Design simulation and information dashboard for manufacturing control using systematic approach: a case study of hospital beds production

Abstract

This study is being conducted in a hospital bed industry which uses a special workbench to assemble the beds. This papers outlines the efforts taken to setup manufacturing information system which is use mode D min 1 WIP buffer production scenario. The main objective of the study is to design production planning simulation tool to implements mode D min 1 WIP buffer production scenario and manufacturing control dashboard as feed back of the manufacturing control system. The study conducted to a company which is implemented ERP SAP R/3 enterprise with the module used are FI, CO, SD, PP and MM. The ERP SAP system only effective on the company level but in the production floor does not. The production floor consist of multistage of production, the SAP system cannot reach information of production floor in every production stage. Every production stage has their own system to make production schedule and activity run. Not one system integrated production information for each of stage production. The system not able to make succeed supply chain system to supply components complete in the right time for every stage of production. This study provide dashboard with information of production in every stage production with their production status, to assure availability of components to build products complete. To solve the problems implemented systematic approach method to define the overall function of the production information system and then breakdown overall function to the function structure. For every function structure can be describe input variable and the output expected. Using matlab to setup function as describe in the function structure to define the output. The output shown in dashboard is base on windows display using GUI system which is available in matlab environment. Prototype of dashboard has been built to give production information of incoming part to welding plant, paint shop and in the assembly line. The dashboard has ability to show production status in every production stage real time. This dashboard able to cover the lose of ERP SAP system with giving feed back to management.