LeanMES

Harri Nieminen, Fastems Oy Ab

Challenge

Predictable world?

We are working with operation control and decision-making systems based on stand-alone concepts highly optimized for achieving its goals in a stable predictably behaving environment.

Real life!

When we look at the bigger entities, in real life only predictable thing is unpredictability. A stable, predictably behaving environment do not exist.

Important problems

Local optimization•  One facility•  One system•  One organization

block

Communication gaps

Lack of visibility

Motivation

Information quality Information securityChain of forecasts

Time gaps

Lack of proper tools

Compexity

Poor competiveness

Needs from the Field

Increase the productivity and efficiency in all

levels

Operational flexibility, rapid reaction and adaptation to

changes

Lower the costs generated from the non-value adding

processes

Enabling the efficiency of

networks

Support the human worker in

different ways

Competiveness

LeanMES mission

‘The ultimate goal of the project is to provide lean, scalable and extendable concept for new type of MES that supports the human

operator in a dynamically changing environment’

LeanMES -project and consortium  Project’s run time 08/2013-12/2017  Budget: 6663 kEUR  Workload: active period 60 man-years

Aims for LeanMES

  From local optimization to understanding cause and effects of a complex system  Achieve more efficient and continuously

evolving processes and systems  Combine best of soft methods and hard

technology  Efficient networks, SME perspective

Objectives and novelty of LeanMES  Research objective 1: Web of Knowledge

–  Transparency of actions and knowledge–  Flow of information–  Standardized Interfaces –  Modularity

  Research Objective 2: Human-Machine Cooperation–  Lean as a guideline–  Human-centered but process oriented–  Guiding yet not constraining–  Interactive systems and system intelligence–  High level UX

  Research Objective 3: Competitive MES concept–  Lean, fast to install and easy to learn–  Traceable and Sustainable KPIs–  True support for networked manufacturing

LeanMES - scientific goals   Goal 1: Study and plan various methods to implement LEAN principles in MES system. The study

serves as the state-of-the-art document for the Lean MES Roadmap.  Goal 2: Definition of “best of breed” interfaces that are implementable now and in near future as well

as definition of gaps that are most critical now.  Goal 3: Definition of new types of Lean KPIs that are traceable and reliable throughout the network.   Goal 4: Define and test (proof of concept) feasibly of MES concept for managing networked, global

production chain especially within OEM and in subcontracting context.  Goal 5: Definition of Machine level MES software toolset (view) that has different user roles for office

and machine control in factory floor and possibility to test/select different optimization methods for given cases (such as integrated automatic nesting).

  Goal 6: Understanding of how automated material handling and related information gathering can be used to improve productivity and flexibility of small series production especially in small to medium size companies in manufacturing segment.  

  Goal 7: Provide ideal selection tracking methods that support both MES and automatic material handling and definition of gaps that are most critical now and possible solutions for those.  

  Goal 8: Provide concepts that support information visibility and rapid reaction to changes for SMEs that are looking production from the supplier and customer perspectives. 

  Goal 9: Provide solid business plan for SMEs that need to update their way of operation to be more lean and agile in future. This requires understanding the business transactions, to operation schemes and best of breed ICT solutions for given case.

LeanMES scope

ERP

LeanMES -layer

Humans Devices Systems

’There might be... / What if...’

’Sometimes there is...’

’It always features...’

Others

Others

Enterprice scheduling & management

Network

Examples of LeanMES enablers

  Visibility–  Inhouse–  Suppliers–  Customers

LeanMES

  Information security

  Status information–  Online status for

  Manufacturing  Storages  Changes /

modifications–  Automatic reminders

  Project data structure–  Simulations–  Manufacturing data–  Material data–  Order data

  Optimization models–  Time–  Costs–  Quality–  Foot print

  Views–  Sourcing–  Manufacturing–  Quality–  Customer–  R&D

  Technical solutions–  Cloud services–  WEB –technologies–  Novel HMI -technologies–  Databases

What could LeanMES mean in my factory?

Transparency for manufacturing and material balance data for supply chain partners

Real-time tracking , monitoring and verifying – humans and parts in manufacturing, storage

Optimizing and scheduling work orders

Tracking and monitoring performance and key figures: humans, machines, storages and systems

Engineering change management for progressing orders

Tracking, monitoring and estimating production resources - tools, fixtures, programs, materials

Support for various work schemes

Enabling independently to choose control scheme – part-processes, resource groups

Human in the loop

Benifits from the socio-technical systems

Network wide change management

LeanMES -project tasks

1.  Important needs and state of the art in the field2.  LeanMES concept definition 3.  Lean KPIs and human friendly information exchange

in evolving environment 4.  LeanMES control and optimization schemes in human

centric operations5.  Material logistics in LeanMES6.  Implementation, testing and demonstrations7.  Dissemination

Thank You!