Precision Castparts Corporation Manufacturing Planning Systems

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Precision Castparts CorporationManufacturing
Planning Systems

• Summer 2004
• Gordon Edwards
• Portland State University

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Presentation Outline

• Problem Statement
• Project Definition
• Project Methodology
• Analysis Process/Project Development
• Comparison Study
• First
• Second
• Current Status
• Next Steps
• Questions

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Problem Statement

• The PCC Large Parts Campus wishes to implement a
  decision support tool which will enable the
  organization to plan and control its in-house
  manufacturing processes (less Steel
  Manufacturing) and integrate these activities
  with outside processing steps as well as company
  business processes.

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Project Definition

• Project Scope
• Planning and execution of Titanium Manufacturing
• All LPC activities less Steel Manufacturing
• Understand the process dont change it
• Didnt include cost or implementation effort
• Constraints and Limitations
• COTS product with limited modification
• Consistent with the Theory of Constraints
• Interface with existing ERP system
• Timeframe 14 June to 17 September
• Not to include Business Optimization

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Project Methodology

• Analysis of initial statement of work and problem
  definition
• Stakeholder Interviews
• Functional Analysis of system requirements (FRAT)
• Search for suitable commercial systems
• Filtering of potential solutions
• Weighting of selection criteria
• Scoring of candidate systems
• Confirm they meet mandatory requirements
• Assess strengths and weaknesses

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Stakeholder Interviews

• Planners
• Engineering Teams
• Sales Marketing
• Titanium Manufacturing
• Managers
• PCC MIS
• OSP Companies - surrogate

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Planning Tools Project Boundaries

• Engr Svcs
• Tooling Fixture Design
• Tooling Fixture Procurement
• CAD
• Calibration/Repair

Process Engineering
Part Estimating
Purchasing (OSP Contracts)
Other Dept Ti Casting

• Engr Svcs
• Tooling Fixture Availability
• Tooling Fixture Capacity
• CMM
• Layout
• Targeting

• Planning
• Master Scheduling
• Customer Svc
• OSP Capacity/
• Scheduling
• Dispatch
• Materials Testing

SLA
Transportation/ Shipping

• Engineering
• Development
• Production
• Trial
• Router Information

Core Facility
Titanium Manufacturing

• MIS
• Visibility Interface
• Infrastructure
• Information Security

Check Film
Quality Process Control
Statistical Analysis
Legend
Sales Marketing
OSP Venders
Information
Steel Manufacturing
Heat Treating
Material
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Essential Requirements

• 29 essential requirements defined
• Examples/nature of requirements
• ERP Interface
• User Interface
• Capacity Planning capability
• Flow Analysis/Bottle neck identification
• Planner ability to conduct what if scenarios
• Sales ability to assess orders on the road
• Etc

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First Comparison Study

• Assessed 24 potential systems
• Aim to reduce the list to a manageable number for
  detailed assessment
• Based on a sub-set of requirements
• Data Management
• Constraints
• Flow Analysis
• Operating System
• Database Requirement
• Statistical Analysis
• Selected six as appearing to meet all requirements

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Second Comparison Study

• Six candidate systems

Product Company Remarks
ASPROVA ASPROVA Corporation Japan Production Modeling Corporation Dearborn, Michigan
MxSuite Matrikon Edmonton, Alberta Sales Office in Houston, Texas
NaView RSS Solutions Kitchener-Waterloo, Ontario Sales Office in Chicago, Illinois
Preactor APS (400) Preactor International Wiltshire, United Kingdom Quinn Associates Inc State College, Pennsylvania
SCM MAPICS Los Angeles, California Thru-Put Technologies/ Thru-Put 5
TACTIC Waterloo Manufacturing Software Redondo Beach, California
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Second Comparison Study

• Essential Requirements
• 29 requirements total
• 23 requirements scored/assessed
• 6 requirements not scored hands on
• Must meet all assessed requirements (minimum
  required functionality)
• Desirable Requirements
• 10 requirements total all assessed
• Weighted for value
• Method to differentiate between suitable
  candidate solutions

