Advanced Digitalization Makes Best Practice, Part 2: Adaptive Planning

In the first part of this series, I examined digital remastering, as it refers to the process of creating the digital product model from design and bill of materials (BOM) information, with conversion then, by digital engineering tools, into execution-ready engineering data. In our new digital MES environment, this process is not just to create a single execution instance for a pre-designated line configuration as was mandated in the past, but for all capable configurations, to provide choice at actual run-time.  We now look towards the next step in our new digital factory best practices that digital remastering of engineering data has made possible: the software known as Adaptive Planning, created by Adaptive Insights.

The Challenge of Factory Planning

The dedication of production lines to products, or more recently, groups of products, has become a rather comfortable environment, with just one set of engineering data to support, a single supply-chain of materials, lined up hours in advance, so no concerns for production at all. The flaw in this plan is best illustrated by considering the simplest form of production and having a product running at high-volume on one such dedicated line. Many operations dream about the good ol’ days where such high-volume lines were common and have forgotten that even the operation of those lines were hiding significant losses to the business overall.

Take the case where such a line would make 1,000 products per day, over many days. This is the most efficient example of how SMT equipment automation could be used. It consisted of extremely welloptimized machine programs and carefully balanced lines, where work was split as equally as possible over all machines to get to a single consistent takt time with no losses in between. The 1,000 products would be made, and then disappear into the warehouse. Job done, for SMT. From the business perspective however, unnecessary costs then start to accumulate. It is extremely unlikely that the optimal capacity of the line was exactly meeting the delivery need of the customer. If the customer would take only 900 per day, then 100 additional pieces would have to remain in stock in the factory warehouse. Without careful finished-goods management, the warehouse could soon fill to capacity. The 1,000 per day line capacity was necessary however, as the customer could take the full 1,000 per day or even slightly more. Whenever the assigned warehouse locations became overloaded, the SMT line would be told to stop. Though triggered by a physical threshold, the cost of storage of this “dead” inventory was the significant factor. Often, the SMT line had to stop for just a couple of hours here or there, when the time could be taken advantage of, performing routine maintenance for example, but often, the line would stop for a shift or even longer, getting progressively worse as the fluctuation in customer demand increased.

To read the full version of this article which originally appeared in the August 2018 issue of SMT007 Magazine, click here.
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2018

Advanced Digitalization Makes Best Practice, Part 2: Adaptive Planning

08-27-2018

For Industry 4.0 operations, Adaptive Planning has the capability of replacing both legacy APS tools, simulations, and even Excel solutions. As time goes on, with increases in the scope, quality and reliability of live data coming from the shop-floor, using for example the CFX, it is expected that Adaptive Planning solutions will become progressively smarter, offering greater guidance while managing constraints as well as optimization.

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Advanced Digitalization Makes Best Practice Part 1: Digital Remastering

07-02-2018

As digitalization and the use of IoT in the manufacturing environment continues to pick up speed, critical changes are enabled, which are needed to achieve the levels of performance and flexibility expected with Industry 4.0. This first part of a series on new digital best practices looks at examples of the traditional barriers to flexibility and value creation, and suggests new digital best practices to see how these barriers can be avoided, or even eliminated.

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Configure to Order: Different by Design

01-15-2018

Perhaps in the future, sentient robots looking back at humans today will consider that we were a somewhat random bunch of people as no two of us are the same. Human actions and choices cannot be predicted reliably, worse even than the weather. As with any team however, our ability to rationalize in many different ways in parallel is, in fact, our strength, creating a kind of biological “fuzzy logic.”

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2017

Counterfeit: A Quality Conundrum

10-01-2017

There is an imminent, critical challenge facing every manufacturer in the industry. The rise in the ingress of counterfeit materials into the supply chain has made them prolific, though yet, the extent is understated. What needs to be faced now is the need for incoming inspection, but at what cost to industry, and does anyone remember how to do it?

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