Daily Schedule with Machine Use

  25. Performance Monitoring • Pallet Flow Time • The pallet flow time monitor displays the elapsed time from when a pallet leaves the load station until it leaves the load station its next time. This elapsed time includes the transport time, machine cycle time, waiting in machine queue or buffer stand, and the load – unload time. All time that it takes to cycle the pallet is captured and reported.

  26. Pallet Flow Time

  27. Performance Monitoring • Machine Cycle Time • The Machine Cycle Time is a display of the observed cycle times at the machines. These cycles are the elapsed time from a cycle start to cycle end.

  28. Machine Cycle Time

  29. SAILData Flow Diagram Job Management System Factory Communications Daily / Weekly Scheduling Performance Monitoring Cell Controller CNC Controls Load Station Control

  30. Web Page Broadcast of Performance • Monitor Current Schedule of Work • Monitor Expected Completion Times of Jobs • Monitor Machine Productivity • Monitor Cost per Part

  31. Sample Web Page

  32. Case StudyTEAM Industry Problem • Their machine utilization and throughput were not running at full potential. Results of SAIL • Increase machine utilization and throughput from 60% to 80% • Add 1000 hours of machine hours per man per year.

  33. Case StudyLarge Midwestern Corporation Problem • They wanted to determine the impact of unallocated burden on manufacturing cost. Results of SAIL • SAIL’s cost model allowed for a planned cost that is adjusted using efficiency to determine an actual manufacturing cost

  34. Case StudyThermoking Corporation Problem • Machine utilization and Throughput was not at maximum level. Results of SAIL • Operators who were used to 50-70 parts per shift were now producing 400 parts per shift. • Machine utilization was now at 85%.

  35. Case StudySouthern Manufacturer Problem • Had a two machine system, with room for expansion, but hesitated because of low machine utilization. Results of SAIL • Machine utilization reached 85% • They now could easily justify the third machine expansion.

  36. A Management System that • Starts with the Factory Order System • To Generate an Optimal Shift-by-Shift Schedule • That downloads Instructions to the Cell Control • For Execution and Operation • While Monitoring and Broadcasting Performance

  37. Target Users/Applications • SAIL is a tool designed for manufacturers with flexible machining systems, automated machine cells, and automated handling systems. • Three days of training are recommended for use of this software. Additional training is required to integrate SAIL to other computer systems such as factory systems and cell control computers.

  38. SAIL

  39. CMS Research, Inc. 1610 S. Main Street Oshkosh, WI 54902 Tel: 920.235.3356 Fax: 920.235.3816 cms@cmsres.com

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