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Asprova High Speed Scheduling. Melissa Brankamp brankamp.2@osu.edu Erin Johnson johnson.1915@osu.edu Gerald Eheduru eheduru.1@osu.edu Rosaida Cestari cestari.1@osu.edu Suprena Isaac isaac.22@osu.edu. Basics from Asprova Corporation.
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AsprovaHigh Speed Scheduling Melissa Brankamp brankamp.2@osu.edu Erin Johnson johnson.1915@osu.edu Gerald Eheduru eheduru.1@osu.edu Rosaida Cestari cestari.1@osu.edu Suprena Isaac isaac.22@osu.edu
Basics from Asprova Corporation • Production scheduling is the central mechanism for controlling production in a factory and making decisions about what to produce, when to produce it, and what resources to use in its production. It is also the key to knowing and understanding what is going on in your factory - not just now, but hours, days, and weeks into the future. • Enormous improvements have been made in production scheduling in the past years through the development of high-speed automated production scheduling software. Most noted among these is the scheduling system Asprova, which has its roots in the artificial intelligence boom and Japanese just-in-time manufacturing practices, and which has long been accepted as the de-facto standard for production scheduling among Japanese manufacturers. • Asprova is a production scheduling system developed and distributed by Asprova Corporation.
How Does Asprova Work? • It manipulates input and output data by default via the operating system's file system, so that it is not dependent upon any particular database format. The data is comprised of files containing Project Settings and Guide Settings, as well as multiple table files. As all this data is read into memory when the project is loaded, file access during scheduling is unnecessary, allowing computation to be performed at extremely high speeds. • A single schedule along with all related data is called a Project. Asprova is capable of having multiple projects open at the same time. Each project includes multiple tables (databases) which contain the data upon which the schedule is based. • Asprova's scheduling engine is extremely rich in features. But when viewed from a different angle, the activity of the scheduling engine is quite simple. • The fundamental function of Asprova's Guide is to display information from the project's tables visually from every possible angle. An example is changing assigned resources and times by dragging a job on the Gantt chart. The core of Asprova's GUI is the Gantt chart and the other graph windows. These windows display the table contents along a time line or display the aggregate results in a histogram.
Asprova's Main Window (1) Menu Bar Used in executing various Asprova functions. The menu items available for execution will vary depending on the type of window in the foreground. (2) Toolbar Allows execution of Asprova commands with a single button click. (3) Windows Multiple windows can be open at the same time, including project windows, Gantt charts, evaluation graphs, table views, and custom HTML views. (4) Tab Click on a tab to bring a different window into the foreground. (5) Output Window Currently consists of a single message window tab. (6) Output Window Close Button Click this to close the output window. (7) Status Bar Displays short messages describing the object at the current location of the mouse pointer. (8) Number of Unassigned Jobs Displays the current number of unassigned jobs. Note that this number will be zero if job generation has not yet been performed, or if all jobs have been successfully assigned.
Environment Settings The data specified in the environment settings dialog affects the whole of Asprova. Environment Settings has the following pages: General Settings Display Color Messages User Registration Sound Log Toolbars Commands Options Advance Settings
Project Settings • The data specified in the project settings dialog affects the currently active project. • Project name • You can specify here a name for the current project, which will be displayed in the title bar of all related windows to distinguish them from windows of other projects. The project name does not affect the actual functionality of Asprova. • Table holding results data • You can specify here whether results data will be entered and maintained in the results table or in the job table. This choice should generally be made before introduction of Asprova into the factory, as it will affect the way in which Asprova is integrated with other data management systems. • Comments • You can enter here comments regarding the current project. These comments do not affect the actual functionality of Asprova.
Project Settings (contd.) Scheduling basis time The scheduling basis time generally refers to the "present time.“ Scheduling period You can specify here the start and end times of the scheduling period via the time setting dialog. Scheduling freeze time Defines the end of the scheduling freeze period. The meaning of the scheduling freeze period is that whenever the project is loaded, Asprova will automatically mark all jobs within the scheduling freeze period as "frozen", which will prevent the assignment status of those jobs from being changed when rescheduling is performed. Display period start time You can specify here the start time of Asprova's display period. The end time of the display period is always the scheduling end time. Day demarcation time The time at which one day is considered to end and the next to start -- as a time of day between 0:00:00 and 23:59:59.
