Process Efficiency through Integration. Stefan Rosenwald MESA EU Conference,

Transkript

1 Process Efficiency through Integration MESA EU Conference,

2 Agenda 1 Daimler AG / Mercedes-Benz Cars 2 Powertrain 3 Integration Process Efficiency through Integration : MESA, 09. November 2010 Folie 2

3 Daimler AG The Portfolio of Daimler AG the five pillars of success. Mercedes-Benz Cars Daimler Trucks Mercedes-Benz Vans Daimler Buses Daimler Financial Services Process Efficiency through Integration : MESA, 09. November 2010 Folie 3

4 Mercedes-Benz Cars Fascinating Brands. Process Efficiency through Integration : MESA, 09. November 2010 Folie 4

5 Agenda 1 Daimler AG / Mercedes-Benz Cars 2 Powertrain 3 Integration Folie 5

6 Powertrain plants Germany Hamburg Axles Exhaust systems Assemblies Light weight structural stabilizers Berlin Gasoline engines: V12 Diesel engines: V6, V8 Engine Management Pumps, fuel systems Gearbox assemblies Stuttgart Gasoline engines: R4, V6, V8 Diesel engines: R4 Transmissions, axles, cast and forged parts MDC Power GmbH Gasoline engines: R3, R4 Diesel engines: R3, R4 Folie 6

7 Production program (2009) Untertürkheim Hamburg Engines: Front and rear axles: Transmissions: St. 1,03 Mio. St St. Front axles: Rear axles: St St. Berlin Kölleda Engines: St. Engines: St. Folie 7

8 From Germany to the rest of the World. Powertrain deliveries to customers within MBC (Mercedes-Benz, Maybach, and smart). Sindelfingen (MB) Rastatt (MB) Bremen (MB) Hambach (smart) Affalterbach (AMG) Peking (MB) Tuscaloosa (MB) Juiz de Fora (MB) East London (MB) CKD plants: CKD/SKD Egypt CKD/SKD Indonesia CKD India CKD Malaysia CKD Thailand CKD/SKD Vietnam Folie 8

9 Powertrain Plant Untertürkheim Sub-plants. Bad Cannstatt Untertürkheim Hedelfingen Mettingen Brühl V-engines Gasoline and diesel inline engines Forge Transmissions Axles Foundry Maintenance training programs Not pictured: Zuffenhausen Replacement transmission repair and front-wheel drive transmission assembly Sirnauer Brücke Flexible production Folie 9

10 Agenda 1 Daimler AG / Mercedes-Benz Cars 2 Powertrain 3 Integration Folie 10

11 The process covers the entire logistic production chain of the customer order process for components. The IT application architecture is strictly realized with standard software. ERP: Enterprise Ressource Planning MES Shop-Floor Cell control R3 Order Processing (JIT, JIS). xls APO APO Cycle planning Per day capacity planning Sequence planning SIMATIC IT t t t t Vehicle production plant R3 Ability to supply controlling Manufacturing Control Supervisory Level Definition of the rule sets for the assembly lines, generation of technical orders, block orders, unblock orders, rebuild, change,. ZS ZS ZS Test bay, QA, actioning, rework ZS Prüffeld, GUSI, Aktionen, Nacharbeit R3 Dispositive Dispatch Dispatch - Management Dispatch systems AmSECAM ZS+PT Folie 11

12 Target: Strict focus on a harmonized and standardized coverage of the entire Powertrain IT for the customer order process for components was accomplished. Actual IT landscape Target IT landscape Manufacturing Planning Process Order processing Per day capacity planning Untertürkheim Berlin Hamburg Kölleda MBC Powertrain plants, AMG Planning level ERP PT-Master SAP Standard software SAP R/3, APO Manufacturing Control Sequence planning Manufacturing Control (Shopfloor) Montagesteuerung (Anlage) ZS+ A9 Engine Manufacturing Control MES (Manufacturing Execution System) ZS+PT Shop floor level ZS Dispatch Dispositive Dispatch Dispatch sysetems PT-Master SAP Dispositive Dispatch Dispatch control level Dispatch systems Folie 12

