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Oracle Production SchedulingMaximize shop floor throughput and optimize resource utilization
How can you:– Sequence orders to best use your production resources?– Offload production to alternate resources?– Minimize the effect of unplanned production and down time?– Evaluate the impact of a supply shortage on fill rates?– Support revenue growth using existing production assets?
Typical Scheduling Challenges
Large amounts of work in process inventoryConstant expeditingPoor shop floor performance and poor delivery performanceUnpredictable manufacturing throughput timesNo visibility to future planned requirementsVulnerable to unplanned downtime
Poor visibility to changes, manual process, expedite everything
Poor visibility to demand and production plan, many disparate spreadsheets, rush everything
Long cycle times
Traditional Approach
Feasible schedules that respect manufacturing constraintsImproved utilization and minimal setup timeConsistent manufacturing cycle timesImproved schedule adherence and delivery performanceReduced work in process inventoriesSecure and integrated system
Feasible on-time schedules with improved throughput and utilization
Complete visibility to demand and production plan, secure integrated system, improved cycle time
Monitorperformance
Analyzeexceptions
Short cycle times
Better Approach: Production Scheduling
How
Delivers
Maximize throughput of bottleneck resources– Automatic detection of bottlenecks– Minimize setup with intelligent sequencing
Improve shop floor performance– Minimize the effect of unplanned downtime– Easy identification of issues– What-if rescheduling– Drag and drop
Quickly determine the best schedule– Fast easy simulation– Scenario comparison and key performance indicators
Implement quickly by leveraging out-of-the-box integration
– Integrated manufacturing planning and scheduling– Fully integrated with Oracle E-Business Suite
Maximize shop floor throughput and optimize resource utilizationOracle Production Scheduling
Complete e-business planning solution
Collaborative Planning CP
Real-Time Sales and Operations Planning
From
det
ail t
o su
mm
ary
CP
From short-term to long-term
SC Exception Management
PSProduction Scheduling
ASCPDistribution Planning
GOPGlobal Order Promising
ASCPSupply Chain & Manufacturing Planning
IOInventory Optimization
DMDemand Management
SCISupply Chain Intelligence
DevelopMarketSellOrderPlan
Procure
Make
FulfillService
Maintain FinanceHR
ProjectsAll Product,Customer,& SupplierInformation
SNONetwork Design
Oracle Advanced Planning
* Integration with Oracle EBS (R11.I.10)
Increase bottleneck utilization up to 25%
Reduce work in process up to 25%
Reduce scheduling cycle time from weeks to minutes
Drive continuous improvement
Typical key benefitsOracle Production Scheduling
Maximize throughput and increase resource utilization
Improve shop floor performance
Determine the best schedule
Comprehensively plan and schedule production
Enables you to…
Oracle Production Scheduling
Determine a feasible schedule considering all your constraints
– Schedule and synchronizes multiple stages of production
– Automatically detects floating bottlenecks
– Considers all material and resource constraints
Easily identify issues– Exceptions highlight constraints– Drill directly to root causes
Easily create feasible schedulesMaximize Resource Utilization
Minimize setup time– Intelligent sequencing to minimize
major and minor setups– Recognizes last operation run– Setup information comes directly
from Oracle EBS
Run optimization– Plan for campaigns to optimize
setup while respecting minimum run constraints
– Weigh on-time performance versus setup costs
Minimize lost utilization due to setup timeMaximize Resource Utilization
Sequence work on a paint line from light to dark paint to minimize changeover and cleaning times between color changes, assuming 10hours run per job
PAINT LINE
Time
Orders needing WHITE paint Orders needing BLUE paint Orders needing BLACK paint
Changeover time from white to blue
From To: White Blue Black
White 0 2 6
Blue 10 0 4
Black 10 10 0
Changeover Times (Hours)
Orders Total setup
Total Run Total Time
90 138
9690
Un-sequenced White, blue, black, white, blue, black, white, blue, black 48
Sequenced White, white, white, blue, blue, blue, black, black, black 6
Example: Sequencing
Live on Production Scheduling since September, 2005
Nampak, South Africa
CompanyGlobal manufacturer with 126 facilities in 19 countriesManufacturer packaging products
Planning problem solvedMoved from manually intensive spreadsheet schedules to daily schedules that respect all material and capacity constraintsInstituted standard scheduling practices across multiple facilities
