1. © C.Hicks, University of Newcastle Manufacturing Systems Research Chris Hicks

2. © C.Hicks, University of Newcastle Computer Aided Production Management Systems in Engineer to Order Companies ACME grant in collaboration with NEI Objectives Identify the characteristics of companies in ETO/MTO sector Evaluate the status of CAPM Identify common CAPM problems Develop methods for modelling CAPM systems in ETO/MTO environments Apply modelling methods to identify solutions to CAPM problems

3. © C.Hicks, University of Newcastle Identification of Company Characteristics and CAPM problems Nine one day visits Three long visits (3 days - 1 month) Developed semi-structured “audit” methodology Developed methods for company classification

4. © C.Hicks, University of Newcastle Audit Markets Products Processes Manufacturing Systems CAPM Systems

5. © C.Hicks, University of Newcastle Company Classification ShallowDeep Product Structure Jobbing Batch Flow Manufacturing Process Main product Spares Subcontract Company Type “A”

6. © C.Hicks, University of Newcastle Company Type “B” ShallowDeep Product Structure Jobbing Batch Flow Manufacturing Process Valves & Pumps Motors Cabs

7. © C.Hicks, University of Newcastle Control Approaches ShallowDeep Product Structure Jobbing Batch Flow Manufacturing Process Project Management MRP + JIT JIT

8. © C.Hicks, University of Newcastle Audit Conclusions Markets - demand highly variable and lumpy Products - complex, highly customised, mix of products Processes - wide range yet all areas tend to be controlled in same way Manufacturing systems - mainly functional layouts, high capital employed CAPM systems - poor integration, wide variety of subsystems, incorrect data structures, poor operational procedures, generally unsuccessful

9. © C.Hicks, University of Newcastle Systems Modelling Functional models decompose complex systems using a hierarchical top-down approach. They provide a means of understanding activities and interrelationships Information models enable structure of information to be described Dynamic models show changing behaviour over time.

10. © C.Hicks, University of Newcastle Company X - Context Diagram Company X ITT Tender Contract Awarded a Customer a Progress Report b Supplier b Quote ITT Order

11. © C.Hicks, University of Newcastle

13. Method Limitations Audit, systems analysis and data modelling provide static “snapshot” views. Longitudinal studies are a series of snapshots. No model of system dynamics. At best enable “best practice” or potential solutions to be described and documented. Not possible to perform experiments to examine alternative configurations and evaluate them in terms of specified performance criteria

14. © C.Hicks, University of Newcastle Simulation Allows modelling of system dynamics Very expensive in terms of model building and computational resources Validation often a problem Predominantly used for either small scale models or rough-cut high level models

15. © C.Hicks, University of Newcastle Simulation Model CAPM Modules

16. © C.Hicks, University of Newcastle

17. Key Features Large scale model allows whole manufacturing facilities to be represented Models facilities, products, processes and planning and control systems Many product families can be represented with shallow, medium or deep product structure Data structures match ETO/MTO requirements Allows variety of planning and control methods to meet local requirements May be used as a research tool or for planning and simulation.

18. © C.Hicks, University of Newcastle Simulation Case Study Heavy Machine Shop used for case study Static configuration used layout and other resource constraint information BOM information obtained for products Process data and planning data obtained for 18 month period.

19. © C.Hicks, University of Newcastle Experimental Design Series of full factorial experiments Factors Process - assembly lead time, minimum set-up, machining and transfer CAPM, scheduling methods, BOMs, dispatching rules, capacity planning Product mix / load Operational - data update period

20. © C.Hicks, University of Newcastle Conclusions Assembly planning and capacity planning important CAPM subsystems “Dispatching” rules not very significant Manufacturing performance sensitive to transfer times. Significant advantages gained through having close control of key resources Real time data recording led to improved manufacturing performance

21. © C.Hicks, University of Newcastle Consequent research topics Manufacturing Layout (Hinrichs, Wall) Capacity planning (Tay, Holmes, Hines, Pongcharoen) Assembly planning (Sullivan..) Planning of product development activities Planning under uncertainty (Wall, Brand, Song) Integration of project planning methods with MRP type approaches (EPSRC proposal) Plan Optimisation through Genetic Algorithms

22. © C.Hicks, University of Newcastle Manufacturing Layout All data required for layout analysis, clustering and generation in simulation data structures Work started with Chris Lee who was interested in improving the layout of Vickers’ Scotswood Road factory Much work in layout has focused on moving from functional layout to cellular layouts

23. © C.Hicks, University of Newcastle Methods Clustering –Matrix based methods –Similarity coefficient methods Layout generation –Starting with some candidate solution generate new layout that minimises (maximises) some objective function –Simulated annealing –Genetic algorithms

24. © C.Hicks, University of Newcastle Capacity Planning Finite / infinite loading Re-planning rules (Tay) Finite loading rules (Holmes) Interactive tools (Hines, Poncharoen) Schedule “optimisation” (Poncharoen)

25. © C.Hicks, University of Newcastle Supply Chain Management ETO companies moving towards buy rather than make Business process analysis approach (McGovern, Earl, Harrison, Hamilton) Agent based modelling of supply chains (Harvey, McLeay, Hines)

26. © C.Hicks, University of Newcastle IT Implementation Embodies audit, business process analysis and requirements definition Transfer of computing expertise 3 Teaching Company Schemes

27. © C.Hicks, University of Newcastle Layout design & effect on benchmarks Tony Wells Siemens Semiconductors Data from North Tyneside, US, Germany, Taiwan. Pareto analysis of costs Identification of cost drivers Relating cost drivers to plant design configurations Results so far: potential cost reduction of 50% on £30m/annum -pity the plant has closed!

28. © C.Hicks, University of Newcastle Management of Knowledge Data modelling / systems analysis based upon thematic knowledge that is formal, explicit and easily shared Knowledge management requires knowledge of product and process structure “Tacit” or embedded knowledge that is disorganised, informal, context dependent and relatively inaccessible often important. Interested in developing methodologies for systems integration that include both thematic and tacit knowledge LABS Proposal with Paul Braiden

29. © C.Hicks, University of Newcastle Other Activities £180k EDF grant with ISRU to develop distance learning material (Dave Stewardson & Mark Gary) TCS with House of Hardy aimed at improving manufacturing efficiency (Rob Davidson & Paul Braiden)

30. © C.Hicks, University of Newcastle Summary Wide portfolio of manufacturing systems research Various types of research undertaken from the theoretical through to applied. “Market led” rather than “product led”