Success through Optimum Sequence of Orders

Challenges faced in the planning of porcelain production

Challenges:

  • In the process of decorating the order sequencing for each resource should consider the individual specifications (in this case the color code of items in order to achieve a minimization of setup times)
  • In the process of heat treatment the resource furnace should be taken into account with its individual specifications
  • Splitting of lot size can take place

Processes

Graphic display: By default function "Graphical display" the master data of individual items are illustrated. The level of detail of the display can be changed. In the chosen medium level of detail, the process flow is shown with available resources per process.

Integrated Master Editor Table: In the Integrated Master Editor Table routing in combination with BOM are managed. Each process (each operation) has use instructions by which the required resources for this process are shown. Several alternative resources with individual setup and processing times and other specifications / restrictions are displayed, the alternative resources have the same instruction codes within a process.
Item Table: Properties of individual items that are relevant for the planning are specified in the Item Table. In the given example, the property “Color Code” of the item was deposited as a specification, as this will have an impact on the order sequence in a planning period of decorating resources.
Resource Table: In the resource table the properties of each resource are specified (e.g. resource group, production limits, minimum and maximum resources lot sizes, limitations of the suspend times ...). Based on this information, appropriate or optimal resource can be selected from several alternatives. In our example, resources were grouped. For the resource furnace, it was defined that no suspend time occurs between split operations of the same process of an order.
Specification (-n) – setup table: The changeover times are displayed in special matrices. The individual duration of the changeover from one to the next item, property or resource is automatically available for planning. In the given example, setup times for the resource group “Decor” are depending on the stored Specification 1 (“Color Code”) of the deposited item.
Shift Table: In the shift table hours of labor, which can be assigned to each resource are performed with pauses. Here also extra shifts can be entered.
Calendar Table Working days and shifts are assigned to each resource. Thus, even holidays, maintenance, vacations, machine failure, tool failure ... can be displayed to be automatically taken into account in the planning.
Order Table: Ordinary orders will be imported from the ERP system or created directly in Asprova. After rescheduling the order table filled with automatically generated replenishment and production orders for individual components (e.g. molded parts, which are then submitted as input in the decor and the heat treatment process).
Scheduling results: The Resource Gantt Chart visualizes the scheduling result. The setup and production operations that have been assigned to the individual resources are visualized in time. The pegging between the individual processes within an order (blue line connections) and between different orders (red line connections) is quickly comprehensible. The minimum waiting time of 72h between the processes Forming and Decorating (specified in the Integrated Master Editor Table) is automatically taken into account in the planning.
Resource Gantt Chart (only decor style): In this stored style a representation of the individual decor resource takes place. As the display color of the bars the individual color of color codes is specified. As a bar text the order code and the color code is defined, so that a simple analysis of the sequence of orders may take place in terms of color of the item. In this visualization, it is clear that orders with the same colors were planned in sequence on a resource to minimize setup times (defined in the setup table).
Resource Gantt Chart (only furnace style): In this stored style the resource furnace (this is a continuous furnace) is discussed. From the depiction it is evident that orders are loaded in sequence into the furnace (the loading time is the resource "furnace") and then processed for a certain time (14.5h) in the furnace.
The Order Gantt Chart shows the individual orders in its time course. Based on this diagram, the planner can get a quick overview of all orders, analyze their lead times and superior measures that can lead to a better result (e.g. split operation). The possible actions are simulated in advance.
The Load Graph: Asprova optimizes and levels out the utilization of all resources according to configurable rules. The high computing speed of Asprova allows a successive optimization, by configuring different planning scenarios. For example: A wide variety of labor and machine time models can be simulated in just a few minutes and selected accordingly.
The Operation Table: All planned operations are listed in detail in a table, which can be sorted and filtered individually. Several table views can be stored (this also applies for all other tables, charts and graphs in Asprova).

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