INDUSTRIAL CASE: HOMAG

Company Profile – HOMAG Group AG

Worlds Leading Manufacturer of Machines, Plants and Systems for Wood Working

Furniture (84%) Structural Elements (12%) timber frame house construction (4%)

• Founded in 1960• 798 Mio € Turnover (2011)• 5110 Employees (2011)• 9 domestic Producing Companies

• 6 International Production Sites• 21 Directly Owned Sales and

Servicing Companies• 130 Sales Partners

U. Doll – HOMAG

Slide 2

Company Profile – HOMAG GmbH

• Machine classes produced at HOMAG GmbH, Schopfloch

• single-sided edge-banding• double-sided edge-banding• double-end-tenoner• CNC machining center

• Very heterogeneous requirements regarding work pieces (dimensions, material, features), productivity and flexibility

• Machines are individually configured using a construction kit with “machine units” to fulfill customer requirements

• For higher productivity machines are combined with handling and automation equipment to automated production lines

• Offers services in factory and production planning Slide 3

U. Doll – HOMAG

Requirement of HOMAG to support of the Production Planning procedure with the four main Planning Phases:

Factory Operation

Management of KPIs and

requirements

Production DesignSimulation

AS-IS situation

Slide 4

U. Doll – HOMAG

Main Weaknesses of the current Factory Planning Procedure

• Heterogeneous planning tools

• Some planning steps are not supported by tools (e.g. requirements)

• Simultaneous/collaborative planning using the same data is not possible

• Missing feedback from planning results

• Limited re-use of experience from previous projects

Current weakness/needs

Slide 5

U. Doll – HOMAG

HOMAG Scenario

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U. Doll – HOMAG

HOMAG Next Factory Scenario:

• Planning of a new furniture production Line, consisting of HOMAG machine units

• Performance indicators, customer requirements on capacity and further planning constraints

• Support and improvement of the HOMAG factory planning procedure:

• Use of new and integrated VFF modules and their functionalities

• Integration with the Virtual Factory Framework

TO-BE Situation

Slide 7

U. Doll – HOMAG

VF Manager

KPI Planning

Requirements Management

Production Resource Planning

Factory Performance

Simulation

Requirements Management and KPI

Planning RMP (ETHZ & NOVA)

Discrete Event Simulation EUVEDES (Tecnalia)

Assignment of Customer

Orders

Factory Performance and Process Planning

FP³ (FhG-IPA)

VFF functional modules

Planning steps

Knowledge Association Engine KAE

(LMS)

Slide 8

HOMAG Scenario - Overview

HIL Simulation(Factory Operation)

PAD (Tecnalia)

Control Station for Production Fine

PlanningFPS (PSI)

U. Doll – HOMAG

Pilot Case

• Produce order specific office furniture (e.g. cabinets, tables, separating walls, from 300x230x10 up to 2810x1010x25) in batch size one production

• Edge and finish processing

• Requirements on production line: To produce approx. 900000 parts per year

• First implementation of pilot case with the use of new and integrated VFF modules and their functionalities

Slide 9

U. Doll – HOMAG

Slide 10

* DEMO *

U. Doll – HOMAG

VF Manager

KPI Planning

Requirements Management

Production Resource Planning

Factory Performance

Simulation

Requirements Management and KPI Planning

RMP (ETHZ & NOVA)

Discrete Event Simulation EUVEDES (Tecnalia)

Assignment of Customer

Orders

Factory Performance and Process Planning

FP³ (FhG-IPA)

VFF functional modules

Planning steps

Knowledge Association Engine

KAE (LMS)

Slide 11

HOMAG Scenario - Speakers

HIL Simulation(Factory Operation)

PAD (Tecnalia)

Control Station for Production Fine

PlanningFPS (PSI)

HOMAG

FhG-IPA – ProductionPlanning Team

Tecnalia – Simulation Team

U. Doll – HOMAG

1Handover

2Rotating

90°input

15Handover

3Trimming

4Bending

6Shapemilling

8Handover

14Rotating

90°

9Trimming

13ShapeMilling

11Cutting

10Bending

output

5Cutting

7ShapeMilling

12Shapemilling

M01_Handover M02_Rotating

M03_KFL610

M06_Rotating

M07_Handover

M04_Dual_Angle_Transfer

Unit01_03_Trimming

Unit02_03_Bending

Unit03_03_Cutting

Unit04_03_Shape_Milling

Unit05_03_Shape_Milling

Unit05_05_Shape_Milling

Unit04_05_Shape_Milling

Unit03_05_Cutting

Unit02_05_Bending

Unit01_05_TrimmingM05_KFL610

HOMAG Next Factory Scenario Planning Results and Conclusion:

