1. NIST Manufacturing Engineering Laboratory Intelligent Systems Division Theme

2. NIST Manufacturing Engineering Laboratory Intelligent Systems Division What is a factory and what are the data factors?

3. NIST Manufacturing Engineering Laboratory Intelligent Systems Division

4. Planning

5. NIST Manufacturing Engineering Laboratory Intelligent Systems Division What to measure?  Requirements  Important, effective, necessary,  Random  Tradeoff between 100% quality and infinite time  KPI  ISO standard: ISO 22400  Process cycle time, process yield, resource time between failure, resource time to repair, process cycle times, process setup and paused times, resource/process energy consumption  DES  Statistical inference of plant behavior  Faults

6. NIST Manufacturing Engineering Laboratory Intelligent Systems Division Definitions  The primary goal of a MES is to provide an information system that can be used for optimizing production activities in a manufacturing facility with the focus on quick response to changing conditions.  A MES is a system that consists of a set of integrated software and hardware components that provide functions for managing production activities from job order launch to finished products.

7. NIST Manufacturing Engineering Laboratory Intelligent Systems Division  Key Business Drivers  Key business drivers are the areas of performance that are most critical to an organization's success  Available To Promise  Requires detailed knowledge of available capacity  Reduced Cycle Time  Major performance indicator with a direct impact on corporate profitability  Supply Chain Optimization  Optimizing the manufacturing link in the supply chain –agile & responsive  Asset Efficiency  Requires detailed knowledge of actual use  Agile Manufacturing  Requires ability to quickly synchronize planning and production

8. NIST Manufacturing Engineering Laboratory Intelligent Systems Division  Track Production Units and Resources  Provide the information on where any production unit is at all times and its disposition. Also provide the product genealogical information, such as who worked on it, current production information, component materials by supplier, lot number, serial number, any rework, measured data, or other exceptions related to the product.  ISA-95 - Operations Schedule What actions to perform – Materials to make – Priority and/or dates – What materials to use – What equipment to use – What personnel to use – Production parameters (e.g. Color, Options,…) Per Segment (step in production) Per location (Site, Area, …) Per week day shift order

9. NIST Manufacturing Engineering Laboratory Intelligent Systems Division Discussion  Measuring shop-floor data for LCA analysis using MTConnect is feasible  Efficient – quick turnaround for performing Kaizen Energy Consumption and Event archiving  Best for non-real-time data analysis  Cost-effective for smaller operations  Actual shop floor data helped understand LCA energy consumption during production  Machine tools are relatively efficient  Energy consumption results compare well to related energy consumption work performed at NIST Lanz, M, Mani, M. Lyons K. Ranta, A., Ikkala, K and Bengtsson, N. 2010, “Impact of energy measurements in machining operations”. In 2010 ASME Design and Engineering Technical Conference (DETC), Proceedings of 2010 International Computers and Information in Engineering Conference, ASME.  Sensitivity and Trending analysis  Future plans are for examining quality relationship between process and energy consumption. For example, an unexpected rise in energy consumption could indicate an underlying process error.

10. NIST Manufacturing Engineering Laboratory Intelligent Systems Division