Unique aspects of implementationHigh volume production of a diverse product mixVery complex changeover matrix with over 40,000 entriesMultiple implementations each with unique manufacturing constraints
Significantly reduced scheduling cycle time
Increased utilization of bottleneck resources and reduced setup time
Increased manufacturing flexibility by moving to daily scheduling
Maximize throughput and increase resource utilization
Improve shop floor performance
Determine the best schedule
Comprehensively plan and schedule production
Enables you to…
Oracle Production Scheduling
Exceptions and alerts highlight issues
– Identify potential late demands – Alerts identify the root cause of
the issue– Easy drill directly to the problem
area
Fast simulation and drag and drop rescheduling
– Enables scheduler to quickly asses potential corrective action
Easily identify and resolve issuesImprove Shop Floor Performance
Publish schedule directly to execution
– Reschedules of existing work orders
– Release of new production– Assignment to alternate
resources
Publish dispatch list with detailed schedule and priorities
– Easily view list of operations on a resource
– Clear and up-to-date priorities for production
Seamlessly communicate current priorities to productionImprove Shop Floor Performance
Live on Production Scheduling since June, 2005
W. L. Gore and Associates
CompanyGlobal Manufacturer with revenue over $1.5 BillionManufacturer Gore-Tex fabrics used in many consumer products
Planning problem solvedDetailed scheduling of fabric lamination to improve throughput of critical bottleneck resources
Unique aspects of implementationComplex scheduling problem with floating bottlenecks
Reduced work in process inventory by more than 25 percent
Reduced scheduling cycle time from 1-2 weeks to minutes
Reduced overtime and expediting
Maximize throughput and increase resource utilization
Improve shop floor performance
Determine the best schedule
Comprehensively plan and schedule production
Enables you to…
Oracle Production Scheduling
Easily compare multiple scenarios– Unlimited what if scenarios– Seeded key performance indicators to
assess schedule quality
Evaluate schedule on multiple metrics– Delivery performance (late days, late
orders)– Cost– Inventory performance
Easily implement the approved schedule
– Release approved schedule directly to execution
Quickly determine the most optimal shop floor scheduleDetermine the Best Schedule
Issue– Important demands are not going to
be met on time
Analysis– One resource is the bottleneck and is
completely consumed– All production on this resource is
required for critical production– Working weekend overtime would
enable all demand to be met on time
Decision– Authorize overtime for the weekend– Release new schedule to the shop
floor– Get approval for cost of overtime
Example: evaluate and adjust schedulesDetermine the Best Schedule
Live on Production Scheduling
Toyota Racing Development
CompanyA subsidiary of Toyota Motor Sales USA.Produces high performance engines for the Toyota racing teams
Planning problem solvedMoved from 2 week long spreadsheet based scheduling process to daily schedulingAutomatically generate multiple what if scenarios each day to determine optimal staffing plans
Unique aspects of implementationExtremely complex manufacturing process with many operations andextremely tight tolerancesVery highly constrained by complex automated machining centers
Reduced scheduling cycle time from two weeks to minutes
Reduction in time loss due to retooling
Increased ability to react to engineering changes
Maximize throughput and increase resource utilization
Improve shop floor performance
Determine the best schedule
Comprehensively plan and schedule production
Enables you to…
Oracle Production Scheduling
Make better decisions faster by choosing alternatives
– Automatically detects floating bottlenecks
– Offloads to alternate resources– Enforces all capacity constraints
including materials, resources, and tools
Start quickly– Planners define the problem to solve– Seamless integration with Advanced
Supply Chain Planning and Oracle E-Business suite – Leverage existing setup data
Scheduling for planners, not programmersOut-of-the-box Scheduling
Complete, integrated Manufacturing Planning and Scheduling processSUPPLY PLANNING (ASCP)
PRODUCTION SCHEDULING (PS)
ScheduleWeek 0
ScheduleWeek 1
ScheduleWeek 2
ScheduleWeek 3
ScheduleWeek 4
FIRM
PLANNED
ScheduleWeek 1
ScheduleWeek 2
ScheduleWeek 3
ScheduleWeek 4
ScheduleWeek 5
ScheduleWeek 2
ScheduleWeek 3
ScheduleWeek 4
