Proplanner PFEP Overview - 092912

PFEP System Overview
(Plan for Every Part)

Lean Factories Require Lean Material Handling Systems
Dr. David P. Sly

President, Proplanner Adjunct Professor, Iowa State University
Proplanner PFEP
Presentation Overview
Background
eKanban
eKitting
Extensions of PFEP Data
World Leading Process & Industrial Engineering Software
Proplanner PFEP
Background
eKanban
eKitting
Background
Proplanner Overview
Formed in 2002 in the USA
Iowa State University Research Park Branched off from EDS PLM Solutions Focus on engineering software solutions for manufacturing. PFEP originally created for Case New Holland (CNH)
President: Dr. Dave Sly

BSIE, MSIE, PhD IE, MBA, Licensed PE Adjunct Professor Iowa State University
Employees
20 highly educated and experienced engineers and software developers create world leading process & industrial engineering software. Made in the USA.
Technical Classification
Manufacturing Data Management (MDM) and Product Lifecycle Management (PLM) solutions.
Map of Proplanner Customers
Background
Proplanner Products Overview
Product Data Management (PDM) System
Engr Change Management (ECO, ECR, MCO)
Part Data (eBOM)
PFEP eKanban & eKitting
Operator & Material Flow Analysis
Proplanner Assembly Planner System (integrated central source of production process & data)
Sequence Planning
eBOM Changes Process Planning
eWork Instructions
Time & Motion Study
Auto- Line Balancing
Static Work Instructs
Process data (mBOM), product routings, stations, times, etc.
ERP / MRP / MES Systems
Product Build List
Background
Proplanner PFEP Definition
PFEP is a material handling database application suite, including:
1. Complete definition of in-plant logistics and storage for all parts, from receiving to consumption. This includes the detailed logistics plan for every part (e.g. containers, locations, delivery methods, etc.). 2. Manufacturing Bill of Material (mBOM) for all product models & variants. 3. Electronic part delivery support systems:
eKanban: Replenishment method for small, low cost, bulk parts - when containers become empty. eKitting: Just-in-Sequence part picking and delivery of unit specific parts - when they are required on the assembly line.
4. Supervisory and administrative aids:

Scheduler, Dashboards, Reports, Label Printing, etc.
Background
Proplanner PFEP Definition
Complete definition of in-plant logistics and storage for all parts from receiving to consumption.
Every part has a location and a logistics plan.
Increases efficient use of space and indirect labor. Reduce waste associated with inefficient storage and delivery of materials within the plant.
Launch new products (units and parts) to production more quickly and with fewer (expensive) last minute changes required during the pilot launch.
Background
Single Location of Material Logistics Data
Single location of data entry and management via domain experts (people and systems).
PFEP brings together data from multiple sources, which greatly reduces the effort by a single engineer to collect, synchronize and maintain hard to find logistics information that constantly changes.
Suppliers and Purchasing (parts received at docks) Industrial/Manufacturing Engineering (parts consumed at stations, and container layout within stations) Materials Handling (off-line storage and delivery of parts) Product Engineering (parts required for specific models and options)
Production Planning (production sequence of products with models and options)
Background
Unique PFEP Approach
Proplanners PFEP approach is unique in the way that data and workflows are integrated.
Proplanners PFEP will ensure sustainability of your data accuracy while minimizing the work required by your engineering staff.
All part receiving (parts received at docks) is synchronized with Purchasing/Logistics via the web-based vendor interface. All new and revised part data is synchronized via ECO and MCO integration with PDM and/or ERP (if utilizing AP engineering change module). All part consumption (parts assigned to stations) is synchronized with line balancing and mBOM revisions (if using AP line balancing module). Parts consumed per unit is synchronized to Sequence Planner (if using SP).
All part layout and logistics (method) information is automatically synchronized to the AutoCAD layout (if using Flow Planner).
Background
Material Class One Way to Categorize Parts
User Inputs (each part):
Size: XL, L, M, S, XS Cost: Expensive (>$x), or Inexpensive Commonality: Low, Medium, High
PFEP Determines:
Material Class
Delivery Method
Background
Data Requirements
eKanban eKitting Part Picker Utilization
# of Containers Picked Pick Cycle Time (from label to tugger)
Kitter Utilization
# of Kits Opened & Closed Time Required to Close Kit by unit serial #, by product type, and by delivery location.
Driver Utilization
# of Containers Delivered # of Kits Delivered
Parts Containers / Totes
Parts w/ Model & Option Mapping Supply Location
Consuming Location Carts per Location
Supply Location
Consuming Location : .
Time taken from Dock to Supermarket Time taken from Supermarket to Line Location
Time taken for Tugger Delivery Route : .
Product Build Seq.

