Optimal use of Resources Increases Productivity

Challenges faced planning the production of car-bumpers

  • Optimum provision of metal casting molds
  • Optimal use of resources - increasing productivity
  • Creating optimum work orders for individual resources

Processes

  • Manufacturing metal casting products (end products) on form casting machines
    - (24/7) Production 
  • On 3 molding machines, 5 different end products are produced
    - Each end product is assigned one metal mold
    - Each SG-form is available once
  • A Setup Team 
    - Takes over the internal set-up of metal casting molds
    - Monitors the molding machine during production
    - The external set-up of metal molds is not considered in the example
  • Particularity:
    - Focus lie on optimally utilizing the metal casting machines

Pactical Examples

Integrated Master Editor Table: The Integrated Master Editor Table manages work plans, BOM and detailed process characteristics for each resource (machine, machine operator, R├╝stteam, tools, materials).
Instruction Code
- M: Main resource (0 = set-up time is controlled via the "Article race table")
- S0: Subressource (0 = tied to production time of the main resource)
- S1: Subressource (0 = bound to set-up time of the main resource)

Setup times- and orders for articles and resources can be determined individually, either related to a particular item, or globally with all items in the previous procedure (Article L) - or following operation (Article R).
Shift Table: In the Shift Table individual work times are deposited and provided with a unique name (shift code).
Calendar Table: The Calendar Table references the shift and resource table.
It allows targeted allocation of working hours and shifting patterns to certain resources.
Order Table: In addition to "classical" order data, the order table contains e.g. custom property fields. In this example, manufacturing orders are transferred to Asprova.
Resource Table: The Resource Table is referenced by the Integrated Master Editor Table.
In the Resource Table, resource-specific properties are stored, such as the constitution of resource groups, production and setup suspend times MIN / MAX, resources lot sizes, dependancy on preceeding or succeeding resources, display color and position in the Gantt Charts.
Particularity:
- Molding machines 1-3 are summarized in the group: Molding machine. In the work plan of the Integrated Master Editor Table, this group will be referred to. Asprova will select the optimal resources at the appropriate time.
Scheduling results: The Resource Gantt Chart visualizes the scheduling result and gives a quick overview e.g. about delayed orders, bottleneck resources, process flow, waiting times between the operations.
Per drag-and-drop individual processes can be moved, fixed, unfixed or released - always taking into account the prescribed planning parameters and rules.
Quick overview of all operations of one particular item.
The Order Gantt Chart shows the time course of the scheduled jobs, both in general overview (intermediate products, inventory, replenishment and purchasing orders, outsourcing, etc.), as well as in specific detail of individual orders.
Load Graph: Asprova optimizes and levels out the utilization of all resources according to configurable rules. The high computing speed of Asprova allows for successive optimization by configuring different planning scenarios. For example, you can simulate a wide variety of labor and machine time models in a few minutes and selecting any of them.
Work Instructions: Asprova generates work instructions for each workplace, each resource and each process and provides them for export to other systems. The level of information content and detail are individually configurable.
The Operation Table: provides detailed (configurable) information on all precesses.
The Item Table provides detailed (configurable) Information on all items.
Requirements and inventory: Asprova gives a quick overview of supply, demand and inventory for every single item.

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