• New and optimized Furniture Production Line for HOMAG(Designed Production Resources consists of 2 edge banding machines and their machine units, feedings with an integrated buffer station, 2 turning stations, one angular transfer all connected by conveyors)

• Fulfilled Customer Requirements on Line Capacity and other Planning Constraints

• Application of new planning functionalities of VFF modules

• Enhanced planning performance due data storage and transfer via VFF Repository

Conclusion

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U. Doll – HOMAG

Benefits:

Improvement of planning performance (Planning time, Planning effort)

• Integrated planning framework

• Optimized tools for the different planning tasks

Improvement of planning quality (Fulfillment of customer requirements)

• Direct propagation of planning results to all other planning instances Collaborative planning

• Closed control loop between requirements and planning results

Improvement of standardization (Past and alternative solutions)

• Offering best practice knowledge

• Reuse past similar manufacturing line and configurations

Benefits

Slide 13

U. Doll – HOMAG

U. Doll – HOMAG

*BACK UP*

HOMAG Next Factory Scenario - Storyline

Slide 16

HOMAG Next Factory Scenario – Actions

1. Collecting the Requirements and setup of the Performance Measurement System. Map and align KPIs, to set target values and also to define constraints in a structured way. Constant Monitoring of KPI throughout the planning project. (ETHZ)

2. Analysis of past similar resources and production line configurations. Retrieve and reuse of past solutions based on sample past manufacturing lines. (LMS)

3. Production Resource Planning and Capacity Calculation. Further Technical and Economical Calculations. Calculation of defined performance indicators of the manufacturing line. (FhG-IPA)

4. Create production sequence for customer orders (planned production steps) within HOMAG Production line. Virtual Production Sequence used in further simulations. (PSI)

5. Discrete Event Simulation of the HOMAG production line simulating the Capacity and Energy Consumption with fine planned and optimized production sequence. (Tecnalia)

6. HIL simulation for the calculation of optimized cycle times for the production sequence with collision detection. Calculation of KPI referred to the cycle time.(Tecnalia)

HOMAG Next Factory Scenario - Storyline

Slide 17

HOMAG Next Factory Scenario – Conclusion

• Constant monitoring and control of Key Performance Indicators and Performance Requirements of the HOMAG Line.

• Suitable past production line configurations used as a basis for the planning project.

• Production Resources and Processes have been planned and the line capacity is calculated. Further Technical and Economical Calculations have been performed.

• Production sequence for customer orders (planned production steps) within HOMAG Production line have been established

• Capacity and Energy Consumption has been simulated and verified with the required line performance.

• Visualisation and optimisation of production sequence and smaller gap between the parts to be produced.

Requirement Management and Planning Module

RMP HOMAG Scenario Planning TasksImport:Functional Requirements, KPIs, target values, planning constraints [from HOMAG Customer].  Executed Planning Tasks:Collecting the Requirements and setup of the Performance Measurement System. The module helps to collect a rough process idea, to map and align KPIs, to set target values and also to define constraints in a structured way. Export:KPIs, Target values, Rough Process Description, Planning constraints[to all Scenario Partners via Virtual Factory Manager]

Figure: RMP Module - Screenshot

Knowledge Repository and Knowledge Association Engine Module

KR-KAE HOMAG Scenario Planning Tasks

Import:KPIs Target Values [from RMP module via Virtual Factory Manager].Sample Resource Structures and pasts solutions concerning resource planning from HOMAG.

Executed Planning Tasks:Propose past similar resources/ production line configurations. The module helps to retrieve and reuse past solutions based on sample past manufacturing lines.

Figure: KR-KAE Module - Screenshot

Factory Performance and Process Planning Module

FP³ HOMAG Scenario Planning TasksImport:Customer Requirements concerning Capacity and required Production Processes [from RMP Module via Virtual Factory Manager].

Executed Planning Tasks:Production Resource Planning and Capacity Calculation. Further Technical and Economical Calculations

Export:Process sequence and related Resource Structure of the planned HOMAG Line, Calculated KPI values (e.g. Calculated Capacity Per Year, Loading Of Production, …)[to all Scenario Partners via Virtual Factory Manager]

Figure: FP³ Module - Screenshot

Fine Production Planning Module

FPS HOMAG Scenario Planning Tasks

Import:Process sequence and related Resource Structure of the planned HOMAG Line, [from FP³ via Virtual Factory Manager]. Planned Production Steps [from HOMAG ERP System and integration into the VFF Repository] Executed Planning Tasks:Create production sequence for customer orders (planned production steps) within HOMAG Production line. Export:Planning Sequence – Fine Planned Production Steps [to DES module via Virtual Factory Manager] and KPI Required Handover Cycle Time [to RMP module via Virtual Factory Manager].