:
: . .
Background
PFEP User Interface Data Authoring
Proplanner PFEP
Background
eKanban
eKitting
eKanban
Workflow
Empty
Full
Assembly Line
PFEP
Supermarket
eKanban
Workflow
Empty
Full
Kanban Driver Finds & Scans Empty Containers
1
Returns Empty Containers to Supermarket
Scan of Empty Container Sends New Label to Supermarket Printer
Assembly Line Supermarket
PFEP
eKanban
Workflow
Empty
Full
1
PFEP
2
Driver Removes & Destroys Labels from Returned Containers
eKanban
Workflow
Empty
Full
1
PFEP
Restock Containers & Apply New Labels
Scan Label & Location to Ensure Accuracy (poke yoke)
2
Supermarket Scans Containers Picked for Delivery
eKanban
Workflow
Line Operators Consume Parts as Needed
Empty
Full
1
Driver Delivers Full Containers to Line Side Storage
Scan Rack Location when Delivered
4
PFEP
Scan Label & Location to Ensure Accuracy (poke yoke)
Restock Containers & Apply New Labels
2
Supermarket Scans Containers Picked for Delivery
eKanban
Request Process
Driver Pulls Empty Tote
Driver Scans Empty Tote
System Auto-Prints New Label for Full Tote in Supermarket
Driver Returns Empty Totes
Driver Removes Label
eKanban
Replenish Process
Driver Brings Full Tote to Line
Scanner Prompts Driver with Next Location & Kanban ID
Driver Scans Rack Label to Verify Proper Delivery
Driver Scans Tote Label
eKanban
System Current Status
eKanban
System Current Issues
Kanban Transaction Issues Report
Check traffic light indicators for parts not meeting the restocking time parameters
Delivery Issue
eKanban
System Current Issues & Performance History
Performance alerts are sent out via email or page. Kanban Delivery History & Statistics are Captured.
Delivery Issue
eKanban
Results at a Large, Complex Assembly Factory
66% - Delivery Cycle Time
84% - Line Side Inventory 98% - Part Shortages
(over 1,000 different parts supplied line side via eKanban)
FARGO Plant
Corporate Data Center 1
Shop Floor Database
2
LXE (MX7) Scanner
PFEP Web Service
WAN
3
Print Service (Windows Service)
Dashboard
Zebra Printer @ Fargo Plant
5
TCP or UDP (printer driver setting) Zebra Printer @ Magnum
Proplanner PFEP
Background
eKanban
eKitting
Next Steps
eKitting Just in Sequence

Data Flow
From MRP ERP
Part Pick List (per product, by Supermarket / Delivery Location / Rack Location
Orders w/Product Build List
mBOM per Model & Variant
Web Server Web Server

Sends Pick Lists to Scanners
Retrieves & Logs Scan Data
PFEP

Data Flow & Supermarket Workflow
From MRP ERP
Part Pick List (per product, by Supermarket / Delivery Location / Rack Location
Orders w/Product Build List
mBOM per Model & Variant
Web Server Web Server

Sends Pick Lists to Scanners
Retrieves & Logs Scan Data
PFEP
Scan Empty Cart
Pick Part 1 & Scan Loc1
Pick Part n & Scan Loc n
Scan Full Cart
Operator Picks All Parts for Selected Unit(s) / Delivery Location in Single Pass Thru Supermarket

Cart Related Information
Carts
Every Cart has a unique ID Every Cart is an instance of a Cart Type
Cart Type
Serves one source location (supermarket), and one destination (delivery/consuming location). Part Plan assigns Kitted Part to a Cart Type. May support parts for one or multiple units.
Cart Scan Types Open - Begin picking

Closed Transit Delivered Query Picking completed Passed thru location (may be multiple) Arrived at destination List parts loaded & unit(s) they are for

Data Flow - Generating a Part Pick List
Orders (Model / Variant per unit)
ERP
Production Schedule
PFEP
Part Records Consuming Location, Supermarket Location, Cart Type
Cart Records Cart Type, Units per Cart, Unique Cart ID
Kitted Parts BOM / unit
Pick List
Per Cart Type Per Unit Build Sequence + n Takt Cycles
Build List

Data Flow - Generating a Part Pick List
Orders (Model / Variant per unit)
ERP
Production Schedule
PFEP
Part Records Consuming Location, Supermarket Location, Cart Type
Cart Records Cart Type, Units per Cart, Unique Cart ID
Units:
615 616 617 618 619 620 621 622
Units:
Line Supervisor Can Adjust Build Sequence
615 616 617 619 620 621 622 618
Kitted Parts BOM / unit
Skips Can Be Moved Down or Removed From Build List, & PFEP automatically adjusts Pick Lists.
Pick List
Per Cart Type Per Unit Build Sequence + n Takt Cycles
Build List

Part Picking Scanner User Interface
After Scanning Cart ID, Picker is Prompted for Next Units to Pick
# Parts Picked so Far / Total Parts to be Picked for this Cart
Next Part to Pick Based on Sorted Storage Locations

Qty of Part to Pick, for Each Unit, & Total Location to Pick this Part from Part Not Available Scan Rack Location Label to Verify the Correct Part is Picked

Part Picking Scanner Workflow
Logon JIS Part Picking Select Supermarket
Scan Cart ID
More Parts to Pick All
Display Units & Part/Loc to Pick Scan Loc ID
Skip Pressed
Input # Skipped Parts

< All
>0 Part Shortage Alert Email & Flag on Supervisor Dashboard
Ready for Next Cart
All Parts Picked
Scan Cart ID Print PickSheet For Each Unit On Cart

Delivery of Kits
Closed pick sheets can be seen in the sleeves for each kit cart.

