E-manufacturing as a web-based decision-making support for collaborating SME-S in machine-building cluster.

Loun, Kaia ; Riives, Jyri ; Otto, Tauno 等

Abstract: Mainly batch-production-oriented SME-s need web-based simple manufacturing, planning, and monitoring systems which could include larger sensor systems and databases. E-manufacturing can be determined as IT-based manufacturing model, optimizing resource handling over entire enterprise and extended supply chain. Proposed such a system forms network between enterprises of the cluster.

Key words: Network monitoring, e-community, e-manufacturing, resource allocation, databases.

1. INTRODUCTION

Today the competitive marketplace requires that enterprises should be more flexible, innovative and responsive to their customers' needs. Therefore, the small and medium sized enterprises (SME-s), in order to gain competitive advantages, should change their traditional business models and adopt new ones to facilitate collaboration with suppliers and customers. Enterprises form collaboration networks that value speed and quality. These networks will have an ability to react dynamically according to individual objectives (e.g. customize a product, provide special services, outsourcing). Since 70-ties development of Material Resources Planning (MRP) has made a long step. The MRP based initially upon bookkeeping and storage vacancies modules. Thereafter it was completed with supply chain and production planning elements. Such integrated business software systems are called Enterprise Resource Planning (ERP) systems. Typical ERP systems are oriented to large enterprises (SAP R13, BAAN) or average sized enterprises characterized by complex business processes. For SME-s, increased integration through SCM, using e-Marketplaces and exchanges will continue (Sumner, 2005).

Conventional Enterprise Resource Planning (ERP) systems have complex architecture and price level, not feasible for SME (Greeff & Ghoshal, 2004). The main reason for this is caused because of such ERP systems use complex data models and therefore need essential resources for handling. This turned out also at Hanover Industry Exhibition 2007, where halls 14-17 were completely targeted towards development of e-manufacturing and factory automation. Development of e-manufacturing system is demanding task, requiring synergy of different competencies.

E-manufacturing can be determined as "IT-based manufacturing model, optimizing resource handling over entire enterprise and extended supply chain"(Lee, 2003). To realize it, a common framework is developed to plan and control manufacturing in a cluster of enterprises. Information exchange is performed on web-base. Previous attempts to realize e-manufacturing have suffered poor data of the workshop, as manufacturing managers are not aware of the technical details of the manufacturing (Zurawski, 2005).

E-manufacturing needs development experience, what is gathered through development of previous Metal Engineering, Machinery and Apparatus Sector Network (www.metnet.ee; Otto et al, 2004). In practice for SME, where workload to manufacturing resources varies in great extent, is needed more flexible and simple integrated systems, covering several enterprises. Such a system bases on description of inner and cluster-wide networks description, where data channels using embedded systems provide precise input for making decisions.

Wireless sensor networks provide us with a lot of opportunities. Smart dust based measurements give sufficient data about used machining conditions or parameters for CNC machine tools and industrial robots in industrial environment. (Preden et al., 2007). Providing provably instructions to employees is possible only when having adequate process and manager behavioral models. Elaborated model-checking module can be implemented with minor changes in other sectors as well to reduce wrong decisions caused by human factor.

2. MAIN GOALS OF E-MANUFACTURING

Intelligent prediction of manufacturing capability in enterprises cluster for preventing management failures thus following the Predict and Prevent Bottleneck manufacturing paradigm enables through use of intelligent integrated e-manufacturing achieving of near-zero down-time and the best possible quality of product in comparison with the currently prevalent Fail and Fix paradigm mirrored in reactively addressing and fixing the manufacturing problem once it occurs (see Fig 1.).

In scientific matter, use of embedded systems enables to link enterprise information systems in a new way. Web-enabled and information technologies play indispensable roles in supporting and enabling the complex practices of design and manufacturing by providing the mechanisms to facilitate and manage the integrated system discipline with the higher system levels such as Supply Chain Management and ERP.

[FIGURE 1 OMITTED]

Proactive solutions are major pillars that support the success of the integration of e-Manufacturing and e-business.

