material and production planning options with xa deborah vermillion, cpim, cirm cistech inc
Post on 26-Dec-2015
219 Views
Preview:
TRANSCRIPT
Material and Production
Planning Optionswith
XA
Deborah Vermillion, CPIM, CIRMCISTECH Inc.
www.cistech.net
Agenda
• Traditional Planning-MPSP, MRP, CRP
• Advanced Planner
• Thru-Put
PRODUCT PRODUCT DATADATA(PDM+, IM)(PDM+, IM)
Item MasterItem Master
Bills Of Bills Of MaterialsMaterials
RoutingsRoutings
Inventory Inventory LevelsLevels
WorkcentersWorkcenters
Existing MosExisting Mos
Existing POsExisting POs
FFiinnaanncciiaall
CCoonnttrrooll
TRADITIONAL TRADITIONAL CAPACITY PLANNINGCAPACITY PLANNING
MPSPMPSP
Production SchedulesProduction Schedules(Inventory Management)(Inventory Management)
ProcurementProcurement(Procurement Management +)(Procurement Management +)
ProductionProductionSHOP FLOOR CONTROLSHOP FLOOR CONTROL
(PM&C, PC&C, Paperless)(PM&C, PC&C, Paperless)
Vendor SchedulingVendor Scheduling(Procurement Management +)(Procurement Management +)
ShippingShipping(COM)(COM)
ReceivingReceiving(Inventory Management)(Inventory Management)
Customer OrdersCustomer Orders(COM)(COM)
ForecastsForecasts(Forecasting)(Forecasting)
ReportingReporting(Browser)(Browser)
MRPMRPCapacity Capacity and Materialand Material
AnalysisAnalysis
Traditional Planning Cycle
• Master Scheduling– Interface with Forecast thru DMDIFF file– Blends COM orders and Forecast or Forecast
only– Allows build up for seasonal demand– Rough cut capacity for critical items
Traditional Planning Cycle
• But:– Limited view of
capacity– Can be
Iterative, time consuming…
Traditional Planning Cycle
• Material Requirements Planning– Uses Master Schedule from MPSP, COM Orders
or Manual requirements to drive plan– Uses PO’s, MO’s, Rep Schedules to satisfy plan
requirements – Result is Time phased purchased material and
production plan
Traditional Planning Cycle
• But:– Capacity not
considered– Requires MPSP update
for changes in blended demand
– ‘what-if’ capabilities limited (manual req’s)
– Impact of new demand-wait until night
Order/Schedule Order/Schedule Recommendation by ItemRecommendation by Item
Traditional Planning Cycle
• How does yours work today?– Appropriate staff effort?– Integration from demand to scheduling?– Length of planning cycle, can we provide
quick response to changes in customer demand?
– What if we get this order?– On time deliveries and consistent schedule
performance?– Excess inventories?
• Do shortfalls cost us time/money/cust sat?
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
AV
P E
ngi
ne
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/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.
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 1-999 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 Orders that can be offloaded-Yellowoffloaded-Yellow
Planned Orders- Planned Orders- GreenGreen
New Colors at AVP New Colors at AVP 6.1:6.1:
Firm Planned- PinkFirm Planned- Pink
Released- Light Released- Light OrangeOrange
Load To Capacity Chart
Red – W/C is overloadedYellow – W/C has past due backlogBlue – 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
Estimating the Labor Requirement
Which Orders to push out
New Commands show New Commands show the potential order list the potential order list that will be delayed that will be delayed based upon the current based upon the current schedule.schedule.
Global Records not limited to within the Global Records not limited to within the Facility. “Which Customer Orders..” lists only Facility. “Which Customer Orders..” lists only Customer Orders where Demand Suggested Customer Orders where Demand Suggested Date > Demand Due Date. Customer Orders Date > Demand Due Date. Customer Orders pushed out will be displayed from the “List of pushed out will be displayed from the “List of Customer Orders..” Customer Orders..”
Generated from within the Generated from within the Facility. Lists supply orders Facility. Lists supply orders where Supply Due Date > where Supply Due Date > Supply Suggested DatedSupply Suggested Dated
Questions?
Why Thru-Put?• AVP is a planning tool; Thru-Put is an execution
tool.
1.Use Thru-Put to identify all resources (internal –machines, tools, labor and external-suppliers, subcontractors) that limit your output (your constraints)
2.Decide how to best exploit the constraints’ capacity-Synchronize the work sequence of your constraints with prioritized demand
Why Thru-Put?