13 LT 1 LT 2 LT 3 LT 4 LT 5 LT 6 LT 7 LT 8 LT 9 LT 10 LT 11 LT 12 LT 13 LT 14 LT 15 LT 16 LT 17 LT 18 LT 19 LT 20 LT 1 LT 2 LT 3 LT 4 LT 5 LT 6 LT 7 LT 8 LT 9 LT 10 LT 11 LT 12 LT 13 LT 14 LT 15 LT 16 LT 17 LT 18 LT 19 LT 20 Customer order process Final assembly Kölleda Legende: PLA = ProduktLebensAkte EKM/K = Entkopplungsmodul Kölleda VSD/K = Versand/Kölleda ZS = Zellsystem ZS+PT = Zellsystem Powertrain R/3 = SAP System Customer orders Customer dispatch R/3 Advanced Planer and Optimizer (APO) PLA ZS+PT PRISMA QDA8 (Quality data) EKM/K ZS ZS ZS VSD/K RM FM Folie 13

14 Basic functionality provided by SIMATIC IT is extended by customer specific implementation - Customer specific extensions Extract of the basic functionality Generation of technical orders Management and control on precise ident level Receiving and maintenance of master data Definition of the rule sets for assembly lines Passing on orders to the line Supply cell and dispatch systems Manufacturing control functionality Providing APO and R/3 with order status and order feedback Backup cell systems in case of failure Management of special processes SIMATIC IT Production Suite Customer Libraries Industry Libraries -> Mechatronics Library Project extension Project cost SIMATIC IT Components Production Order Manager Material Manager Messaging Manager Report Manager Client Application Builder SIMATIC IT Framework Cell systems Master Controls Daimler Systems Folie 14

15 Utilized line net models Line net model I Pre and final assembly Dispatch Line net model II cylinder head assembly I cylinder head assembly II Line net model III Pre assembly I Pre assembly II Pre assembly III Final assembly and test bay Final Assembly I Dispatch cylinder head assembly Pre-assembly I Pre-assembly II Test Bay Buffering module Plant 1 Buffering module Plant 2 Final Assembly II Final Assembly III Dispatch Folie 15

16 Project schedule Aggregatesteuerung Project Aggregatesteuerung Target processes & concept OM651 Realization V-engines A-class Rear Axles Front Axles Inline Engines Transmissions Folie 16

17 MES enables real-time exchange with ERP of the status of every single production order ERP Update Production order status in real time MES Xxx Start Production technical order Xxx Ende Produktion technical order Folie 17

18 Safety concept ZS/ZS+PT ZS+PT (Cluster) ZS ZS ZS buffer buffer buffer Downtime ZS+PT up to x hours without impact for the production (emergency operation ZS) Servers centralized in datacenter Order stock up to x hours (emergency operation ) Buffer Buffer Buffer Standby Standby Standby ZS ZS ZS Servers nearby shop floor Production S07 Production Production S07 S07 Line 1 Line 2 LIne 21 (Hot standby) Folie 18

19 Availability To fulfill the require availability of 99,75% (max. down time of 30 minutes) the servers are implemented in cluster groups and connected by the network to external storage systems (SAN). Shared Storage Folie 19

20 Functions of ZS+PT Receiving of the relevant master data from SAP Creation and configuration of the line nets Definition of the rule sets for the assembly lines Generation of technical orders Passing on technical orders to the line and the dispatch systems Manufacturing control functionality on precise ident level Providing APO and R/3 with order status, order feedback and dispatch note Providing connected systems with order information Backup cell systems in case of failure Management and control of special processes ( unload from line, reload on line, handling of returns, ) Folie 20

21 Productive Operation ZS+PT System is operational in the following areas: Pilot line world diesel since Engine roll out I since Engine roll out II since Rear axles Rollout since ca units per day Partially running in 3 shifts as required by market Folie 21

22 Thank you for your attention Folie 22

23 Mercedes-Benz Cars Production plants worldwide. Tuscaloosa/USA Beijing/China 6th of October/Ägypten Pune/Indien Ho Chi Minh Stadt/ Vietnam Samutprakan/Thailand Hamburg Bremen Berlin Juiz de Fora/Brasilien East London/Südafrika Pekan/Malaysia Wanaherang/Indonesien Kölleda Hambach Rastatt Affalterbach Stuttgart-Untertürkheim Sindelfingen Graz Production of cars Production Powertrain Beteiligung CKD-Werk External Partners Engines AMG EDS3 Folie 23

24 Folie 23 EDS3 Beteiligung Elisabeth Desmet;

25 Konfiguration Selektion Transfer Daten sammeln Status Update Die MES-Ebene erweitert und vervollständigt. den vom ERP-System kommenden Produktionsauftrag um technische Informationen für eine korrekte Produktion. Fertigungsvorbereitung Fertigungsdurchführung Konfiguration Selektion Transfer Daten sammeln Status Update Regel- Konfigurator Erstellung, Simulation und Aktivierung von Regeln Regel- Engine Erstellung von technischen Aufträgen Broker Download der technischen Aufträge an die Linien Tracking Produktionsdatensammlung für Traceability WIP (Work in process) Status Update Produktionsauftrag an ERP- System REGEL EDITOR Folie 24

