pagerinkite užsakymų įvykdymą laiku naudodami šiuolaikinius gamybos planavimo įrankius
TRANSCRIPT
HOW TO IMPROVE YOUR ON-TIME DELIVERY WITH A SMART PRODUCTION PLANNING AND SCHEDULING SOLUTION MICHAL PRĘTCZYŃSKI PROJECT MANAGER FOR SIMATIC IT PREACTOR APS IMPLEMENTATIONS AT PRĘTCZYŃSKI LTD.
4/15/2016
2
AGENDA AGENDA
1. Understanding the problem
2. Finding the solution with SIMATIC IT Preactor APS
3. Presentation of SIMATIC IT Preactor APS
4. Areas of potential benefits
5. Questions and answers
A REAL-LIFE EXAMPLE
• Manufacturing company was aware that due to changing market requirements, one of its main problems was the process of production planning. Ineffective planning process influenced their responsiveness and on-time deliveries.
• Company went from understanding market requirements, through creating business requirements for better process, to looking for better software tools that would help.
• The goal was to help Planner in Make to Order environment with many products, smaller batch sizes, more orders = more data to be scheduled by Planner.
• To ensure maximum flexibility in generating a production schedule while extending planning horizon.
3
A REAL-LIFE EXAMPLE
• To achieve higher optimization with possible cost reductions and to consider many criteria while scheduling.
• To integrate with new ERP system and to distribute schedule within organization.
• To introduce the concept of priorities set by Management and not individual Sales representatives within Sales Department.
• To change the planning process that was divided into three planning departments and to introduce a concept of a central schedule with a ‘Main Planner’.
4
5
First department - planning using
Excel/manual work
Third department - planning using
Excel/manual work
Sales Department
has received new
order enquiry from
Customer
24 Hours to answer - 72
Hours in total ->
Unacceptable waiting
time.
24 Hours to answer
order enquiry
24 Hours to answer -
48 Hours in total
When we can deliver
this order ?
Second department - planning
using Excel/manual work
A REAL-LIFE EXAMPLE
CHALLENGES IN PRODUCTION PLANNING
• Planning using Excel / Decision on shop floor. All in the mind and hands of Planner / Planners. Little support from ERP system with its standard functionality.
• No central planning using global priorities. The necessity of arrangements between different departments.
• No representation of actual capacity. No interactivity and no automation in sequencing. A need to optimize sequence to reduce cost.
• Short planning horizon. Unknown impact of changes (new priorities, machine breakdown) in a longer term.
• Problems with due date performance and the answer to the question "When we can deliver this order?" The pressure on Planning Department.
6
BASIC FUNCTIONALITY THAT IS NEEDED FOR SCHEDULING SYSTEM
• The ability to schedule more accurately at the machine level and to schedule precisely (hours, minutes) as opposed to time buckets like week.
• The ability to integrate with other systems like ERP.
• The ability to sequence orders based on due date, priority or minimize changeover times.
• The ability to schedule using multiple constraints, such as tooling and operators. The ability to synchronize the schedule with material constraints.
• The ability to schedule quickly (minutes or seconds) and maintain a real-time view of the schedule.
7
8
AGENDA AGENDA
1. Understanding the problem
2. Finding the solution with SIMATIC IT Preactor APS
3. Presentation of SIMATIC IT Preactor APS
4. Areas of potential benefits
5. Questions and answers
INTRODUCING SIMATIC IT PREACTOR APS
9
Siemens SIMATIC IT Preactor is a range of advanced
planning and scheduling (APS) software for the
manufacturing industry.
Quick facts:
SIMATIC IT Preactor AS is a scheduling tool primarily for
manufacturers who need to schedule machines, production
lines and resources, but Preactor is also used in services and
logistics.
SIMATIC IT Preactor AP considers forecast and long term
orders to decide feasibility and set general direction of
production; Dynamically sets target stock levels to meet
future demand; Load balance across multiple resources
considering eg constraints, materials shelf life.
INTRODUCING SIMATIC IT PREACTOR APS
Key functionality:
• Modelling actual production capacity (machinery / operators / tooling) - operations planned when resources and materials are available.
• Automating planning by generating production plan using scheduling rules. The rules may include customer priorities/due dates or minimization of changeovers.
• Interactive planning board where Planner can change sequence. Analysis of different versions of the schedule before accepting.
• Simulations "When we can deliver this order?" Analysis of due date performance. Early information on potential late orders.
• Including material control calculations to check that all materials required are available
10
INTRODUCING SIMATIC IT PREACTOR APS
11
Examples of integrations
available: Microsoft Dynamics
AX and NAV.
INTRODUCING SIMATIC IT PREACTOR APS
12
Large install base serving the manufacturing sector
across the globe. Implementations in Baltic region with
Columbus.
Quick facts:
Customer base ranges from mid-size to some of the largest
multi-national companies in the world.
