CP-108:Advanced Planning and Scheduling to Maximize Production

Zac Jackson, Yulista Manufacturing Peter Cox, Dynafact Software Inc.

Agenda• Introduction to Dynafact -Pete

• What is Dynafact (DMS) -Zac

• Yulista’s DMS implementation overview

• Forecasting capacity with DMS

• How DMS/Costpoint(CP) Import drives execution schedules

• DMS Orders Job Grid-How this dashboard and export is used to status internal and external customer

• On Time Delivery-How DMS helped raise OTD % by over 15%

• What’s new in DMS and other highlights - Pete

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 2

About Dynafact

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• Dynafact is an Advanced Planning and Scheduling software development and services company.

• Founders over 50 years of experience in the design and application of manufacturing scheduling technology

• Dynafact brings value to its customers by providing them with the tools they need to reduce waste and improve throughput

• Focus on one product with a philosophy of continuous improvement

• Chosen top APS Company and best fit by Deltek in 2008 after an in-depth evaluation of several companies and technologies

Some of Dynafact’s Customers:

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The Spreadsheet Illusion

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• It is difficult to comprehend that many multimillion dollar manufacturing facilities are still relying of Spreadsheet information in order to make important decisions!

• The problem with Spreadsheets are:– They are highly prone to error

– They contain static information

– They are not integrated

– They do not incorporate information already available

– They usually are reliant on one or two individuals

– Paper never refused ink and spreadsheets do not refuse fiction.

Overcome the Impediments to Drive Value in Your Processes!Focuses on the Value Drivers of your orb removing the manufacturing impediments to success.

ImproveProfitability

Improve Competitiveness

DecreaseOperational

Costs

Increase Revenue

Value Creation

ImproveCustomer

Satisfaction

Increase On-Time Delivery

Decrease Lead Time

Decrease Expediting Costs

Decrease Cost of Overtime

Reduce Inventory

Manufacturing Value Drivers

Impediments to greater

achievement

•Failing to recover from Rework and

emergency work interruptions

•Difficulty to accurately predict ETC

•Unexpected bottlenecks (skill sets and

special equipment)

•Unplanned Overtime

•Limited ‘timely’ visibility to EVM (Project

statuses)

•Customer commitments based on “Standard

Lead Times” and not reality

• No visibility to the impact of changes to the

schedule

•Not prioritizing work with the “big picture” in

mind

•Initiating assembly parts before ready

•Keeping just in case inventory

•Depending on spreadsheets for capacity

planning

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Project Manufacturing IntegrationParts

Bills of Material

ECN

Drawings

Models

PLM

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Dynafact Gives you Visibility toPlan. Predict. Control!

What is Dynafact Manufacturing System(DMS)

• The Dynafact Manufacturing System (DMS) is a sophisticated Advanced Planning and Scheduling technology designed to complement your ERP system or function as a stand-alone solution for complex "job shop" environments.– Accurate work-flow modeling and quick production simulations– Cost/benefit analysis for overtime and outsourcing to ensure you meet

demand requirements– Accurate capacity requirements based on real demand– Detailed shop dispatches ensuring your people are working on the

right jobs at the right time– Shop Floor schedule engine that automates resource loading and

capacity planning

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 9

What is Dynafact Manufacturing System(DMS)

• The Dynafact Manufacturing System (DMS) is a sophisticated Advanced Planning and Scheduling technology designed to complement your ERP system or function as a stand-alone solution for complex "job shop" environments.– Accurate work-flow modeling and quick production simulations– Cost/benefit analysis for overtime and outsourcing to ensure you meet

demand requirements– Accurate capacity requirements based on real demand– Detailed shop dispatches ensuring your people are working on the

right jobs at the right time– Shop Floor schedule engine that automates resource loading and

capacity planning

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 10

Yulista DMS Implementation Overview

• Our goal– Was to stand up, connect, and implement Dynafact(DMS)

and Costpoint(CP) Materials software tools to improve planning, procurement, scheduling and shop floor control while accurately and reliably speeding up the manufacturing process and its outlying functional touches.

