Revolutionize Material and Production Planning with Advanced Planner Deborah Vermillion, CPIM, CIRM CISTECH Inc.

What is Advanced Planner? Advanced Planner is an alternative to XA MPSP, MRP and CRP Windows based fast MRP that helps you to do interactive planning Allows you to visualize load on the facilities (work centers). AVP uses color coded graphs and charts that makes it easier to manage the master schedule process. This includes material and capacity testing Helps you to take appropriate decisions such as offloading, outsourcing, level loading etc to meet the on time delivery of your customer orders You can also estimate the labor requirements to support your plant schedules Generates suggested supplies( both MOs and POs), supply exceptions, detailed operation start times and shipment delivery dates

How does AVP do this? Planning information is downloaded from the AS400 creating an Access database on the PC Planning run is done on the PC eliminating job conflicts on the 400 and decreasing processing time. This allows for “more” planning runs. Quicker response time!!!

Product Structures part attributes Standard and workorder bills Standard and workorder routings AVP Engine Demand Forecasts customer orders Replenishment policy Supply inventory on hand shop orders and allocations Outside operations purchase orders Plant Structures Workcenters Labor Procurement Plan purchase order releases expedite; defer; cancel Production Plan manufacturing order releases load vs. capacity workcenter schedules Shipping Plan customer promise dates AVP- Input Output

AVP/MRP Similarities Both use all the planning modifiers in the Item Balance/Plan record Both use the MRP Execution Options for re- scheduling, auto-release, etc. Both use the MRP Horizon Dates Both have direct or indirect interface to Mapics Forecast module Both use the Manufactured due date from the customer orders for planning

AVP vs. MRP An MRP generation is performed by a BOM explosion and netting routine usually overnight With Advanced Planner NO AS400 MRP generation is ever necessary MRP has multi-planning warehouse capabilities 6.1 Provides multi-warehouse planning

MRP/CRP uses Mapics calendars AVP has its own calendar within the database. This calendar holds hours of operation per day. MRP has no easy “what if” capability short of a new MRP generation AVP has powerful “what if” capability directly with the AVP access database on the PC AVP vs. MRP

AVP vs. MRP cont’d MRP interfaces with MPSP AVP has its own Master Schedule Routine MRP uses Lead Time to calculate start date AVP uses backward scheduling and the times in the routing to calculate start date

MPSP uses the greater of Customer Order or Forecast AVP nets the CO’s against the Forecast and plans with the CO’s and Net Forecast MRP assumes infinite capacity AVP plans the work load in each work center for capacity review prior to accepting the plan AVP vs. MRP cont’d

MRP provides a warning if a planned order quantity exceeds the Maximum AVP uses the Maximum to create multiple orders due on the same day for the Max quantity (or less) MRP plans an order to be due the same day as the requirement AVP plans an order to be due the day before the requirement AVP vs. MRP cont’d

Forecast can be consumed in four ways: – –Individual Item: The sales of each item consume the item forecast – –An item and its parents: If many possible finished product configurations exist, made from a small number of components, you can forecast at the component level rather than the finished product level. The sales of the item and any parent consume the item forecast – –Planning bill Family: Identify an item as a planning bill item and enter shippable forecasts for the item (% based on qty per in Planning Bill. Forecast is consumed by end item and matching configurations in the Bill of Material – –Product Family: Does not use a Planning Bill. The ‘Base’ Item is forecasted. Customer Order Demand for items within the Product Family consume the ‘Base’ Item’s forecast. (introduced at AVP 6.1) AVP extras: Forecast Consumption

Forecast Consumption This is the forecast consumption chart within AVP

AVP Extras Config.ini settings to: – –Calculate run time by flow or batch method – –Uses RM Quantity (at the time of the RM transaction) or Operation Quantity Completed (from Labor Reporting) to calculate balance due – –Can define horizon length values days

AVP Extras You can optionally update either or both – –The promise date on the customer order – –The manufacturing due date on the customer order

Questions?

Advanced Planner Process Downloading Data to the Engine – –Pulls BOM, Route, Item, Item process, Item plan, Forecast, CO’s and/or Manual Requirements – –Creates flat files that are pulled in to create access database

Generating the Plan – –Forecast Consumption – –Nets the Requirements against on hand & on order (Load Project) using Access Database Builds product structure network using the BOM and Routing Plans Orders (PO, MO & Schedules) Advanced Planner Process

Manipulate the Plan – –View Load to Capacity Chart – –View items on Load – –Level Load both Material and Capacity – –Time phased view – –Drill down/up – –Perform “what-if” planning Advanced Planner Process

Load To Capacity and Time phased load : Identify overload problem Orders that can be offloaded-Yellow Planned Orders- Green New Colors at AVP 6.1: Firm Planned- Pink Released- Light Orange

Load To Capacity Chart Red – W/C is overloaded Yellow – W/C has past due backlog Blue – Overload within one time period that can be corrected by re- scheduling, offloading, etc. Green – Plan is within capacity constraints Routing Facilities Process Hours; Setup hours; Capacity hours

As decisions are taken you get instant feedback

Order waterfall view: Identify what is needed when and the Critical chain

Advanced Planner Process Upload to Mapics Files – –Loads info into the MRP planning work files: Requirements-unconsumed forecast and generated demand Planned Orders-all supply orders, including open, firm planned and planned Demand Ref-Demand information Reschedule Activity-rescheduling actions

Advanced Planner Process What happens? – –Reschedules open MO’s/PO’s/Rep schedules according to set up – –Updates the CO dates if specified in the upload options – –Updates work center file in the MO/REP operations as specified during offloading – –Loads the MRP planning files – –Creates the Order Review file – –Prints MRP reports as specified

Planning Execution Once plan is saved – –Execute plan using OBPM OR – –Green Screen Order review and release OR – –Repetitive

Execute Plan using OBPM

Green Screen Execution

MRP Requirements inquiry

Questions?

AVP 6.1 New Functionality Planning Multiple warehouses in one planning run Saving the Schedules to database on the client machine Support for SQL server and Oracle databases Time phased Labor loads Job-step information in the waterfall Automatic offload from one facility to other by batch size Which customer orders to be pushed out Adjusting the operation start times of intermediate operations thru Modifying the delay times Demand Prioritization Ability to handle negative on hand balances.

Waterfall with Job step information

Estimating the Labor Requirement

Which Orders to push out New Commands show the potential order list that will be delayed based upon the current schedule. Global Records not limited to within the Facility. “Which Customer Orders..” lists only Customer Orders where Demand Suggested Date > Demand Due Date. Customer Orders pushed out will be displayed from the “List of Customer Orders..” Generated from within the Facility. Lists supply orders where Supply Due Date > Supply Suggested Dated

AVP Benefits Improves capacity usage—maximize factory productivity Increases revenue—the ability to consistently provide more accurate dates and deliver on time will attract more business Streamlines purchasing an item that has an m-plan or s-plan order (outsourcing)

AVP Benefits Expediting costs are lowered due to improved planning Improves internal processing coordination—running your planning process quickly and more frequently will Catch changes and allow you to alert the shop floor and suppliers quicker

AVP Summary Alternative to traditional MPSP/MRP/CRP Tight integration for quick implementation Quick ROI from improved capacity planning Improved Capacity usage Decreased Lead time and inventory Decreased costs

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