Project Settings (contd.) You can choose here the method for handling inventory data in Asprova.
Project Settings (contd.) Reflect reported quantities onto scheduled quantities Suppose that a certain job was scheduled to produce 100 of its output item, but results data was reported saying that the job was completed after producing only 90 items. If this option is checked, then the fact that this job completed only 90 percent of its scheduled output will be reflected onto the schedule of the entire lot by decreasing the scheduled production quantity of the finished item by 10 percent. It this option is not checked, then the schedule will remain unchanged, regardless of the possibility of an item shortage in later jobs. Automatically delete result records not bound to jobs You can specify here whether or not to automatically delete result records which have fallen out of use because of the deletion of the corresponding job or because of the existence of a more recent result record for that job. Don't calculate setup time for results jobs Skip calculation of setup time for jobs with results.
Scheduling Parameter Settings Dispatching A dispatching rule in Asprova is defined by up to 5 different sort keys, with the first sort key having highest precedence. You should first specify the number of sort keys you will use, and then for each one specify the type of sort key and whether it will sort the jobs/lots in ascending or descending order. Weights You can specify here the weights to be applied to the various criteria for evaluating the tentative assignment of a task to a candidate resource during scheduling. Options You can specify the methods you will be using to determining the resource to which a task will be assigned. Target Lots On this property page you can specify various conditions for filtering the target lots to be assigned with the current scheduling parameter. Target Period You have the option here of explicitly defining the start and/or end time of the assignment period, in which jobs will be assigned.
Calendar Settings The calendar settings dialog allows you to set the available time and the shift of each resource for each day.
Tools Settings The tool settings dialog allows you to register external tools in Asprova.
Plugin Settings The plugin settings dialog allows you to view information for currently registered plugins and to register new plugin modules which you have created to customize Asprova's capabilities.
Asprova's Basic Samples (contd.) One way to express these on the database is by grouping. For example, designate the group of items which can be produced with K1 as group A1, and the group of items which can be produced with K2 and K3 as group A2 in the Item Table. Then in the resource capacity table, set the output item of resource K1 to group A1, and the output item of resources K2, K3 to A2. Note that this example is a simple one and you can perform the same designation job without grouping. Just set the output item of each resource in the resource capacity table one by one. In this sample, two resources are used in one production process. In this case, the molding machine is called the main resource and the metal mold is called the secondary resource. When the secondary resource is used, it is necessary to define the required data in the resource table.
Asprova's Basic Samples (contd.) This is a sample of an automobile parts-processing factory. There are 5 items to be produced, namely, XT1, XT2, XT3, XT4, and XT5. XT1, XT2, and XT3 are produced through 13 processes as shown in the above figure. XT4 and XT5 are produced through 16 processes. In the cutting process, the setup time varies depending on the sequential relation of items. First set the Spec1 in the Item Table, and then set the setup time of Cutter 1 in the Spec 1 Setup Table.
Asprova’s Benefits • Helps to reduce on-hand inventory. • Dramatically reduces schedule generation time from several hours to seconds. • Cuts order turnaround time. • Promotes consistency in production schedules and delivery schedules across the plant. Greatly improves shop-floor discipline by following the schedules generated.
Asprova’s Benefits (contd.) • Impact customer satisfaction by providing 100% on-time delivery. • Significantly reduces Work In Process. • Cuts overtime and material variance. • Has a fast implementation cycle through a host of database systems.
Asprova’s Benefits (contd.) • “What-if” analysis capabilities are able to determine the possibility of eliminating a shift without negatively affecting throughput. • Increases client’s on-time delivery rate to the warehouse.
Asprova’s Benefits (contd.) • Minimizes clean-up and changeover times by employing simulation-based scheduling rules. • Helps to predict late orders, giving the client time to respond to them more effectively. • Provides end-to-end visibility across the entire production process.