ScheduleWeek 5
ScheduleWeek 6
Production Plan Week 1 - 12
Production Plan Week 2-13
Production Plan Week 3-14
Production Plan Week 4-15
Planned orders
Firm work orders
Comprehensive Manufacturing Planning and Scheduling Solution
Discrete Manufacturing– Simultaneous resources– Minimum transfer quantities– Sequence dependent setups
Process Manufacturing– Co-products and by-products– Hard links– Campaigns– Changeovers
Semiconductor– Binning– Network routings
Detailed schedules for all Oracle execution processesSchedule Any Mode of Manufacturing
Architecture
Reliable– All plan information resides in the
database – Hot backup and recovery– Leverages grid computing
infrastructure
Open and standards based– Deploy against legacy systems– XML, flat file support
Database-centric architecture
APIs
Oracle ERP
Legacy Systems
XMLFlat file
KPIs Workflows
Internet
PortalPortal
TRADING PARTNERS INTERNAL USERS
Advanced Planning Architecture
Plans and Schedules
OrderPromising
Engine
Scalable and Open Architecture
Supply Chain and Manufacturing Planning
Collaborative Planning
Demand Management DM
Inventory Optimization IO
Global Order Promising GOP
CP
ASCP
Sales and Operations Planning
Forecast
Customerforecast
Orderforecast
Constrained plans
Supplier capacity
Time-phased safety stocks
Forecast and demand variability
Supplycommits
Orderforecast
Network Design SNOForecast scenarios
Production Scheduling
Planned orders
Supply schedule
Sourcing rules
Sourcing rules
Leverage integration at incremental investment
PS
CUSTOMERS
PLANNING PROCESS
SUPPLIERS
Safety stock targets
Integrated, yet Modular
Oracle EBS / PS Integration
Production Scheduling Integration Description
Advanced Supply Chain Planning Production SchedulingPlan for multiple facilities
Which plant makes what products and when
Pre-builds based on capacity shortages
Alternate facilities, suppliers andprocesses
Schedule a single facility
Sequence Production to meetdemands on this facility
Account for detailed productionconstraints and come up with an executable schedule
Constrained dependent demands, Independent Demands, Planned Orders
Detailed Sequence of activities near term to constrain the medium / long term plan
Production Scheduling Integration Description
Scope of ASCP – Planning the entire Supply Chain
Scope of PS – Scheduling a single Plant
DC1
DC2
Customer X
Customer Y
Customer Z
Plant 1
Plant 2
Plant 3
Supplier A
Supplier B
Supplier C
Production Scheduling Integration Description – Logical Information Flow
ASCP
Planned OrdersPlanned Order DemandsSales OrdersForecasts
Production Scheduling
Source ERPWork Order ReschedulesNew Work Orders
ItemsBill of MaterialsRoutingsResourcesWork OrderSales OrdersOn Hand...
Production Scheduling Integration Description – Modes of Running PS
Running PS “Standalone” Running PS with reference to an ASCP Plan
Schedule work orders only Schedule work orders and planned orders
Forecast demands specified via Demand schedules
Forecast demands come in via the referenced ASCP plan
Inter-org demands included only via internal sales orders
Inter-org demands also include planned order demands from the ASCP plan
Items to be included in PS specified via specification of category sets / categories
Items to be included in PS derived from the items in the ASCP plan
No Forecast consumption Forecast consumption performed in ASCP is retained within PS
Production Scheduling Integration Description – System Information Flow
Client PC
Collections
PS
Browser
PS Model FilesSnapshot PS DataFrom Planning Server
Oracle ApplicationsLogin
Rescheduled / NewDiscrete Jobs / Lot Based
Jobs / OPM Batches
PlanningData
Repository
Define Schedule names and Options
Invoke Data Snapshot
Open PS Workbench
Publish Schedule from PS(Release Process)
EBSSource
Summary
Feasible schedules that respect manufacturing constraintsImproved utilization and minimal setup timeConsistent manufacturing cycle timesImproved schedule adherence and delivery performanceReduced work in process inventoriesSecure and integrated system
Feasible on-time schedules with improved throughput and utilization
Complete visibility to demand and production plan, secure integrated system, improved cycle time
Manageperformance
Analyzeexceptions
Oracle Production Scheduling
Enables you to…
Oracle Production Scheduling
Maximize throughput and increase resource utilization
Improve shop floor performance
Determine the best schedule
Comprehensively plan and schedule production
Best in class, proven production scheduling solution
Integrated manufacturing planning, scheduling, and execution
Designed for planners, not programmers
Integrated performance management
Why Oracle!