Material and Production Planning OptionswithXA Deborah Vermillion, CPIM, CIRM CISTECH Inc. www.cistech.net
Agenda • Traditional Planning-MPSP, MRP, CRP • Advanced Planner • Thru-Put
TRADITIONAL CAPACITY PLANNING Reporting (Browser) Customer Orders (COM) Forecasts (Forecasting) F i n a n c i a l C o n t r o l MPSP • PRODUCT DATA • (PDM+, IM) • Item Master • Bills Of Materials • Routings • Inventory Levels • Workcenters • Existing Mos • Existing POs MRP Capacity and Material Analysis Production Schedules (Inventory Management) Procurement (Procurement Management +) Production SHOP FLOOR CONTROL (PM&C, PC&C, Paperless) Vendor Scheduling (Procurement Management +) Shipping (COM) Receiving (Inventory Management)
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
Traditional Planning Cycle • But: • Limited view of capacity • Can be Iterative, time consuming…
Traditional Planning Cycle • Material Requirements Planning • Uses Master Schedule from MPSP, COM Orders or Manual requirements to drive plan • Uses PO’s, MO’s, Rep Schedules to satisfy plan requirements • Result is Time phased purchased material and production plan
Traditional Planning Cycle • But: • Capacity not considered • Requires MPSP update for changes in blended demand • ‘what-if’ capabilities limited (manual req’s) • Impact of new demand-wait until night Order/Schedule Recommendation by Item
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?
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
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!!!
AVP- Input Output • Procurement Plan • purchase order releases • expedite; defer; cancel • Production Plan • manufacturing order releases • load vs. capacity • workcenter schedules • Shipping Plan • customer promise dates • 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
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
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
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
AVP vs. MRP cont’d • 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
AVP vs. MRP cont’d • MPSP uses the greater of Customer Order or Forecast • AVP nets the CO’s against the Forecast and plans with the CO’s and Net Forecast • MRP assumes infinite capacity • AVP plans the work load in each work center for capacity review prior to accepting the plan
AVP vs. MRP cont’d • 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
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’ Item’s forecast.
Forecast Consumption This is the forecast consumption chart within AVP
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
AVP Extras • You can optionally update either or both • The promise date on the customer order • The manufacturing due date on the customer order
Advanced Planner Process • Downloading Data to the Engine • Pulls BOM, Route, Item, Item process, Item plan, Forecast, CO’s and/or Manual Requirements • Creates flat files that are pulled in to create access database
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)
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
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
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
Order waterfall view:Identify what is needed when and the Critical chain
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
Advanced Planner Process • What happens? • Reschedules open MO’s/PO’s/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
Planning Execution • Once plan is saved • Execute plan using OBPM • OR • Green Screen Order review and release • OR • Repetitive
Which Orders to push out Generated from within the Facility. Lists supply orders where Supply Due Date > 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 > Demand Due Date. Customer Orders pushed out will be displayed from the “List of Customer Orders..”
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
Why 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.
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 Server’s memory
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
Phase 1 – Analyze Purchased Parts • Users follow Thru-Put’s 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
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
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.
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.
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
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