Advanced Scheduler for Wonderware MES

1. Advanced Scheduler for Wonderware MES Chris Mollison Scheduling Solutions

2. Introduction Project Solution Agenda Benefits Considerations Summary

3. Background to the Project • This presentation shows how the Preactor scheduling functionality has been integrated with Wonderware Operations 3.4 • It discusses the benefits of using finite scheduling functionality. • It reviews the results obtained at Aquacolor where Wonderware Operations and Preactor are integrated

4. Background to the Project Make Unit Preparation Batching Receive Ship Packaging Manufacturing Order Management Enterprise Integration Finite Scheduling Dispatching Material Management/ Formula Manufacturing Performance Management Manufacturing Reporting/ Analysis/ Dashboard In Line Product Quality Compliance Equipment Condition Monitoring Production Capacity Management (OEE, TEEP) Deviation/ Yield Management/ Scrap Rework Material Management Material Receivables Food and beverage solution map Pre-Weighing/ Dispensing Inventory Material Management Material Quality Inspection Manufacturing Operations Execution WIP Status Management Production Practices Enforcement (multi Unit) Product Traceability Brand Integrity/ Quality Sample Plan Management Container Management (Tote bin management) Regulative Compliance (HACCP) Batch/ Process Execution Batch/ Unit Execution Final Inventory Process Automation Control Bar Code Printing Secondary Production Execution RFID Coding Production Order Execution Shipping Execution Discrete Automation Control

5. Project Goals • To create a certified integration between Wonderware Operations 3.4 and Preactor.

6. Introduction Project Solution Agenda Benefits Considerations Summary

7. Where does APS fit? ERP MES APS Automation System Control Jurgen Kletti, 2008

8. APS Role in MES Fills the MESA function group for detailed planning: Sequence and time optimization of the orders finely tuned to the performance of the machines, including their finite capacity and relationship to other resources

9. Why is scheduling different from planning? • Planning systems are bucketed (monthly, weekly, daily) and cannot preserve operation sequences within the time bucket • True scheduling systems are bucketless, preserving sequencing, and capable of generating work-to or dispatch lists. • Assignment of operation to resource is a key function to achieve operational efficiency and optimizing performance

10. SAP APO • APO is a global Supply Chain solution • APO is made up of several modules : • Collaborative Planning (CP) • Supply Chain Cockpit (SCP) • Demand Planning (DP) • Supply Network Planning (SNP) • Production Planning & DetailedScheduling (PP/DS) • Global Available-to-Promise • Preactordoes not competewith APO, but onlywith the “Production Planning & DetailedScheduling” (PP/DS) module of APO

11. Limitations PP/DS for MES • PP uses an MRP calculation with infinite capacity and large planning and scheduling ‘bucket’ sizes (typically a week) and mid/long term vision • Hence a planning system with all the limitations • DS does not link dependent WOs (pegging), it uses launch date data, • No synchronization of materials between dependent WOs or WOs to WOs • APO uses heuristics technology • Very difficult to parameterize • Solver cycle long and not repeatable • Very difficult for users to understand • Limited, rigid rule set

12. Where does APO fit? ERP/PPS CP SCP DP SNP GATP MES APS

13. Why Preactor? • Founded in 1993 – 15 years of experience in developing and implementing scheduling solutions • Microsoft Gold Partner • International coverage across 5 continents • Over 10 000 licenses sold

14. Preactor’s Install Base Why Preactor? Since its first release in 1993 more than 10,000 Preactor scheduling systems have been installed in the broadest range of verticals…..

15. Data Flow • Production Order • item • qty • date ERP SYSTEM • Operations management • production process • recipe management • inspection • tracking Wonderware Operations 3.4 • Sequencing • sequencing logic • dates & times • resources to use APS

16. Integration with Wonderware Operations Work Order Wonderware Ops (MES) Data Sent per Op Scheduled Start Time Target Scheduled Resource Data Sent per Op Initial Scheduled Resource Required Finish Time Priority Route constraints Actual Start Time Preactor APS

17. Integration structure • Demand passed from Operations 3.4 to Preactor APS • Schedule is released from Preactor APS to Operations 3.4 • Context sensitive windows in Preactor shows data from WIS • Resource calendar exceptions sent from Operations 3.4 • Shop floor data updates Preactor APS • Static data synchronized from Entities • Preactor Gantt charts available though WIS Links with Operations 3.4 Wonderware's Operation Modules (Factelligence) Supply Chain Connector Clients

18. Integration Example

19. Flash Demo of Preactor

20. Aquacolor • Aquacolor is also heavily involved in the development of applied nanotechnology for textiles finishing and works with leading fashion brands including Levi Strauss, Burberry, Hugo Boss and Trussardi • The ability to respond to this and consistently deliver high levels of customer service depends on a solid yet flexible manufacturing approach • Different orders may require different levels of dyeing, washing and finishing yet challenges exist for some orders may require repeat operations – typically washing - with some processes – typically dying – involving correction and adjustments during the actual process • Every order may be different

21. Aquacolor • Aquacolor are a Wonderware user and they wanted improved management over shop floor operations. • They selected Wonderware Operations (originally Factivity) to provide the required functionality. • Factivity does not have inbuilt scheduling functionality so Aquacolor selected Preactor to provide this capability.

22. Introduction Project Solution Agenda Benefits Considerations Summary

23. Wonderware Operations - benefits • Benefits achieved from Wonderware Operations implementations • Improved control of operations • Improved recipe management • Improved traceability

24. Preactor - benefits • Benefits achieved from Preactor implementations • VISIBILITY • Decision support • Improved customer service • Improved delivery date promising • Improved delivery performance • Improved productivity • Better machine utilization • Reduced inventories

25. Aquacolor Benefits • Operational improvement at recipe management, operations information and traceability levels, with a direct impact on costs. • 50% reduction in the time spent to build a new work order • Saves 70% time required to give a delivery date • Scheduling overhead reduced 35%

26. Benefits / Goals Achieved • Were the initial goals achieved? • Yes – an integration has been developed • Is the customer happy with the project? • Wonderware and Preactor are happy with the integration. • The interface has been certified. • What benefits (business, technical & other) were gained • A certified solution is now available to Wonderware Operations users to role out scheduling functionality with minimal effort.

27. Introduction Project Solution Agenda Benefits Considerations Summary

28. Lessons Learned • This is possible to integrate Wonderware Operations 3.4 and the Preactor scheduling functionality. • Wonderware has certified the interface. • Linking Wonderware Operations and Preactor delivers measurable benefits.

29. Introduction Project Solution Agenda Benefits Considerations Summary

30. Conclusions • The certified interface shows that it is possible to easily transfer data between Wonderware Operations and Preactor. • Wonderware Operations users can feel secure in knowing that world class scheduling functionality is available to them when required. • Wonderware Operations users can benefit from implementing the scheduling functionality now available to them.

31. ….any questions?