Download SAIL PowerPoint

A Daily Scheduling and Performance
Measurement System for Flexible Machining
Systems
SAIL Overview
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A Plan for Machine Productivity
Challenges
Build to Order
 High Product Mix
 Daily Quantities
 Shared Tools and Fixtures
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Unique Features
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Simulation based forward schedule
Download Schedule to Cell Control
Monitor/Broadcast Cell Performance
Cost per Part Tracking
Unique Feature #1
Simulation Based Forward Schedule
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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
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Unique Feature #2
Download Schedule to Cell Control
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Instructions from Daily Schedule
Rolls out as operation progresses
Routing Instructions
Pallet Active
 Pallet Cycles
 Part Program to Run
 Machine List
 Load Station List
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Unique Feature #3
Monitor/Broadcast Cell Performance
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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
Unique Feature #4
Cost Per Part Tracking
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Based on the MAST Cost Model
Machine Depreciation Per Year
 Hourly wage plus benefits
 Overhead cost applied annually
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Uses actual production to apply cost
Details efficiency and burden costs
SAIL
Data Flow Diagram
Job Management System
Factory
Communications
Daily / Weekly Scheduling
Performance Monitoring
Cell Controller
CNC Controls
Load Station Control
Cell Management from
scheduling to shop floor
through synchronized
execution of software and
hardware systems.
SAIL
Data Flow Diagram
Job Management System
Factory
Communications
Daily / Weekly Scheduling
Performance Monitoring
Cell Controller
CNC Controls
Load Station Control
Daily / Weekly Scheduling
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Planned Hours of Operation
Number of Hours per Day
 Number of Days per Week
 Shift Start and End Times
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Sample Planning Period Screen
“Optimal” Daily Operational Plan
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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
Sample Daily Schedule
SAIL
Data Flow Diagram
Job Management System
Factory
Communications
Daily / Weekly Scheduling
Performance Monitoring
Cell Controller
CNC Controls
Load Station Control
Download Routing Instructions
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Pallet Routing Instructions
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Pallet Number
Part Number
Number of Cycles
Part Program Number
List of Machines to Use
List of Load Stations to Use
Sample Routing Instructions Screen
SAIL
Data Flow Diagram
Job Management System
Factory
Communications
Daily / Weekly Scheduling
Performance Monitoring
Cell Controller
CNC Controls
Load Station Control
Performance Monitoring
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Production Counts
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Records actual production completed against
planned quantities
Maintains history of Actual Production
Daily Schedule with Actual Production
Performance Monitoring
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Weekly – Monthly Totals
Daily Totals Summarized Weekly or Monthly
 Machine Use Averaged
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Weekly Totals Screen
Performance Monitoring
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Machine Use by Shift
Records Elapsed Time
 Uses Current Production
 Determines Actual Use
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Daily Schedule with Machine Use
Performance Monitoring
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Pallet Flow Time
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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.
Pallet Flow Time
Performance Monitoring
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Machine Cycle Time
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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.
Machine Cycle Time
SAIL
Data Flow Diagram
Job Management System
Factory
Communications
Daily / Weekly Scheduling
Performance Monitoring
Cell Controller
CNC Controls
Load Station Control
Web Page Broadcast of Performance
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Monitor Current Schedule of Work
Monitor Expected Completion Times of Jobs
Monitor Machine Productivity
Monitor Cost per Part
Sample Web Page
Case Study
TEAM 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.
Case Study
Large 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
Case Study
Thermoking 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%.
Case Study
Southern 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.
A Management System that
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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
Target Users/Applications
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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.
1610 S. Main Street
Oshkosh, WI 54902
Tel: 920.235.3356
Fax: 920.235.3816
[email protected]