plansee - holding · plansee - holding plansee holding high performance materials hard material...
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PLANSEE - Holding
Plansee Holding
High performance
materials
hard material
matters
Sintered steel parts
50%100% 100%50%
Tungsten and powder
CERATIZIT – structure / organigramm
CERATIZIT Italia - Segments
F1 – Cold heading dies F2 – Drawing dies
F3 – Fastening Industry F4 – special metal forming
Identified Dysfunctions
Not updated process standard times
High variability of processes due to lack of standardization
Not efficient estimation of the order delivery dates
Very low levels of capacity control
Long lead times
High values of tardiness
Low service levels
Estimation of order delivery dates
All orders are managed with highest priority
Due date
delay
standard
Release date
with priority
Release date Time Reduction
M
Queue time
machine
Lack of production control
The MRP in the company works assuming infinite production capacity
The MRP in the company assumes constant lead times
Lead times are not updated
No tool for shop floor control
Due date
fatherchildrenMRP
Shop floor
Capacity
Loading
Modified
Lead times
waiting times increase with the
machine loading
Production capacity control
What piece will make the machine produce
tomorrow ?
Code Description May June July August September October November December January
A1 Production flow analysis
A2 Data collection
A3Definition of production objectives and
constraints
A4Customization/development and testing of
the TPS optimization algorithms
A5 Customization of the TPS data base
A6 First installation
A7 Tuning and final installation
A8Re-engineering of production planning
processes
TPS Project
TPS project
release datesdue dates
production planproduction
available capacity
Central Staff
Periferic Staff
Strategic Process Owner
Process Owner
A0 - Business Unit Organisation
Le
ad
Tim
eA8 - Re-engineering of production planning process
Lean Organization Office
Job Enrichment
Job Enlargment
Reduction Hierarchical Levels
Reduction Lead Time
Production Planning,
Master Scheduling
Material Requirements,
Resource Capability
Scheduling
and Rescheduling
Dispatching
Shop-Floor
Management
Shop-Floor
FLOW
MANAGER
TEAM
LEADER
Schedule
Job LoadingData Collection
Detailed Scheduling
Shop Status
Schedule Performance
PLANNING
MANAGER
Schedule Constraints
Capacity Status
Shop Orders, Release Dates
Quantities, Due Date
Orders
Material Requirements
TPS
SAP + TPS
SAP
CUSTOMER
SERVICESAP + TPS
Le
ad
Tim
eDynamic ATP
A0 - Business Unit Organisation
TPS (APS)
Advance Planning Scheduling
SAP (ERP)
Enterprise Resource Planning
• Central Planner: assign the workload to centers (group of affine machines) on the basis of the due date, availabilities
and customer priorities. If some technological info is available also a specific machine is chosen
• Flow Manager: modifies the assignment made by the central planner between some predefined range (2 days)
Problems
The product information stored in the company ERP does not contain enough technological information
Machine operators are the only persons able to assign properly a product to a machine
Decision making: one central manager, local managers, flow managers
Solution: details
Customer priorities are assigned by the marketing staff (yearly)
Product & machine technological characteristics
Third suppliers of components & processes
Center modeling
Finite capacity machines
Batch working machines
Release dates
Finite number of tasks (of the same order) scheduled in a time window
Integration with the company ERP
Continuous update (15 mins)
T&P project
Goal: to derive a procedure for estimating standard times in Ceratizit processes
DIFF. EFF./STD.
Fre
qu
en
cy
1086420-2
350
300
250
200
150
100
50
0
Mean 0,3676
StDev 0,9522
N 660
Histogram of DIFF. EFF./STD.Normal
Goal: to derive a procedure for estimating standard times in Ceratizit processes
Da
taCODICE LUNGHEZZA
Operaz. standardOperaz. effettivo
*87654321*87654321
12
10
8
6
4
2
0
Boxplot of Operaz. effettivo; Operaz. standard vs CODICE LUNGHEZZA
Da
ta
CODICE DIAMETRO INT. / CHIAVE
Operaz. standardOperaz. effettivo
*87654321*87654321
12
10
8
6
4
2
0
Boxplot of Operaz. effettiv; Operaz. standard vs CODICE DIAMETRO
T&P project
Goal: to derive a procedure for estimating standard times in Ceratizit processes
T&P project