• Two Phase Approach– Stand up DMS as a stand alone planning and scheduling

tool– Connect DMS to Costpoint Material Module

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 11

Forecasting with DMS• Using DMS resource tables and schedule to forecast capacity,

facility, and resource– Using DMS’s multiple level scheduling groups (Departments, Pools,

and Resources) Yulista was able to set up a forecasting process that allows for real time capacity planning based off of estimated demand and current real time facility/resource schedules.

• Set up forecast resources with zero capacity• Load estimated hours by creating forecast jobs that are scheduled with each

DMS schedule run• Use the multiple levels (Departments/Pools) to quickly see both forecasted

demand and live capacity in one screen• Remove forecasted capacity as estimated demand becomes true demand

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 12

Forecasting with DMS

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 13

Forecasting with DMS

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 14

Forecasting with DMS- Load forecast job based on estimated

demand

- Schedule Run gives us the ability to see against all current capacity if we can

meet the needed date

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited.

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How DMS/Costpoint Import Drives Execution Schedules

• Using CMR or MRP within the CP Materials Module drives Purchase Requisitions based on Bill of Material(BOM) Requirements for Manufacturing Orders(MOs)

• All MOs along with the routing operations and material requirement information is imported into DMS.

• Purchase order dates for the MO requirements are imported in DMS and allows for DMS to schedule individual orders at a resource level based on these dates.

• Assembly structure of multi-level BOMs are imported into DMS so that the schedule logic accounts for lower level assemblies, components, and their material requirements.

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 16

How DMS/Costpoint Import Drives Execution Schedules

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or

distribution is prohibited.

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1 2 3

1. PO Number imports from CP 2. Expected date drives schedule until material is received3. Received date drive schedule once material is received

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited.18

How DMS/Costpoint Import Drives Execution Schedules

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is

prohibited.19

How DMS/Costpoint Import Drives Execution Schedules

DMS Orders Job Grid• DMS Orders Job Grid

– Centralized navigation tool for the DMS application– Displays Job status and information in real time– Exports to excel and other applications for reporting

purposes– Multiple search options for easy filter and look up– Completely customizable dashboard– Savable searches allows for easy reporting and status

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 20

DMS Orders Job Grid

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 21

Yulista Orders Job Grid Application• Yulista uses the Orders Job Grid to export and distribute

status to both internal and external customers• Allows for real time part level status• Shows the Job State(phase of production) of all piece parts,

sub assemblies, and over all work orders• Export is filtered out so that each project only sees their

projects manufacturing status• Status shows scheduled end dates and +/- days to due date

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 22

On Time Delivery • The implementation of DMS and Costpoint Materials module has helped

Yulista increase On Time Delivery by 15% taking the OTD metric to over 95% overall for Yulista Manufacturing – Able to better forecast work so that we can set true upfront expectation of

completion based on real time capacity and material lead times– Automated material driven schedules provides more accurate execution– We use the scheduling tools to address any job tracking late to its due date.

Giving us the ability to immediately put in a recovery plan– Daily real time status used to provide internal accountability– Tracking of all job stops or holds using weekly reporting so we can better

mitigate schedule impacts from these issues

Data and information contained on this document is Proprietary/Confidential Information of Yulista Aviation, Inc. Any unauthorized review, use, disclosure or distribution is prohibited. 23

BOM Link Logic is Incorporated into the Interface and is shown in DMS.

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Overtime Cost / Benefit AnalysisMeasures schedule improvement against additional cost

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Assembly Gantt: Graphically shows BOM links between MOs

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Dynafact Job Flow Analysis

Dispatches (To Do Lists) are shown both graphically and in column format with Drag and Drop capability.

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The Project Gantt will graph selected or all projects to give statuses, percent complete, planned and actual hours, start and completion projections.

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Click on a Capacity Bar to pull up a Dispatch ‘To Do’ List.

On demand ETC by Project, MO, or other user defined criteria

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Line of Balance

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