Title: Material and Production Planning Options with XA
1 Material and Production Planning
Optionswith XA
Deborah Vermillion, CPIM, CIRM CISTECH
Inc. www.cistech.net
2Agenda
- Traditional Planning-MPSP, MRP, CRP
- Advanced Planner
- Thru-Put
3(No Transcript)
4Traditional Planning Cycle
- Master Scheduling
- Interface with Forecast thru DMDIFF file
- Blends COM orders and Forecast or Forecast only
- Allows build up for seasonal demand
- Rough cut capacity for critical items
5Traditional Planning Cycle
- But
- Limited view of capacity
- Can be Iterative, time consuming
6Traditional Planning Cycle
- Material Requirements Planning
- Uses Master Schedule from MPSP, COM Orders or
Manual requirements to drive plan - Uses POs, MOs, Rep Schedules to satisfy plan
requirements - Result is Time phased purchased material and
production plan
7Traditional Planning Cycle
Order/Schedule Recommendation by Item
- But
- Capacity not considered
- Requires MPSP update for changes in blended
demand - what-if capabilities limited (manual reqs)
- Impact of new demand-wait until night
8Traditional Planning Cycle
- How does yours work today?
- Appropriate staff effort?
- Integration from demand to scheduling?
- Length of planning cycle, can we provide quick
response to changes in customer demand? - What if we get this order?
- On time deliveries and consistent schedule
performance? - Excess inventories?
- Do shortfalls cost us time/money/cust sat?
9What is Advanced Planner?
- Advanced Planner is an alternative to XA MPSP,
MRP and CRP - Windows based fast MRP that helps you to do
interactive planning - Allows you to visualize load on the facilities
(work centers). AVP uses color coded graphs and
charts that makes it easier to manage the master
schedule process. This includes material and
capacity testing - Helps you to take appropriate decisions such as
offloading, outsourcing, level loading etc to
meet the on time delivery of your customer
orders - You can also estimate the labor requirements to
support your plant schedules - Generates suggested supplies( both MOs and POs),
supply exceptions, detailed operation start times
and shipment delivery dates
10How does AVP do this?
- Planning information is downloaded from the AS400
creating an Access database on the PC - Planning run is done on the PC eliminating job
conflicts on the 400 and decreasing processing
time. This allows for more planning runs.
Quicker response time!!!
11AVP- Input Output
- Demand
- Forecasts
- customer orders
- Replenishment policy
- Supply
- inventory on hand
- shop orders and allocations
- Outside operations
- purchase orders
AVP Engine
- Product Structures
- part attributes
- Standard and workorder bills
- Standard and workorder routings
- Plant Structures
- Workcenters
- Labor
12AVP/MRP Similarities
- Both use all the planning modifiers in the Item
Balance/Plan record - Both use the MRP Execution Options for
re-scheduling, auto-release, etc. - Both use the MRP Horizon Dates
- Both have direct or indirect interface to Mapics
Forecast module - Both use the Manufactured due date from the
customer orders for planning
13AVP vs. MRP
- An MRP generation is performed by a BOM explosion
and netting routine usually overnight - With Advanced Planner NO AS400 MRP generation is
ever necessary
14AVP vs. MRP
- MRP/CRP uses Mapics calendars
- AVP has its own calendar within the database.
This calendar holds hours of operation per day. - MRP has no easy what if capability short of a
new MRP generation - AVP has powerful what if capability directly
with the AVP access database on the PC
15AVP vs. MRP contd
- MRP interfaces with MPSP
- AVP has its own Master Schedule Routine
- MRP uses Lead Time to calculate start date
- AVP uses backward scheduling and the times in the
routing to calculate start date
16AVP vs. MRP contd
- MPSP uses the greater of Customer Order or
Forecast - AVP nets the COs against the Forecast and plans
with the COs and Net Forecast - MRP assumes infinite capacity
- AVP plans the work load in each work center for
capacity review prior to accepting the plan
17AVP vs. MRP contd
- MRP provides a warning if a planned order
quantity exceeds the Maximum - AVP uses the Maximum to create multiple orders
due on the same day for the Max quantity (or
less) - MRP plans an order to be due the same day as the
requirement - AVP plans an order to be due the day before the
requirement
18AVP extras Forecast Consumption
- Forecast can be consumed in four ways
- Individual Item The sales of each item consume
the item forecast - An item and its parents If many possible
finished product configurations exist, made from
a small number of components, you can forecast at
the component level rather than the finished
product level. The sales of the item and any
parent consume the item forecast - Planning bill Family Identify an item as a
planning bill item and enter shippable forecasts
for the item ( based on qty per in Planning
Bill. Forecast is consumed by end item and
matching configurations in the Bill of Material - Product Family Does not use a Planning Bill.
The Base Item is forecasted. Customer Order
Demand for items within the Product Family
consume the Base Items forecast.
19Forecast Consumption
This is the forecast consumption chart within AVP
20AVP Extras
- Config.ini settings to
- Calculate run time by flow or batch method
- Uses RM Quantity (at the time of the RM
transaction) or Operation Quantity Completed
(from Labor Reporting) to calculate balance due - Can define horizon length values 1-999 days
21AVP Extras
- You can optionally update either or both
- The promise date on the customer order
- The manufacturing due date on the customer order
22Questions?
