Success through Optimum Sequence of Orders

Challenges faced planning the spring manufacturing

Challenges:

  • There are many custom springs that have individual process chains
  • Depending on the spring dimensioning (specifications) processes must be assigned to the resources with corresponding production limits
  • Partial repeating process (eg. shot blasting process is sometimes performed several times for the production of an article)
  • Large differences in lot sizes, from one to thousands
  • In spring sets, which consist of several springs of different dimensions (specifications), a synchronization of the individual production orders should 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. By Input instructions process inputs are mapped, in this case, there is a spring set consisting of 4 different springs with a respective quantity of 4 pieces. Also every process has an usage instructions through which the needed resources for this process are displayed. Several alternative resources with individual setup and processing times and other specifications / constraints are mapped. The alternative resources have the same instruction code within a process. The sub-resources (workers, devices, forms) can also be displayed. This makes sense if, for example, several workers are required for operation of a machine or can be used as a tool on multiple machines (property "Required resource qty”).
Item Table: Properties of individual items that are relevant for the planning are specified in the Item Table. In the given example, the wire diameter d, the outer torsion diameter De, the not-taut length L0 and the rod length L were parameterized. The information on these specifications is required to automatically select the appropriate resource in the presence of resources alternatives that have different manufacturing limits.
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 and the production limits for each resource were displayed.
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 “wet-paint” were stored depending on specification 1 (wire diameter d) of an article.
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.
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 marked order is an order for spring sets, consisting of 4 springs with different specifications and a respective quantity of 4 pieces. A synchronization of production orders for individual springs takes place towards their compilation.
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). The output of the production is a detailed sequence planning for each resource. The work orders are synchronized for all resources.

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