Plannifier, Ordonnancer et Contrôler votre production

1. Juin 26, 2007 Jean-Luc Delcuvellerie Plannifier, Ordonnancer et Contrôler votre production Dial-in: USA: 1 800 550 9692 China: 10-800-120-1212 Brazil: 0800-891-1597 France: 0800-902556 Japan: 00531-121467 Mexico: 001-800-349-8644 Poland: 0-0-800-121-1472 PIN: 8060

2. Agenda • Market Need and Customer Solutions • Dispatching et Ordonnancement

3. Cas client • Société américaine avec implantations internationales (France, Suisse) • Client fabriquant d’implants médicaux pour la chirurgie • Gestion de production MFG-PRO: • gestion des articles • MRP • Situation • Production suivi par fiches suiveuses et formulaires • Surcharge de travail liée à l’utilisation du papier et aux ressaisies • Qualité suivi par logiciel SPC spécifique • Pas de collecte de données automatisée • Pas de liaison production et qualité • Mise en place Ordonnancement détaillé à capacité finie

4. Cas client • Objectifs pour l’ordonnancement • Objectifs pour l’exécution • Disposer de données de production fiables et temps réel pour améliorer l’analyse des indicateurs de production et qualité. • Se doter d’un système permettant d’améliorer la fiabilité et la rapidité des saisies de production • Disposer d’informations de production partagées avec les applications existantes pour éviter les saisies redondantes en privilégiant les transmissions en tant réel • Accroître la rapidité et la fiabilité du calcul TRS • Réduire le nombre de documents papier dans les cellules de production • Améliorer la gestion des matières premières • Améliorer la gestion de la qualité (SPC) • Standardiser le système MES dans toutes les usines • Automatiser au maximum la prise d’information des machines ou des opérateurs

5. Ordonnancement et Execution “Execution is the missing link between aspirations and results” Larry Bossidy and Ram Charan In Execution: The Discipline of Getting Things Done, 2002 Business Results Execution Planning

6. Apriso et Preactor ERP Advance Planning & Scheduling Detailed Scheduling MRP Dispatching Trimming Optimization Unplanned Events Sequencing Execution Planning Planning + Optimization Partners + 3rd Party

7. ERP, Ordonnancement et Execution Données statistiques, Optimisation Données temps-réel Performances Critiques Année ERP, MFG PRO Mois OF Gammes Nomenclatures Stocks Semaine Planning optimisé Calcul des Besoins Nets & Ordonnancement Capacité Finie Preactor Manufacturing & Quality Execution Jour Dispatching Résultats Production et Qualité Heure Evénements non planifiés Exécution des opérations Temps-réel

8. Manage ALL elements of Manufacturing Operations GMS OES Production Maintenance Warehouse Quality Labor AEP PLM ERP Order Plan Progress Perfs Tech Data Operation Execution Labor Rework Material Product Machine Scrap Tool

9. Functional Map: ex. for Medical Devices SFG WIP RM FG Prep/Mfg Testing / Finishing Assembly • Quality • Specification control against specifications • Sampling and test characteristics inspection • Corrective Action and Preventative Action (CAPA)* • Root cause analysis • ISO 13485 (EU) Compliance / 21 CFR Part 820 (FDA) • Directed Manufacturing Work Instructions & SOPs • (Production & Process Control PAPC) • Defect severity tracking • Product routing based on quality status • Rework, Scrap and Exemption management • QA Acceptance testing (Hold / release) • SPC* • Shipping Quality control • Customer claims • & return mgmt • Receiving Quality sampling & inspection • Production • Order monitoring & WIP tracking at operation level • Production quantity recording & yield calculation • Material scrap reporting with reason codes • electronic Device History Record (eDHR) with Genealogy • Warehouse • Palette Labeling / RFID • Directed picking • Shipping execution • Customer traceability • Warehouse • Receiving execution • Labeling • Directed putaway • Supplier tracing • Line replenishment • order generation • End to end genealogy • Packaging instructions • Product / box labeling • End to end genealogy • Tooling and spare parts inventory • Warehouse handling system maintenance • Electronic signature • Labor tracking per order • & per operation • Operator certification (skills) • Equipment downtime tracking • Product to equipment genealogy • Maintenance order creation • Task scheduling arbitration • Labor productivity tracking per material move • Maintenance • Equipment usage • Calibration tracking • Equipment configuration tracing (tooling, parts as repaired) • Maintenance work instructions • Consumable material usage • Labor • Time & Attendance • Labor to ERP-HR • Operator polyvalence and qualification monitoring

10. Synchronize Across Operations Quality Inspection Maintenance Production Receiving Shipping Replenishment

11. Long Planning Cycle Planning & Scheduling Execution ERP MRP APS DS Ideal Plan Machine Down How long can you wait? Results