Figure: FPS Module - Screenshot

FPS moduleResource Structure /

MachineConfiguration

Representative set of customer orders(Operational data)

Planning Sequence--

Production Steps

Average Cycle Timefor a defined Machine Unit

FPS business logic

VFF/FPS Connector

Discrete Event Simulation Module

DES HOMAG Scenario Planning TasksImport:Production sequence including parts order and machines cycle times. [from FPS via Virtual Factory Manager] New Production Sequence with updated cycle times from [from PAD via Virtual Factory Manager] Executed Planning Tasks:Simulation of the HOMAG production line simulating the Capacity and Energy Consumption with fine planned cycle times (from FPS) and simulated, optimized cycle times from PAD)

Export:Simulated Capacity and Energy Consumption of the production line taking into consideration machines downtimes. [to RMP and PAD module via Virtual Factory Manager]

Figure: DES Module - Screenshot

Closed Loop based on Process Automation Designer Module

PAD HOMAG Scenario Planning TasksImport:Customer Requirements concerning the Production Process. Production schedule with Fine Planned Production Sequence Steps [from FPS via Virtual Factory Manager]

Executed Planning Tasks:HIL simulation for the calculation of new optimized cycle times with collision detection. KPI referred to the cycle time concerning the handover machine.

Export:Revised Simulation Input Data (Optimized Production Sequence according to the Simulation) for the DES module via Virtual Factory Manager.KPI referred to the cycle time of the handover machine [to RMP module via Virtual Factory Manager]

Figure: PAD Module – Screenshot

Production Operations

Parts Data

Input from VFM

Production sequence ( from virtual customer

orders)

Output to VFM

• KPI cycle time for the critical machine.

• Optimized times in production sequence ( for virtual customer orders )

Cycle Time KPI

Updated Production Operations

Import Export

Requirement Management and Planning Module

RMP HOMAG Scenario Planning TasksImport:Functional Requirements, KPIs, target values, planning constraints [from HOMAG Customer].  Executed Planning Tasks:Collecting the Requirements and setup of the Performance Measurement System. The module helps to collect a rough process idea, to map and align KPIs, to set target values and also to define constraints in a structured way. Export:KPIs, Target values, Rough Process Description, Planning constraints[to all Scenario Partners via Virtual Factory Manager]

Figure: RMP Module - Screenshot

FhG-IPA

HOMAG Next Factory Scenario - Storyline

HOMAG Next Factory Scenario – Subjects

o Planning of a new furniture production Line for HOMAG

o Planning Focus is the fulfillment of customer requirements on capacity and given planning constraints.

o Support and improvement of the HOMAG factory planning procedure

Slide 25

FhG-IPA

HOMAG Next Factory Scenario - Storyline

HOMAG Next Factory Scenario – Actions

1. Collecting the Requirements and setup of the Performance Measurement System. Map and align KPIs, to set target values and also to define constraints in a structured way. Constant Monitoring of KPI throughout the planning project.

2. Analysis of past similar resources and production line configurations. Retrieve and reuse of past solutions based on sample past manufacturing lines.

3. Production Resource Planning and Capacity Calculation. Further Technical and Economical Calculations. Calculation of defined performance indicators of the manufacturing line.

4. Create production sequence for customer orders (planned production steps) within HOMAG Production line. Virtual Production Sequence used in further simulations.

5. Discrete Event Simulation of the HOMAG production line simulating the Capacity and Energy Consumption with fine planned and optimized production sequence.

6. HIL simulation for the calculation of optimized cycle times for the production sequence with collision detection. Calculation of KPI referred to the cycle time concerning the handover machine.

Slide 26

FhG-IPA

HOMAG Next Factory Scenario - Storyline

HOMAG Next Factory Scenario – Conclusion

o Constant monitoring and control of Key Performance Indicators and Performance Requirements of the HOMAG Line.

o Suitable past production line configurations used as a basis for the planning project.

o Production Resources and Processes have been planned and the line capacity is calculated. Further Technical and Economical Calculations have been performed.

o Production sequence for customer orders (planned production steps) within HOMAG Production line have been established

o Capacity and Energy Consumption has been simulated and verified with the required line performance.

o Visualisation and optimisation of production sequence and smaller gap between the parts to be produced.

Slide 27