Open source supply chain planning software

Introduction for production planners

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Agenda

Production planning workflow Data loading Plan generation Plan review and analysis Export to ERP system

A day in the life of a production planner

© 2016 frepple.com

Production planning workflow

Data from external

data sources

+ Sales

forecast+

Inventory planning

parameters

ProposedPlan

Approved plan

Data loadingand initial plan

generation

Plan reviewIncremental plan

changes

Export to external system

Workflow steps:1. Data loading 2. Creation of initial plan3. Plan review and incremental plan changes4. Export to external systems

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Production planning workflow

When frePPLe is used as a standalone tool by the planner:

The planner loads and maintains all data in frePPle Upload Excel spreadsheets Edit forms and data grids in the user interface

The user will generate the plan when all data is ready When frePPLe is used integrated with your

ERP system: Automated data interfaces synchronize the data in

frePPLe with the latest status from the ERP Data interfaces and plan generation typically are

scheduled to run automatically. When the planning arrives in the morning, an initial plan is waiting for review.

1Data loading

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Production planning workflow

FrePPle runs an finite capacity planning and scheduling algorithm

Constrained and unconstrained planning modes Material constraints Capacity constraints Lead time constraints

Bi-directional propagation in the supply chain Backward propagation

demand from sales order to resources and suppliers

Forward propagation of constraints from suppliers and resources to the demand

Demand prioritization

2PlanGeneration

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Production planning workflow

Overall plan review Capacity review Inventory review Delivery plan review of orders

Exception based analysis Late order analysis

Drill down into a customer order that is planned late, review its delivery plan and the causes for the delay

Critical purchase order review Understand for which open purchase orders the

planner should contact the supplier to expedite the delivery

Excess inventory / safety stock violations Identify inventory outside the expected limits

3PlanReview

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Production planning workflow

The plan output for an ERP system consists of: Purchase orders Distribution orders Manufacturing orders

Transactions Proposed

New suggestion by frePPLe, not yet communicated to the ERP Confirmed

Execution is already ongoing, transaction is already in the ERP Closed

Exporting the new proposals from frePPLe can happen in 2 modes:

Incremental export capability for proposals manually selected by the planners

Automated bulk export of all proposals (using configurable filters) after approval of the overall plan

4Export to ERP system for execution

© 2016 frepple.com

Agenda

Production planning workflow Data loading Plan generation Plan review and analysis Export to ERP system

A day in the life of a production planner

© 2016 frepple.com

Cockpit screen

All users workflows start their work on the cockpit screen

Every user can configure a personal dashboard with the widgets that fit his/her tasks

For a production planner the following widgets can be useful:

Purchase orders Manufacturing

orders Distribution orders Late orders Resource utilization Delivery

performance

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Data loading

FrePPLe provides powerful data maintenance capabilities for data that isn’t maintained in other systems

Export/import data as Excel spreadsheet

Intuitive data grid editor supporting inline editing, filtering, and sorting

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Plan generation

From the execution screen the planner can trigger generation of a new plan, either constrained or unconstrained

This task can easily be automated using the command line utility “frepplectl”

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Plan overview

A number of reports provide a overall overview of the plan

Resource report Inventory report Operation report

Reports can be viewed as graph or data grid, and results can be exportedto Excel

Drilldown capabilitiesprovide more detail

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Interactive Gantt chart

Visually review the plan Use colors for criticality,

delay, priority, item category, operation category

Adjust the plan Replan customer

orders Adjust operation

date&quantity Change operation

status Plan changes are automatically propagated

Move an assembly operation => schedule for its subassemblies also moves Add a new assembly operation => the plan for its subassemblies is updated Delete an assembly => some customer orders can no longer be satisfied

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Exception based workflows – Ex. 1Late order analysis

The cockpit screen gives a short list of late orders

Click on the title bar of the widget gives the complete list of late demands

Drilling down on a late demand displays its delivery plan

Red line is due date

Black line is today “Why short or

late” tab shows the constraint causing the delay

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Exception based workflows – Ex. 2 Review critical purchase orders

The cockpit screen gives a short list of critical open purchase orders

Click on the title bar of the widget gives the complete list

The criticality value is an indication of slack time

Criticality of 0 indicates the purchase order is on the critical path for demands

Criticality of 999 indicates redundant purchase orders

The planners use this information to call suppliers to expedite and de-expedite open purchase orders

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Plan export

FrePPLe has packaged integrations for Odoo and Openbravo

Proposed purchase, distribution and manufacturing orders can be selected by the planner and individually exported to the ERP

A bulk export to the ERP of the complete reviewed plan is also possible

Configurable filters control what is getting exported

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Other screens used for occasional review and analysis, depending on the production planners responsabilities:

Other screens

Distribution planning screen Allows editing of the forecast and

inventory planning parameters Also has the capability to review

and approve transactions

Sales order list showing all customer sale orders

Normally this list will be populated with an automated interface from the ERP system

Useful to prioritize orders

Order quoting screen Displays the expected delivery date

for a new customer order you are about to enter in the ERP system

Computes a feasible delivery date considering all capacity, material and lead time constraints

Forecast editor Allows updating of the sales

forecast

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Try it out yourself

Online demos can be accessed at:

https://manufacturing.frepple.comhttps://distribution.frepple.com

User : adminPassword : admin

Hint:Use the “guided tour” to walk through the “day-in-the-life”

workflows