Success through Optimum Synchronisation of Processes

Challenges faced in the planning of SMD and final assembly

Challenges:

  • The surface mounting and QA processes of individual boards must be synchronized to the final assembly process
  • The sequence planning for SMD lines shall be such that no missing parts occur
  • Casings must be ready in time for the final assembly process
  • Different manufacturing and purchasing batches must be considered
  • Existing stocks of components must be considered in the planning
  • Inventory must remain at a defined level (minimum inventory / safety inventory)

Processes

Graphic display: The master data for individual items are illustrated in the graphical display (here master data of the item PCBoard-A (analog PCBoard-B ,one-sided), PCBoard-C (double-sided), final item product 123, consisting of PCBoards A, B , C, and casing). The placement and testing of individual boards are synchronized to the process of final assembly point.

Integrated Master Editor Table: In the Integrated Master Editor Table routings in combination with BOM are managed. Each process (each operation) has use instructions, by which the resources, required for this process, are shown. Several alternative resources (here SMD lines 1 and 2 in the process SMD) with individual setup and processing times and other specifications / restrictions can be displayed. For individual processes inputs are defined - input material input item (here input from various boards and casing in the final assembly process).
Item Table: In the item table the properties of each item, which are relevant for the planning, are specified. In the given example, a lot size MAX is specified for the production of various boards, this is used to determine the size of replenishment orders for these boards that are created automatically. Furthermore, the property inventory MIN is specified, due to which replenishment orders are automatically created in order to hold the (safety) inventory at a defined level.
Resource Table: In the resource table properties of each resource are specified (e.g. resource grouping, production limits, minimum and maximum resource lot sizes, possible restrictions on the suspend times ...). Based on the information in the resource table, the appropriate or optimal resource will be automatically selected from several alternatives. In our example, a grouping of resources has taken place.
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 individual resources. Thus, even holidays, maintenance, vacations, machine failure, tool failure ... can be displayed and automatically taken into account in the planning.
Order Table: Sales orders are 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 (boards) that are manufactured in the factory (i.e. with their own master data). Also replenishment purchase orders are created for items that are defined as purchase items with a certain replacement time.
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 linkages between the individual processes within an order (blue line connections) and between different orders (red line connections) are quickly comprehensible. For the final assembly process, the availability of casings (purchased products) is taken into account, replenishment orders will be created automatically. Replacement times (here 2 days) are taken into account. It is also possible to take into account the date of receipt of the commodities.
The stock of raw materials, intermediates, purchasing and final products is automatically taken into account in the planning. In this combined display with the inventory graph, the deployment of inventory is apparent.
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 outcome (e.g. an order exceeds its due date, consider, if an extra shift at a specific resource(s) would be useful). 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). In this view only events that were planned for the next 3 days are displayed. The output for the production is a detailed sequence planning for each resource. The work instructions are synchronously for all resources. The assembly and QA processes of individual boards are synchronized towards the final assembly process.

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