User Configurable Dashboard Views

Part Picking Dashboard View

This Dashboard shows STATUS of all Kit Cart picks. Color coding from previous slide.
Last 4 digits Unit Serial #
Cart Type
Specific Carts
Time of Delivery

SHOW ALL (ROW FILTER):
Displays full day, required scrolling during shift to keep current time displayed.
FILTER ROWS (ROW FILTER):

Displays n takt cycles before and after current time (no scrolling required)
Proplanner PFEP
Background
eKanban
eKitting

Factory Layout & Material Handling Analysis
Only Proplanners PFEP solution integrates with the AutoCAD layout in order to provide unparalleled accuracy of travel distances and indirect labor times. Aisle-based and Point-to-Point graphical flow diagrams are automatically generated for logistics analysis and visualization.
Integration with AutoCAD layout provides instant travel distance and time updates to the PFEP database, as the layout is updated. Proplanners sophisticated analysis algorithms will greatly enhance the designs of layouts, material handling methods, and tugger delivery routes.

Flow Planner
Creates Material Flow Diagrams and computes distance, cost and time. Determines required number of people to move materials around facility.
Assists designing facility layouts around material and people flow.

Visualizes material and people flow for presentation and discussion.

Flow Planner Tugger (Tow-Train) Analysis
Generate and analyze tow-train routes for material delivery schedule requirements. Evaluate alternative zoning, routes, trip frequency to determine optimum plan. Time / Trip
Load/Unload vs Travel
Cart Capacity/Trip

Flow Planner Dock, Storage, Line-Side Analysis
Flow Planner analyzes material flow from dock to receiving to storage, & minimizes distance traveled by selecting optimal dock & storage locations.

Flow Planner Aisle Congestion Analysis
Actual path calculations are automatically analyzed to reveal aisle paths with the most, and least, congestion.
Proplanner PFEP
Background
eKanban
eKitting
Proplanner PFEP
Contact Information
Call: 1-515-296-9914 (main)
E-Mail: dave@proplanner.com
Website: www.proplanner.com
Web Enabled Manufacturing Data Management (MDM) and Product Lifecycle Management (PLM) Solutions.

Proplanner PFEP Overview - 092912

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Droits d'auteur :

Proplanner PFEP Overview - 092912

Transféré par

Droits d'auteur :

PFEP System Overview

(Plan for Every Part)

Dr. David P. Sly

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

President: Dr. Dave Sly

Map of Proplanner Customers

World Leading Process & Industrial Engineering Software

Engr Change Management (ECO, ECR, MCO)

Part Data (eBOM)

PFEP eKanban & eKitting

Operator & Material Flow Analysis

Time & Motion Study

Auto- Line Balancing

Static Work Instructs

Process data (mBOM), product routings, stations, times, etc.

ERP / MRP / MES Systems

Product Build List

World Leading Process & Industrial Engineering Software

4. Supervisory and administrative aids:

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

Production Planning (production sequence of products with models and options)

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

Parts Containers / Totes

Parts w/ Model & Option Mapping Supply Location

Consuming Location Carts per Location

Product Build Seq.

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

Kanban Driver Finds & Scans Empty Containers

Scan of Empty Container Sends New Label to Supermarket Printer

Assembly Line Supermarket

World Leading Process & Industrial Engineering Software

Kanban Driver Finds & Scans Empty Containers

Scan of Empty Container Sends New Label to Supermarket Printer

Assembly Line Supermarket

World Leading Process & Industrial Engineering Software

Kanban Driver Finds & Scans Empty Containers

Scan of Empty Container Sends New Label to Supermarket Printer

Assembly Line Supermarket

Supermarket Scans Containers Picked for Delivery

World Leading Process & Industrial Engineering Software

Kanban Driver Finds & Scans Empty Containers

Scan of Empty Container Sends New Label to Supermarket Printer

Returns Empty Containers to Supermarket

Assembly Line Supermarket

Restock Containers & Apply New Labels

Supermarket Scans Containers Picked for Delivery

World Leading Process & Industrial Engineering Software

Driver Pulls Empty Tote

Driver Scans Empty Tote

System Auto-Prints New Label for Full Tote in Supermarket

Driver Returns Empty Totes

Driver Removes Label

World Leading Process & Industrial Engineering Software

Driver Brings Full Tote to Line

Scanner Prompts Driver with Next Location & Kanban ID

Driver Scans Rack Label to Verify Proper Delivery

Driver Scans Tote Label

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software

World Leading Process & Industrial Engineering Software