26 Konfiguration Selektion Transfer Daten sammeln Status Update Regelkonfigurator Produkt- Spezifikation Materialnummer Bill of Material (BOM) Bündel Arbeitsplan etc. Anforderungen / Bedingungen Spezifikation der Liniensegmente INPUT INPUT REGELKONFIGURATOR 1 Erstellung von Regeln und Strukturen von technischen Aufträgen für Liniensegmente 2 3 Equipment ( Segment) Regel Set Attribute Regeln Simulation Aktivierung Bedingung Anweisung Aktive Regeln Repository OUTPUT Regel Set Für jede Teilenummer und Liniensegment Beispiel: Attribut ist Typ Kolben" Regel 1: Kolbenstange M25", Wert: Konstant 0000", Bedingung: "Code enthält M25" Regel 2: Kolbenstange M30", Wert: Konstant 0001", Bedingung: "Code enthält M30" Attribut ist Schrauberprogramm" Regel 1: Programm A", Wert: Konstant A", Bedingung: Bündel Identifikation XYZ123456I" Regel 2: Programm B", Wert: Konstant B", immer Folie 25

27 Konfiguration Selektion Transfer Daten sammeln Status Update In der Run Time transformiert die Regelengine den Produktionsauftrag auf Basis der konfigurierten Regelsets in technische Aufträge. Produktionsauftrag Produktions- Auftrag (In Sequenz aus dem ERP System) Materialnummer, Linie ERP INPUT Backflush zum ERP in Echtzeit REGELENGINE 1 Import Produktionsaufträge (Möglichkeit Update von Produktionsaufträgen oder Sequenz) 2 Transformation (Prüft Regeln / Bedingungen, Output beinhaltet nur gültige Regeln) Anforderung Liniensegment zum Download von technischen Aufträgen OUTPUT (Download) 5 4 Technischer Auftrag Liste von Attributen = Anweisungen (Regeln) für Arbeitsstationen der Segmente LINIE 1 SEGMENT A Regel Set Tech. Auftrag LINIE 1 SEGMENT B Aktive Regeln Repository Regel-Konfigurator INPUT 3 Technischer Auftrag angelegt Tech. Auftrag Tech. Auftrag... LINIE 1 SEGMENT C LINIE 1 SEGMENT D Folie 26

28 Logout Optionen Kopieren in Zwischenablage Exportieren in Excel Drucken (Screenshot, pdf) Hilfe Auftragssequenz Komponenten-Selektion Abschnitts-Selektion Navigationsleiste Hauptfunktionen z.b. Ein- / ausblendbarer Filterbereich -AggId AggId AggId AggId AggId AggId AggId AggId AggId AggId-0010 Dialoge zur Hauptfunktion -MatNr MatNr MatNr-0003 Suchen -MatNr MatNr MatNr-0006 Blockieren -MatNr MatNr-0008 Freigeben -MatNr MatNr-0010 etc. -AggId MatNr AggId MatNr AggId MatNr AggId MatNr AggId MatNr AggId MatNr AggId MatNr-0017 Benutzer-Filter Sequenz Aktionen Sonderabläufe Stammdaten etc. Spaltenselektion Folie 27

29 Auftragsdetails AggId-0815 Mat Auftragskopfdaten SYS TEST MO 04 Bündel 0001 Bündel 0002 Bündel 0003 Bündel 0004 Bündel 0005 Mat 0001 Mat 0002 Mat 0003 Mat 0004 Mat 0005 Etiketten / Belege Stationsmeldungen Technische Aufträge Blockieren / freigeben Arbeitspläne Stücklisten Sonderabläufe Folie 28

30 Stücklistenvergleich Vergleich mit Vorgänger Stückliste löschen Stückliste aktivieren Alternative Stk.-L. erstellen Stücklisten vergleichen Mat-0001 Mat-0002 Mat-0003 Mat-0004 Mat-0005 Mat-0006 Mat-0007 Mat-0008 Mat-0009 Mat-0010 Mat-0011 Mat-0012 Mat-0013 Mat-0014 Mat-0015 Mat-0016 Mat-0017 Folie 29

31 Reportmanager Zeitfenster Batchreport Turnus Dateiformat (pdf, xls,..) Versand Ausgabe auf Drucker Folie 30

32 Online-Help Folie 31