Operates across multiple sectors, this shows the flexibility to
solve any scheduling requirement.
Global presence of the Siemens Manufacturing Operations
Management Team - probably the largest Manufacturing IT
organization in the world.
13
AGENDA AGENDA
1. Understanding the problem
2. Finding the solution with SIMATIC IT Preactor APS
3. Presentation of SIMATIC IT Preactor APS
4. Areas of potential benefits
5. Questions and answers
PLANNING SCENARIOS FOR LIVE DEMONSTRATION
• Automating planning for all orders. Are all orders on-time?
• High priority order that requires re-planning. Which orders will be delayed?
• A breakdown of machine occurs. Which orders will be affected?
• How changes in material delivery will affect our plan?
• Can we combine priority for due date and a need to minimize changeover times?
14
27
AGENDA AGENDA
1. Understanding the problem
2. Finding the solution with SIMATIC IT Preactor APS
3. Presentation of SIMATIC IT Preactor APS
4. Areas of potential benefits
5. Questions and answers
A REAL-LIFE SUCCESS STORY
• To introduce a concept of a central schedule with a ‘Main Planner’ -> central schedule with Preactor and changing planning procedures.
• Flexibility in generating a production schedule -> visualization on Gantt chart and drag & drop on planning board.
• Optimization with possible cost reductions -> sequence dependent changeover time matrices and scheduling rules minimizing changeover times.
• Priorities -> introducing concept of customer-based priorities.
„Together with an instant feedback about expected delivery dates it has improved effectiveness of work in the sales department and decreased time needed for customer service.”
„Flexibility and an easy way to change schedules gives us the ability to react quickly to market requirements.”
28
PLANNING PROCEDURE FOR PLANNER
1
All the production data from previous day,
including quantities produced, must be
entered by Shift leader into ERP till 8:00
Importing current status of
operations and orders from ERP
to Preactor
2 Planner can analyze changes in Preactor and
initiate schedule repair function
Updating schedule in Preactor
with current status of
operations/orders
3 All new production orders, generated from
sales orders by Sales Department, must be
entered till 12:00, so Planner can schedule a
batch of orders and look at priorities
Importing new orders from ERP
to Preactor, updating orders in
schedule with changes
4 Planner reviews new orders, applies
preferred sequence rules, runs What-If
scenarios, accepts the schedule
Generating new schedule in
Preactor
5 Around 14:00 Sales Department receives
information on new dates for work orders
within ERP system
Exporting schedule with new
order dates back to ERP system
6 New production plan is send to Shift Leaders
in each of Departments. Gantt chart is
published on website
Printing new 'Work to-do list'
reports for resources
A REAL-LIFE SUCCESS STORY
30
First department - planning in
central schedule with APS, view on
all resources
Third department - Preactor Viewer
Sales Department has
received new order
enquiry from Customer
-> Order in ERP
When we can deliver
this order ?
Second department - Preactor
Viewer
Exchanging information
based on prepared
schedule - dealing mainly
with exceptions
Answer with expected
Order End Date
within hours
Before 72 hours
-
After within 4 hours
AREAS OF POTENTIAL BENEFITS
31
Improving the planning process
Automation of the process, compared to manual system or Excel can allow for extra time that can be used to optimize the process.
In the case of centralized schedule less demand for planning resources, for example reducing overtime.
One of the users with Case Studies reported 70% reduction time needed for production planning.
Improving the customer service
The ability to quickly give feedback on the planned delivery date of the order, especially in the case of changes to the plan.
Lowering the cost of delays for example penalties or additional costs for the logistics.
Some of the users with Case Studies reported up to 80% improvement in delivery performance.
Improving the productivity
Better use of resources, for example by minimizing changeover times due to dynamic aggregation of operations on machines, or reduction of overtime.
Better use of subcontractors based on real production plan.
Some of the users with Case Studies reported up to 25% increase in productivity.
Improving material management and make span reduction
Extension of the planning horizon and better synchronization of raw material purchases to the production plan based on the limited manufacturing capacity.
Improving synchronization of operations and orders between departments.
Some of the users with Case Studies reported 50% reduction in raw material stock.
AREAS OF POTENTIAL BENEFITS
32
More than 200 case studies published at preactor.com
25% increase in productivity
50% reduction in raw material stock
50% reduction in work-in-process
80% improvement in delivery performance
Preactor
Detailed
Scheduling
(figures taken from various Preactor case studies)
33
AGENDA AGENDA
1. Understanding the problem
2. Finding the solution with SIMATIC IT Preactor APS
3. Presentation of SIMATIC IT Preactor APS
4. Areas of potential benefits
5. Questions and answers
34
Contact local Columbus just now:
Estonia: [email protected]
Latvia [email protected]
Lithuania [email protected]
Presenter:
Michał Prętczyński
E-mail: [email protected]
www.pretczynski.biz
THANK YOU!