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Desirable Requirements

• Tooling Data
• Statistical Analysis
• Adv Constraints
• Engineer Planning
• Work Load Planning

• Consider tooling and fixture data in scheduling
• Ability to conduct statistical analysis
• The ability to manage scheduling through fifteen
  constraints
• "what if" analysis by people other than just
  planners
• Work Center work load planning

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Desirable Requirements

• Engineer Review
• Production Monitoring
• OSP Reports
• Work Orders
• Database Requirement

• Automatic notification of pending tasks
• Management oversight of schedule vs. actual
  production status
• Ability to report OSP loading schedule
• Load work orders in Visibility
• Compatibility with current systems in use

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Requirement Weighting
Extremely important or useful Work Load Planning
Extremely important or useful Work Orders
Extremely important or useful Tooling Data
Extremely important or useful Production Monitoring
Very important or useful OSP Reports
Very important or useful Adv Constraints
Important/Useful Database Requirement
Important/Useful Statistical Analysis
Somewhat/Potentially important or useful Engineer Planning
Somewhat/Potentially important or useful Engineer Review
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Requirement Weighting
Title Score Weight
Tooling Data 50 0.13
Statistical Analysis 30 0.08
Adv Constraints 40 0.11
Engineer Planning 20 0.05
Work Load Planning 50 0.13
Engineer Review 20 0.05
Production Monitoring 50 0.13
OSP Reports 40 0.11
Work Orders 50 0.13
Database Requirement 30 0.08
380 1.00
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Current Status

• Five systems fully assessed
• Production Modeling Corporation/ASPROVA
• Matrikon/MxSuite
• RSS Solutions/NaView
• Quinn Associates/Preactor
• Waterloo Manufacturing Software/TACTIC
• Not responded
• MAPICS/SCM

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Current Rating
Ref Title Title Weight ASPROVA MxSuite NaView Preactor TACTIC
R-2-003 TOOLING DATA TOOLING DATA 0.13 0.39 1.30 1.30 1.30 1.30
R-2-008 STATISTICAL ANALYSIS STATISTICAL ANALYSIS 0.08 0.40 0.40 0.40 0.40 0.00
R-2-014 ADV CONSTRAINTS ADV CONSTRAINTS 0.11 1.10 1.10 1.10 1.10 1.10
R-2-021 ENGINEER PLANNING ENGINEER PLANNING 0.05 0.50 0.35 0.50 0.35 0.20
R-2-031 WORK LOAD PLANNING WORK LOAD PLANNING 0.13 1.30 1.30 1.30 1.30 0.52
R-2-034 ENGINEER REVIEW ENGINEER REVIEW 0.05 0.25 0.35 0.15 0.50 0.15
R-2-037 PRODUCTION MONITORING PRODUCTION MONITORING 0.13 1.30 1.30 1.30 1.30 1.30
R-2-038 OSP REPORTS OSP REPORTS 0.11 0.77 1.10 1.10 1.10 0.22
R-2-049 WORK ORDERS WORK ORDERS 0.13 1.30 1.30 1.30 1.30 0.52
R-2-050 DATABASE REQUIREMENT DATABASE REQUIREMENT 0.08 0.56 0.40 0.40 0.56 0.00
TOTAL (Perfect score 10) TOTAL (Perfect score 10) TOTAL (Perfect score 10) 1.00 7.87 8.90 8.85 9.21 5.31
                 
RANK RANK RANK RANK 4 2 3 1 5
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Next Steps

• Select system(s) to trial
• Risk vs. Reward
• Address cost as a requirement
• Address investment in implementation
• Planning/manufacturing process definition
• Get quotes/arrange demonstration trial
• Other Foundry ERP systems
• BL Information Systems Inc/Odyssey
• Guardian Software Systems/Foundry

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Questions