a journey from unconstrained to constrained
Download
Skip this Video
Download Presentation
A Journey from Unconstrained to Constrained:

Loading in 2 Seconds...

play fullscreen
1 / 22

A Journey from Unconstrained to Constrained: - PowerPoint PPT Presentation


  • 430 Views
  • Uploaded on

A Journey from Unconstrained to Constrained:. Implementing Manufacturing Scheduling and ASCP. At a Glance. Global leader providing mission critical time and frequency solutions Headquartered in San Jose, CA. Offices throughout the US, as well as the United Kingdom, Germany and Malaysia

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'A Journey from Unconstrained to Constrained:' - medwin


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
a journey from unconstrained to constrained

A Journey from Unconstrained to Constrained:

Implementing Manufacturing Scheduling and ASCP

at a glance
At a Glance
  • Global leader providing mission critical time and frequency solutions
  • Headquartered in San Jose, CA.
  • Offices throughout the US, as well as the United Kingdom, Germany and Malaysia
  • Manufacturing in SF Bay Area, Massachusetts and Puerto Rico
  • FY05 revenue $181M
  • ~800 employees
markets we serve
Enterprise and IT Networks

WirelineNetworks

Space, Defense and Avionics

Government Communications

Markets We Serve

Wireless Networks

a sampling of customers
A Sampling of Customers

Telecom

Government

Enterprise

oracle environment
Oracle Environment
  • Hosted by Oracle On Demand
  • E-Business Suite 11.5.10 CU1
  • Dell Servers running Red Hat Linux
  • Live since June 2001
oracle modules
Oracle Modules
  • Manufacturing
    • INV
    • WIP (Discrete)
    • ENG
    • BOM
    • MRP
  • Order Mgmt/CRM
    • OM
    • TeleService
    • Contracts
  • Miscellaneous
    • HR
    • ICM
  • Financials
    • AR
    • AP
    • GL
    • Projects
    • FA
    • Time&Labor
    • iExpense
  • Procurement
    • PO
    • iSupplier
    • iProcurement
project madison
Project Madison
  • Overall Project Goal
    • Project Madison will implement three distinct yet interdependent modules of Oracle: Manufacturing Scheduling, Advanced Supply Chain Planning and Global Order Promising
  • Primary Project Goal
    • Provide accurate Ship Dates to our customers quickly
project madison8
Project Madison
  • Initial Rollout in our Aguadilla, PR facility
    • Includes about 80% of production
  • Focus on ASCP and Manufacturing Scheduling First
    • Fine tune GOP once ASCP and MS are stable
  • Use Internal Resources Primarily
    • Gain a deep understanding of products and processes
    • Less Expensive
    • Longer Project Timeline
selling it
Selling It

Operations Challenges

project challenges
Project Challenges
  • Dirty Data
    • PO & WO Dates not Maintained
    • Sales Order Ship Dates not Maintained
    • Short Orders Left Open (PO and WO)
    • Inaccurate Lead Times
    • Scrap not Scrapped
  • Systems and Application Issues
  • Team Resources
  • Change Management
keys to capacity planning
Keys to Capacity Planning
  • Accurate Routings
  • Accurate Capacity for Machines and People
routing update
Routing Update
  • Existing Routings Primarily Supported Costing
    • Only contained Human Resources
    • Used “Transit” resource to simulate extended machine time
    • Resources and Departments used legacy nomenclature

Sample Routing Here

routing update13
Routing Update
  • Rules of Engagement
    • Don’t Change Standard Costs
    • Don’t Interrupt WIP
  • Complex Process Steps to Model
    • Test Operations
    • Operator Attended and Autonomous Processes
    • Shared Resources
    • Batchable Resources
    • Variable Process Times
routing update14
Routing Update
  • Example:

Test Fixture Example Here

routing update15
Routing Update
  • >1000 Routings to Update
    • Map Old Depts and Resources to New Depts and Resources
    • Insert Appropriate Machine Resources
    • Evaluate Scheduling Sequence for Depts with People and Machines
  • Prioritization
    • Items Averaging > 1 Job per Month
    • Items with Planned Orders
routing update16
Routing Update
  • Keeping Things Simple
    • All Updates Made on Spreadsheets
routing update17
Routing Update
  • More Simplicity
    • Use Standard Interface Tables and Processes
    • Insert Statements Created Using MS Word Mail Merge Functionality

-- to add new resources

insertinto bom_op_resources_interface

(RESOURCE_SEQ_NUM,ASSIGNED_UNITS,USAGE_RATE_OR_AMOUNT

,SCHEDULE_FLAG,OPERATION_SEQ_NUM,ORGANIZATION_CODE

,ASSEMBLY_ITEM_NUMBER,RESOURCE_CODE,SCHEDULE_SEQ_NUM

,basis_type,EFFECTIVITY_DATE,PROCESS_FLAG,TRANSACTION_TYPE

)

values

(10

,1

,0.001

,1-- need 1 or 2

, 50

,‘PRT'

,‘TT-T654/RB/GPS'

,'STORE'

,NULL

, 1-- basis_type

,to_date('07-SEP-2005','DD-MON-YYYY')+1/24/60

,1-- process_flag

,'CREATE'

)

;

production cutover
Production Cutover
  • Challenges
    • Lots of Work in Process
    • Reporting
    • Scheduling Process During Transition
  • The Plan
    • Leave WIP Alone (for now)
    • Ensure All New Jobs have Updates Routings
    • Tweak Capacity to Create ‘WIP Resistance’
    • After X Weeks Update any Open Jobs with Old Routings
open issues
Open Issues
  • Production Control Reorg??
    • Currently Personnel Segregated by Product Family
  • Maintaining Capacity
  • Fine Tuning
    • Mfg Sched Time Fence vs. ASCP Time Fence
    • Use of Penalties
    • Capacity/Usage/Assigned Units
lessons learned
Lessons Learned
  • Separate Project for Routing Update
  • Allow Time for WIP to Fill with Updated Routings
  • Emphasize Clean and Well Maintained Data
  • Expect and Allow Changes to Standard Costs
what we did right
What We Did Right
  • Used Mostly Internal Resources
  • Completely Revamped Routings
  • Started in Largest Plant
questions
Questions?

?

?

Questions??

?

?

ad