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Material and Production Planning Options with XA

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Title: Material and Production Planning Options with XA


1
Material and Production Planning
Optionswith XA

Deborah Vermillion, CPIM, CIRM CISTECH
Inc. www.cistech.net
2
Agenda
  • Traditional Planning-MPSP, MRP, CRP
  • Advanced Planner
  • Thru-Put

3
(No Transcript)
4
Traditional 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

5
Traditional Planning Cycle
  • But
  • Limited view of capacity
  • Can be Iterative, time consuming

6
Traditional 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

7
Traditional 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

8
Traditional 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?


9
What 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

10
How 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!!!

11
AVP- 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

12
AVP/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

13
AVP 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

14
AVP 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

15
AVP 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

16
AVP 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

17
AVP 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

18
AVP 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.

19
Forecast Consumption
This is the forecast consumption chart within AVP
20
AVP 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

21
AVP Extras
  • You can optionally update either or both
  • The promise date on the customer order
  • The manufacturing due date on the customer order

22
Questions?
23
Advanced 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

24
Advanced 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)

25
Advanced 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

26
Load 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
27
Load 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
28
As decisions are taken you get instant feedback
29
Order waterfall viewIdentify what is needed
when and the Critical chain
30
Advanced 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

31
Advanced 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

32
Planning Execution
  • Once plan is saved
  • Execute plan using OBPM
  • OR
  • Green Screen Order review and release
  • OR
  • Repetitive

33
Execute Plan using OBPM
34
Green Screen Execution
35
MRP Requirements inquiry
36
Estimating the Labor Requirement
37
Which 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..
38
Questions?
39
Why 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

40
Why Thru-Put?
  1. Subordinate everything to the constructed
    schedule-Synchronize all important support
    functions
  2. Promise new orders based on Real Capacity and
    materials constraints, on an ongoing basis.

41
ThruPut 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
42
ThruPut 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
43
Creating an Executable Schedule With Thru-Put
44
Phase 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
45
Phase 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
46
Phase 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.
47
Phase 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.
48
Phase 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
49
Phase 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
50
Executing ThruPut Schedules
51
Execute Schedule Dispatch and Track
After completion, optimized schedules are
available for display and adjustments on
high-resolution, large-format monitors throughout
the facility.
52
Execute 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
53
Execute Schedule Dispatch and Track
Secure access to ThruPut reports and screens can
be tightly controlled using Thru-Puts User
Manager
54
Thank you!!
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