collaboration among sales, production, planning, purchasing, maintenance and management to...
TRANSCRIPT
INTRODUCTION
Collaboration among sales, production, planning, purchasing, maintenance and management to positively impact the bottom line.
CRITICAL BUSINESS ISSUES
Late deliveries due to manufacturing delaysMissed sales due to demand exceeding capacityLost orders due to excessive Work-in-ProcessHigh production costs due to machine set-up or machine down timeExcessive overhead due to managing scheduling changes and impact on delivery scheduleDifficult to plan for future capacity requirements
CRITICAL BUSINESS ISSUES
Job delays due to material shortages (raw materials and/or manufactured components)Excessive overtime costs due to inefficient resource utilizationJob delays due to tooling, molds or dies unavailableDisconnect among departmental objectives (sales, production, planning, purchasing, maintenance and management)Difficult to coordinate between plants and/or planners
Machines
Labor
Tools & Dies
Material
RESOURCES
MANUFACTURING OPERATIONS
• Raw Material• Machine 1 or 2• Saw Blade
Saw
• Machine• Skilled Labor
Paint • Labor Pool
Assemble
On-Time Delivery
Minimize Set-Up
Maximize
Profit
MANAGEMENT OBJECTIVES
MANUFACTURING PROCESS
Line 2
Line 1
Bird House
Bird Feeder
Saw 13/8 “
plywood
Saw 2 1 /4“
plywood
Sand 1
Sand 2
Paint & Dry
House Sub
Assembly
Feeder Sub
Assembly
Final Assembly
PackagingShip
PRODUCTION SCHEDULE
Line 2
Line 1
Bird House
Bird Feeder
Saw 13/8 “
plywood
Saw 2 1 /4“
plywood
Sand 1
Sand 2
Paint & Dry
House Sub
Assembly
Feeder Sub
Assembly
Final Assembly
PackagingShip
SHOP FLOOR DISRUPTIONS
Line 2
Line 1
Bird House
Bird Feeder
Saw 13/8 “
plywood
Saw 2 1 /4“
plywood
Sand 1
Sand 2
Paint & Dry
House Sub
Assembly
Feeder Sub
Assembly
Final Assembly
PackagingShip
J4
J1 J3 J5
J8
J6 J7
J2
Late order material shortage
Inefficient set-up
higher costResource
Bottleneck
Machine down
SHOP FLOOR OPTIMIZATION
Line 2
Line 1
Bird House
Bird Feeder
Saw 13/8 “
plywood
Saw 2 1 /4“
plywood
Sand 1
Sand 2
Paint & Dry
House Sub
Assembly
Feeder Sub
Assembly
Final Assembly
PackagingShip
J4
J8
J2
Late ordermaterial shortage
J2
J3 J5
J1
J6 J7
APS – THE SOLUTION
Plans and schedules production based on available materials, labor and plant capacityOptimizes the schedule to meet customer service objectives, operational efficiencies, cost containment and profit objectivesAllows planners to quickly respond to disruptions on the shop floor and immediately see the impactProvides a safe planning environment using “what-if” as well and ability to “undo” a schedule change
APS - WHO BENEFITS?
Improves communication among departments−Accurate order dates to sales department−Detailed, actionable schedules to production department−Capacity loads to set staffing and machine resources to the planning department
−Schedule-driven material requirements to drive ordering to the purchasing department
−Cash flow projections to management−Maintenance & setup schedules to maintenance
department
APS – THE BOTTOM LINE
Decreased ExpensesReduced Production TimesImproved Machine UtilizationReduced Inventories
Increased RevenueIncreased On-time DeliveriesReduced Customer Stock-outs
Increased Cash FlowReduce Order-to-Cash andCash-to-Cash Conversion Cycle
PROCESS FLOW
BOM Routing
Work Orders
Sales Orders
Forecast
MRP
Purchase Orders
RM Inventory
Shop Floor
FG Inventory
Receiving Production
?
PROCESS FLOW
BOM Routing
Work Orders
Sales Orders
Forecast
MRP
Purchase Orders
RM Inventory
Shop Floor
FG Inventory
Receiving ProductionA
A
NEXT STEP
Call (888) 317-8807
To learn more about how Advanced Planning & Scheduling can work for your business