23Advanced Planner Process
- Downloading Data to the Engine
- Pulls BOM, Route, Item, Item process, Item plan,
Forecast, COs and/or Manual Requirements - Creates flat files that are pulled in to create
access database
24Advanced Planner Process
- Generating the Plan
- Forecast Consumption
- Nets the Requirements against on hand on order
(Load Project) using Access Database - Builds product structure network using the BOM
and Routing - Plans Orders (PO, MO Schedules)
25Advanced Planner Process
- Manipulate the Plan
- View Load to Capacity Chart
- View items on Load
- Level Load both Material and Capacity
- Time phased view
- Drill down/up
- Perform what-if planning
26Load To Capacity and Time phased load
Identify overload problem
Orders that can be offloaded-Yellow Planned
Orders- Green New Colors at AVP 6.1 Firm
Planned- Pink Released- Light Orange
27Load To Capacity Chart
Process Hours Setup hours Capacity hours
Red W/C is overloaded Yellow W/C has past due
backlog Blue Overload within one time period
that can be corrected by re-scheduling,
offloading, etc. Green Plan is within capacity
constraints
Routing Facilities
28As decisions are taken you get instant feedback
29Order waterfall viewIdentify what is needed
when and the Critical chain
30Advanced Planner Process
- Upload to Mapics Files
- Loads info into the MRP planning work files
- Requirements-unconsumed forecast and generated
demand - Planned Orders-all supply orders, including open,
firm planned and planned - Demand Ref-Demand information
- Reschedule Activity-rescheduling actions
31Advanced Planner Process
- What happens?
- Reschedules open MOs/POs/Rep schedules
according to set up - Updates the CO dates if specified in the upload
options - Updates work center file in the MO/REP
operations as specified during offloading - Loads the MRP planning files
- Creates the Order Review file
- Prints MRP reports as specified
32Planning Execution
- Once plan is saved
-
- Execute plan using OBPM
- OR
- Green Screen Order review and release
- OR
- Repetitive
33Execute Plan using OBPM
34Green Screen Execution
35MRP Requirements inquiry
36Estimating the Labor Requirement
37Which Orders to push out
Generated from within the Facility. Lists supply
orders where Supply Due Date gt Supply Suggested
Dated
New Commands show the potential order list that
will be delayed based upon the current schedule.
Global Records not limited to within the
Facility. Which Customer Orders.. lists only
Customer Orders where Demand Suggested Date gt
Demand Due Date. Customer Orders pushed out will
be displayed from the List of Customer Orders..
38Questions?
39Why Thru-Put?
- AVP is a planning tool Thru-Put is an execution
tool. - Use Thru-Put to identify all resources (internal
machines, tools, labor and external-suppliers,
subcontractors) that limit your output (your
constraints) - Decide how to best exploit the constraints
capacity-Synchronize the work sequence of your
constraints with prioritized demand
40Why Thru-Put?
- Subordinate everything to the constructed
schedule-Synchronize all important support
functions - Promise new orders based on Real Capacity and
materials constraints, on an ongoing basis.
41ThruPut Load Data
Thru-Put first reads the database from the host
system(s) ERP, MES or other and pulls all
relevant information into the Servers memory
42ThruPut Quote Delivery Dates
Using a web-based workbench, users quote delivery
dates for new demand based on currently available
capacity AND raw materials
Users also have the option to force new demand
in the schedule, and have Thru-Put calculate the
impact of the new demand on existing orders
43Creating an Executable Schedule With Thru-Put
44Phase 1 Analyze Purchased Parts
- Users follow Thru-Puts phased scheduling
approach which is based on the first 3 steps of
Theory of Constraints - Identify The Constraint(s)
- Exploit the Constraint(s)
- Subordinate everything else to the Constraint(s)
During the first phase of scheduling, Planners
and Buyers analyze materials shortages, based on
existing POs and component lead times. This
phase allows purchasing to work on shortages
BEFORE the corresponding orders are pushed out by
Thru-Put
45Phase 1 Analyze Purchased Parts
Thru-Put highlights materials shortages (required
date prior to available date)
This process allows Purchasing to work with
Planning and determine possible solutions to
shortages PRIOR TO analyzing capacity
46Phase 2 Analyze Machine Capacity
During the identify machine constraints phase,
ThruPut calculates load on all work centers based
on released and planned work, and corresponding
demand. It displays resulting of load to
capacity in simple bar charts and graphs.
Automatic level-loading is also available to the
user at this stage.
47Phase 3 Analyze Labor Constraints
Thru-Put displays the results of a detailed
analysis of labor capacity and load. Users can
then limit the work centers capacity based on
labor availability.
48Phase 4 Level-Load Constraint(s)
Thru-Put then level loads all work on selected
constraints using a finite capacity model.
Various tools such as Overtime, Offloading, and
Batching are available to the user to eliminate
lateness caused by capacity shortage
In this simulation, Thru-Put will group all
similar parts scheduled over 3 consecutive days
49Phase 5 Subordinate Non-Constraints
In the last phase of constructing the schedule
(subordination), Thru-Put creates a dispatch
priority list for each non-constraint resource in
the facility. It does so by backward and forward
scheduling from the level-loaded constraints
The result is an EXECUTABLE schedule which
maximizes the output of the constraints hence
the plant, WHILE minimizing necessary WIP and
Purchased Parts inventory to support it
50Executing ThruPut Schedules
51Execute Schedule Dispatch and Track
After completion, optimized schedules are
available for display and adjustments on
high-resolution, large-format monitors throughout
the facility.
52Execute Schedule Dispatch and Track
Users can access several Thru-Put standard
scheduling reports on line at any time, or easily
build their own using off-the-shelf reporting
tools
53Execute Schedule Dispatch and Track
Secure access to ThruPut reports and screens can
be tightly controlled using Thru-Puts User
Manager
54Thank you!!