3. Subordinate everything to the constructed schedule-Synchronize all important support functions
4. Promise new orders based on Real Capacity and materials constraints, on an ongoing basis.
ThruPut – Load Data
Thru-Put first reads the Thru-Put first reads the database from the host database from the host system(s) – ERP, MES or other system(s) – ERP, MES or other – and pulls all relevant – and pulls all relevant information into the Server’s information into the Server’s memorymemory
ThruPut – Quote Delivery DatesUsing a web-based Using a web-based workbench, users quote workbench, users quote delivery dates for new delivery dates for new demand based on demand based on currently available currently available capacity AND raw capacity AND raw materialsmaterials
Users also have Users also have the option to the option to “force” new “force” new demand in the demand in the schedule, and schedule, and have Thru-Put have Thru-Put calculate the calculate the impact of the new impact of the new demand on demand on existing ordersexisting orders
Creating an Executable Schedule With Thru-Put
Phase 1 – Analyze Purchased Parts
During the first phase of During the first phase of scheduling, Planners and scheduling, Planners and Buyers analyze materials Buyers analyze materials shortages, based on existing shortages, based on existing POs and component lead POs and component lead times. times.
This phase allows This phase allows purchasing to work on purchasing to work on shortages BEFORE the shortages BEFORE the corresponding orders are corresponding orders are pushed out by Thru-Putpushed out by Thru-Put
Users follow Thru-Put’s Users follow Thru-Put’s phased scheduling approach phased scheduling approach which is based on the first 3 which is based on the first 3 steps of Theory of steps of Theory of Constraints:Constraints:
-Identify The Constraint(s)Identify The Constraint(s)
-Exploit the Constraint(s)Exploit the Constraint(s)
-Subordinate everything Subordinate everything else to the Constraint(s)else to the Constraint(s)
Thru-Put highlights Thru-Put highlights materials shortages materials shortages (required date prior to (required date prior to available date)available date)
Phase 1 – Analyze Purchased Parts
This process allows This process allows Purchasing to work with Purchasing to work with Planning and determine Planning and determine possible solutions to possible solutions to shortages PRIOR TO shortages PRIOR TO analyzing capacityanalyzing capacity
Phase 2 – Analyze Machine Capacity
During the “identify machine constraints” During the “identify machine constraints” phase, ThruPut calculates load on all work phase, ThruPut calculates load on all work centers based on released and planned centers based on released and planned work, and corresponding demand. It work, and corresponding demand. It displays resulting % of load to capacity in displays resulting % of load to capacity in simple bar charts and graphs. Automatic simple bar charts and graphs. Automatic level-loading is also available to the user level-loading is also available to the user at this stage.at this stage.
Phase 3 – Analyze Labor Constraints
Thru-Put displays the results of a Thru-Put displays the results of a detailed analysis of labor capacity detailed analysis of labor capacity and load. Users can then limit the and load. Users can then limit the work centers capacity based on labor work centers capacity based on labor availability.availability.
Phase 4 – Level-Load Constraint(s)
Thru-Put then level loads all work Thru-Put then level loads all work on selected constraints using a on selected constraints using a finite capacity model. Various tools finite capacity model. Various tools such as Overtime, Offloading, and such as Overtime, Offloading, and Batching are available to the user to Batching are available to the user to eliminate lateness caused by eliminate lateness caused by capacity shortagecapacity shortage
In this In this simulation, simulation, Thru-Put will Thru-Put will group all group all similar parts similar parts scheduled scheduled over 3 over 3 consecutive consecutive daysdays
Phase 5 – Subordinate Non-Constraints
In the last phase of constructing the In the last phase of constructing the schedule (subordination), Thru-Put schedule (subordination), Thru-Put creates a dispatch priority list for creates a dispatch priority list for each non-constraint resource in the each non-constraint resource in the facility. It does so by backward and facility. It does so by backward and forward scheduling from the level-forward scheduling from the level-loaded constraintsloaded constraints
The result is an EXECUTABLE The result is an EXECUTABLE schedule which maximizes schedule which maximizes the output of the constraints the output of the constraints –hence the plant, WHILE –hence the plant, WHILE minimizing necessary WIP minimizing necessary WIP and Purchased Parts and Purchased Parts inventory to support itinventory to support it
Executing ThruPut Schedules
Execute Schedule – Dispatch and Track
After completion, optimized After completion, optimized schedules are available for schedules are available for display and adjustments on high-display and adjustments on high-resolution, large-format monitors resolution, large-format monitors throughout the facility.throughout the facility.
Users can access several Thru-Users can access several Thru-Put standard scheduling reports Put standard scheduling reports on line at any time, or easily on line at any time, or easily build their own using off-the-build their own using off-the-shelf reporting toolsshelf reporting tools
Execute Schedule – Dispatch and Track
Secure access to ThruPut Secure access to ThruPut reports and screens can be reports and screens can be tightly controlled using Thru-tightly controlled using Thru-Put’s User ManagerPut’s User Manager
Execute Schedule – Dispatch and Track
Thank you!!Thank you!!
top related