1 Advanced Planning & Scheduling Presentation
CUSTOMERSCUSTOMERS SUPPLIERSSUPPLIERS PURCHASING PRODUCTION PLANNING CUSTOMER SERVICE FINANCE Acknowledge- ment of the problem Evaluation of the financial impact of the changes Acknowledgement to selected customers Negotiation with Suppliers of related components to delay shipments Any delay in the replanning process eventually results in lower operational performance Review of Production plans Capacity adjustments Review of delivery programs D+? D+?? D D+??? D+????? D+???? Balance Demand & Supply
CUSTOMER SERVICE CUSTOMERSCUSTOMERS SUPPLIERSSUPPLIERS Cycle time variation Capacity problems Production quality problems Material quality problem Yield variation Modification of operational objectives PURCHASING PRODUCTION PLANNING FINANCE Events Which Destroys Balance Order modification (date, quantity, specifications,...) Promotions Sales forecast update Product Listing / Delisting Products Phase in / Phase out Engineering Changes
Impacts of Long Re-Planning Long re-planning cycle times Demand plan and production plan temporarily out of synch Production plan and capacity plan temporarily out of synch Production plan and purchasing plan temporarily out of synch Infeasible plan Late deliveries Poor usage of capacities Late resynchron- ization Late resynchron- ization Premium transportation costs Premium purchasing costs Unnecessary production or purchases Excess inventory Quality issues
Issues Unable to commit and stick to a date Knows it will be delayed but unable to find out how much No visibility of how orders will get affected due to problems Most of time is spent on interacting with other departments Unable to plan taking all material & capacity constraints Multi-products & multi-process makes planning cumbersome Unable to sequence operations effectively
APS Solution PastFutureCurrent Enterprise Resource Planning (ERP) Advanced Planning & Scheduling (APS) Do you want to take decision looking into the past or looking into the future?
IRCA APS Solution PlanningScheduling ExecutionHistory Replenishment Forecast Planned Orders Closed Orders Safety Stock Netted Forecast Customer Schedule Sales Scheduled Orders History Orders Forecast Sales Inventory WIP IRCA ERP Costing
Data Flow Items Inventories BOM Routings Capacities Demand WIP Business Rules Capacity Profile Inventory Profile Shortage On-time Delivery Other Exceptions Alerts Bottleneck Gantt Chart ExportPlanLoad Planvisage InputOutput
Material Constraints Lot Size Material Availability Transfer Batch Quantity Alternate Item Material Reservation Customer Due Date Consolidation By Products Operation Level Consumption Supplier Fair Share
Capacity Constraints Throughput, Setup, Wait and Queue Time Working Shift, Non Working Shift and Over Time Planned and Unplanned Machine Down Time Alternate Resource Alternate Routing Batch, Subcontract, Pooled and Additional Resource Sequence Dependent Setup Time Yield Campaign
Demo of IRCA APS Solution A BC RM_DRM_ERM_F Route_B Route_C Route_A HeatStamp Route_B Run time 2 hours Run time 1 hour AssembleFinishTest Route_A Run time 2 hours Run time 1 hour TurnDrill Route_C Run time 2 hours Run time 1 hour