•  The MAST-SAIL project starts with the identification of most basic data.

•  Start with a list of part numbers 

•  Then add a machine cycle and load/unload time for each part 

• Establish a forecast demand for each part. This can be for any time period (Monthly to Annual) 

• Use this data to begin building a MAST Model

Sequence of Activities: 

1. Generate Daily Schedule 15 minutes prior to 1st shift

2. Download data to cell control

3. Cell Control activates pallets

4. SAIL provided Load Station Instructions

5. Track Paths

6. Mark Parts with SAIL provided serial number

7. Inspection Signals

8. Production Counts

9. OEE Plan vs. Actual

10. Quality Audit

Continuous improvement is the addition and deletion of paths as production mix change over time. The objective is to maintain machine utilization at a target or planned OEE (Overall Equipment Efficiency). The flexibility plan defines the minimum number of paths by percent of machine hours to meet a production mix at a planned OEE. A production mix is specific production quantity for a set of part numbers over a specific set of time typically a month. When the production mix changes, so must the flexibility plan to maintain planned level of OEE. 

Capacity Review

Capacity review is performed periodically using the MAST Modeling software. The frequency and timing for this review is determined by changes in the production mix. Most typically, the capacity review is performed at least once per month while relying on the flexibility plan to maintain target OEE between reviews. Here are the steps for capacity review using MAST. 

1. Open MAST Software

2. Import SAIL template into MAST. Current paths and cycle times that have been maintained in SAIL are used

3. Import forecast demand into MAST (options)

   1. Use SAIL import orders by importing the same csv file directly into MAST

   2. Use 4 column or 5 column import from forecast spreadsheet

   3. Use Orders in process from SAIL Unscheduled Order list

4. Set the production period to match the number of days representing the forecast quantiy

5. Simulate the entire production period

6. If the simulation results show all forecast production completed within the production period, then no changes are needed to the flexibility plan. 

7. If the simulation results show not all production completed, then path configuration must be adjusted for new production mix

   1. Identify Part Number with incomplete production amounts

   2. Check pallet use is below 100%, that pallets are not the bottleneck constraint.

   3. Review the number of active pallets and re simulate at different levels 

   4. Delete paths to shared machines and pallets of competing part numbers

   5. Add paths to part numbers with low production amounts

8. Trial and error by adjusting paths until production mix is complete within production period

9. Export the MAST model to SAIL template

10. SAIL will use the new flexibility plan for schedule generation.

11. Be sure that all paths have been proven production ready

With the new flexibility plan implemented, SAIL will maintain target OEE for the updated production mix. Having a capacity review at regular intervals will ensure that the flexibility plan is capable to maintaining a target OEE as production mix change. A flexibility plan with a high percent of machine hours having alternative paths will support OEE for wider variations in production mix. Regular capacity reviews will determine the relation between frequency and the flexibility plan. 

Reducing Manufacturing Cost with MAST/SAIL software 

Over the past 5 years, MAST/SAIL software has been implemented in a wide variety of manufacturing settings. These settings range from contract machine houses to major corporations. From these experiences, we have observed three outcomes that deliver significant (10-40%) reduction in manufacturing cost. 

From our past years of projects, here are the top three items that reduce manufacturing cost. Note: these are outcomes from successful implementation of the MAST/SAIL software. 

1. Flexible capacity - A minimum of 25% of all machine hours must have an alternative path. A path comprises a part number, process or operation, pallet, fixture, and machine. An alternative path is at least two pallets or two machines capable of process the same part number and operation. Most machine cells are planned with flexibility using alternative paths, but this benefit to reducing cost only when the flexibility is realized in daily decisions. MAST/SAIL software uses modeling to configure the minimum implementation cost that attains 25% flexible hours, and then uses this model to generate daily schedules. The combination of planning for flexibility and daily management is what delivers reduction in manufacturing cost. 

SAIL Screen Captures: MAST – Flow Route showing alternative machines MAST – Part Detail showing alternative pallets Capacity Planning - configuring flexible capacity to match long term (more than one month) demand. SAIL – Routing Instructions 

2. Daily Order Scheduling. Building to daily demand is a Lean Technique proven to minimize waste and reduce manufacturing cost. The difficulty comes in its implementation. MAST/SAIL software provides automatic data flow/sharing from the ERP system directly to cell controls. Orders automatically appear in SAIL Order list via data sharing or Kanban scans. An allocation process customized in SAIL generates a daily schedule and transfer these instructions to cell control computers. As the parts are processed, they are automatically assigned to fill orders as they are completed. MAST/SAIL reports order status every few minutes. This report contains quantity completed, standard hours and actual hours. Reporting actual hours required to complete an order results in knowing actual manufacturing cost. Knowing the actual manufacturing cost allows the adjustment to standard cost and quotations for contract work. 

MAST/SAIL Screen Captures: SAIL – Unscheduled Orders SAIL Watch - Allocation methods and triggers L/U Process - Operator screen SAIL - Order Reporting SAIL – Machine Cycle Monitor (actual hours) 

3. Part serialization based Quality Plan. Most manufacturers see part marking as adding cost without benefits. However, marking parts with serial numbers that reference an electronic record of its path and inspecting paths based on a frequency has delivered significant reduction in scrap. Linking consecutive CMM reports from each path provides a means to observe trends and intervene a corrective action before a quality issue arises. MAST/SAIL software assigns a serial number to every part, tracks the path of the part and interfaces with marking devices. These marking devices range from Zebra ™ printer to print a label, pin printers for robot handling, to depositing parameters in CNC programs for scribing in a machine. Inspection types and signals comprise the quality plan and MAST/SAIL sends signals to unload operator. Inspection data is collected and linked to the serial number of the part. MAST/SAIL software provides quality audit reports for each path where root cause quality issue is resolved. Reducing scrap is a common outcome of SAIL projects. 

MAST/SAIL screen captures: SAIL – Station Log with serial numbers SAIL - Inspection Types and Frequency definition Part Inspection – Inspection List SAIL – Inspection Audit Report 

Lean Manufacturing: Cost savings will only come from reduction in material, labor content, or machine content of a part. Savings associated from reduction of waste (Lean practice) will not have significant benefits for long term cost reduction. Also, this type of savings will not offset the cost pressure from different labor rates of different sources or transportation costs. 

MAST/SAIL - Software that makes machine cells work for you.