12. Empower Minimize the impact of unplanned events Respond to changing customer demands

13. Example: Equipment Maintenance Make to stock Customer orders Unplanned Maintenance Need to Re-schedule Equipment Overloaded

14. Example: Equipment Maintenance Another Equipment has capacity Drag and Drop

15. Example: Equipment Maintenance Drag and Drop Task Lists are updated

16. Example: Equipment Maintenance Drag and Drop Task Lists are updated

17. Example: Equipment Maintenance Still Overloaded

18. Example: Equipment Maintenance Drag and Drop Make-To-Stock Order

19. Example: Equipment Maintenance Slack

20. Example: Equipment Maintenance Drag and Drop Customer Orders

21. Example: Equipment Maintenance Customer Orders On Time Equipment Utilized Capacity Managed Between ERP, MRP, APS Planning Cycles

22. Market Needs addressed in McKenna Scheduling Interface • Planning integrated with Execution • Achieve the Results that planning systems promise • Reduced costs in wip, inventory, setups, transportation, equipment, personnel, etc • Management of Unplanned Events • Cost of Unplanned Events is high • Short lead time • Complex manufacturing • Reduced inventory • High customer expectation Dispatching Board

23. Scheduling Interface Scheduling Interface • Framework for Partnership • Features • Part of Business Integrator • Unified Data Model, integrates with all Modules • Extension to existing XML messages to import schedule information • Extension to existing business components to add schedule information • Extension to existing XML messages to export schedule information • Additional XML messages to export schedule changes

24. Scheduling Interface Benefits Scheduling Interface • Accelerates integration with Planning and Optimization Systems • Flexibility to integrate with best in class solution • Building towards partnerships • Low cost of ownership and maintenance

25. Dispatching Board • Execution Tool • Managers • Supervisors • Planners • Provides Visibility • Real Time Charts • Allows Supervisor Changes • Drag and Drop • Manually create Detailed Schedules • Low volume Dispatching Board

26. Dispatching Board Features • Drag and Drop • Change the Time • Change the Employee, Equipment, Resource • Manually Create a Schedule • Start with a Due Date and Duration • Security controls • Work Center Supervisors can only affect their Work Center • Out of the Box • Practical • Implementable • Integrated • Unified Data Model • Real Time Information • Changes Take Effect Immediately • Integrates with all Modules • Easy to Understand Charts • Gantt, Activities by Resource, Resource Load

27. Example: Machine out of Control • Work Center Supervisor • Sees an alert • SPC Chart is out of control • Creates Unplanned Maintenance • Re-assigns orders (Dispatching Board) • Planner • Sees an alert • Inspects Production schedule (Dispatching Board) • Re-assigns orders to other work centers if necessary (Dispatching Board) • Manager • Sees an alert • Validates that high priority Delivery Orders are going to ship before they are due (Dispatching Board)

28. Example: Work Center Supervisor • Work Center Supervisor sees SPC Chart going out of Control • The Supervisor creates an unplanned maintenance order

29. Example: Work Center Supervisor • New unplanned maintenance order appears. • Supervisor re-assigns high priority orders to other Resources. • Supervisor delays lower priority ones.

30. Example: Work Center Supervisor • Impact of maintenance is minimized • Appears in Task List immediately

31. Example: Machine out of Control • Work Center Supervisor • Sees an alert • SPC Chart is out of control • Creates Unplanned Maintenance • Re-assigns orders (Dispatching Board) • Planner • Sees an alert • Inspects Production schedule (Dispatching Board) • Re-assigns orders to other work centers if necessary (Dispatching Board) • Manager • Sees an alert • Validates that high priority Delivery Orders are going to ship before they are due (Dispatching Board)

32. Benefits of Dispatching Board • Real time visibility • Fast management of unplanned events • Equipment downtime • Employee absences • Component shortages • Other • Detailed planning in the short-term • Between MRP / APS cycles • Informed decision making • Improved on-time delivery • Improved customer satisfaction

33. Global Platform for Operation Execution

34. Dispatching Board and other Modules • Quality • Quality Labs equipment and resources • Inspection orders • Scheduled or ad-hoc Manages all types of Orders and Resources • Warehouse • Deliveries • Shipping docks • Pickers • Packing stations • Maintenance • Equipments • Scheduled and Unplanned Orders • Personnel

35. Dispatching Board and other Modules • Supply Chain Visibility • Orders and Resources outside the four walls • Assign work to contractors Manages all types of Orders and Resources • Labor • Manage sick or absent employees (unplanned) • Assign work to specific key people

36. Dispatching Board and other Modules • Example • An SPC rule is violated • A Maintenance order is created and scheduled • Production orders are re-assigned and re-scheduled • Maintenance order is assigned to Employee Manage Processes Across all Functional Areas