In Estonia, machinery enterprises are mainly SME-s. There are over 400 small and medium sized enterprises in the machinery, apparatus, and metal engineering sector. In most cases the bottleneck is missing methodology for analysis of potential effect of implementation and sharing technologies, therefore the enterprises dare rarely share technological resources a or do it ineffective way. The proposed solution allows to integrate product lifecycle management (PLM) with ubiquitous computing gathering manufacturing data through enterprises network and analyzing it in case of possible alerting situation by decision support system.

3. CONCEPT MODELS

Mainly batch-production-oriented SME-s need web-based simple systems which could include larger sensor systems and databases. Proposed such a system forms network between enterprises of the cluster. The solution is unique, and success of development of INNOMET system (www.innomet.ee; Riives et al., 2007) (commercialization in Estonia as a product is in the process) and METNET system (www.metnet.ee, fully developed and commercialized in 2006) has proven that web based systems are well accepted by SME-s. The general new model is described on Fig. 2.

The methodology includes steps as:

* Product description model elaboration;

* General technological path modeling for the product;

* Order handling system elaboration;

* Technological capabilities database elaboration;

* Development of dynamical model of resources (machine tools, robots) monitoring by embedded systems;

* Expert systems concept development:

** alternative paths generation for the cluster/enterprise;

** best technological path selection and validation according machinery and competencies of enterprises;

* Planning mechanism (PLANNER) development;

* E-manufacturing concept system analysis and programming of modules;

* Prototype solution development;

* Testing and evaluation.

[FIGURE 2 OMITTED]

4. CONCLUSION

Tool-making is one of the most advanced and innovative branches of machine-building industry in Estonia. Tools as stamps and jigs are means for making new products; therefore requirements for quality, design, and reliability are high; manufacturing of these have long-time traditions in Estonia. As domestic market is small (only few plastic molding enterprises), most of the products (ca 80%) are exported. Requirements for exportable goods are increasing; at the same time is persisting pressure by China and other Asian competitors of lowering costs and shortening production time. Tool-making enterprises are well organized, having own subsection under Federation of Estonian Engineering Industry, and they belong into International Special Tooling and Machining Association (ISTMA).

Currently product development is on the upgrade only in a few companies, i.e. most part of enterprises is positioned as subcontractors. The research outputs calculation methods and overview of innovation potential for the sector, offers methodology for stabilized growth of economy not depending on subcontracting offered by firms of other countries having low profit margin.

In principle the resulting model and concept are usable also in other sectors of engineering; the software and hardware products can be commercialized. E-manufacturing gives advantages in shorter production times, more effective order handling and faster product development.

E-manufacturing enables cut costs in following supply chain segments:

* Reduction of costs due shorter cycle time;

* Reduction of costs due minimizing unplanned works;

* Reduction of costs due precise planning;

* Reduction of costs due optimal use of resources;

* Reduction of costs due faster data delivery;

* Reduction of costs due faster product development;

* Reduction of costs due elimination of management mistakes.

Acknowledgements The Estonian Science Foundation (Grant No 6795) and Enterprise Estonia (EAS) are acknowledged for supporting the research.

5. REFERENCES

Greeff, G. & Ghoshal, R. (2004). Practical E-manufacturing and supply chain management, Oxford; Burlington, MA: Newnes

Lee, J. (2003). E-manufacturing--fundamental, tools and transformation. Robotics and Computer Integrated Manufacturing, 19, pp 501-507

Otto, T.; Papstel, J. & Riives, J. (2004). Knowledge management in the framework of technological resources network. Machine Engineering, Vol. 4, No. 1-2, (2004) pp 21-28

Preden, J.; Sarkans, M. & Otto, T. (2007). Diagnostics of Machining and Assembly Systems by Networked Motes. Machine Engineering, Vol. 7, No. 1-2, (2007) pp 68-77

Riives, J.; Otto, T. & Loun, K. (2007). Methods for Enhancing Productivity and Work Efficiency in the Workshop. Machine Engineering, Vol. 7, No. 2, (2007) pp 86-95

Sumner, M. (2005). Enterprise Resource Planning. Pearson Prentice Hall, New Jersey

Zurawski R. (2005). The Industrial Information Technology Handbook. CRC Press