Success through Optimum Timing of the Process Sequence

Challenges faced in the planning of cable manufacturing

  • Shortening the lead time and reducing inventories
  • The first process (cutting) has a short lead time and often causes stagnation in subsequent processes, and lack of transparency
  • Attaining optimum timing of the process sequence to avoid push production from the first process

Processes

  • Production (extrusion and stranding) of copper cable
  • Focus of planning:
    - "Core extrusion" Process: Production sorted by colors (set-up optimization)
    - "Stranding" Process: Color combinations are assigned to different groups of machines

Practical Examples

Integrated Master Editor Table: The Integrated Master Editor Table manages work plans, BOM and detailed process characteristics for each resource (machine, machine operator, Rüstteam, tools, materials).
A graphical display of the item structures in the Integrated Master Editor Table (can be interactively edited).
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. The working hours from Monday to Friday are active for all resources full-time. Resource "Extrusion1" is assigned a higher priority order and additionally assigned Sunday.
Order Table: In this example, the Order Table contains basic job information.
Resource 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.
Scheduling results: The Resource Gantt Chart visualizes the planning result and gives a quick overview e.g. about delayed orders, bottleneck resources, process flow, waiting times between operations.
Per drag-and-drop individual processes can be moved, fixed, unfixed or released - always taking into account the prescribed planning parameters and rules.
The example shows the color sorting of the resource "Extrusion1" for setup optimization.
This combined view shows the stock trends for
- Copper strands (top)
- Insulator blue and red (overall progress)
- Production of cable type "D"
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.
Inventory Graph: This combined representation shows
1. The amount of products produced: Cables A-E (upper range)
2. The stocks development for copper strands and insulators red / blue / green (middle range)
3. The development of the various intermediate cables A-E (lower range).
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 illustrations show only a reduced period of time).


The Operation Table contains detailed results for each individual operation and can be exported (lika all tables).
The Item Table contains all item-specific information, such as
- Minimum stocks
- Production lot sizes
Customize specifications (Spec1, Spec2 and many more.), which are considered according to custom formula expressions and can be taken into account when planning.
Requirements and Stocks: Asprova gives a quick overview of supply, demand and inventory for every single item.
monthly
daily
weekly

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