Perfect Process Synchronization and Precise Work Orders

The Problems of Production Planning faced in Tool Manufacturing

  • non synchronous and therefore no timely completion of various components, as well as
  • long lead times due to poor process synchronization

Worst case scenario: Production Planning and Control, using the ERP system:

  • Creating incorrect production orders with the wrong schedule
  • inaccurate work instructions for individual resources
  • this leads to a delay in delivery, long lead times and high inventory levels

Application examples with Asprova APS

  • Management of work plans and parts lists via the integrated master data table.
  • The --Schichtabelle-- allows the entry of individual tag times.
  • The calendar table allows targeted allocation of working hours and shifting patterns to specific resources.
  • Refill orders are automatically generated.
  • The utilization rates graph allows successive optimization by configuring different planning scenarios.
  • For all orders, jobs, resources and processes, working instructions can be created
  • The plan evaluation table provides detailed information for each planning run available.

Processes

  • Progressive tool to hold 2 tool modules
  • There are 4 different tool modules (TL1-4) available
  • Assignment of the tool inserts made ​​via order data fields (Spec1 and Spec2)
  • Each progressive die is commissioned entirely, including 2 Tool Modules
  • In addition, various items are individually produced and shipped (items, spare parts, etc.)
  • Description supplemented by the term "individually ..."
  • Calculation method: reverse

Practical Examples

Integrated Master Editor Table: The Integrated Master Editor Table manages work plans, parts lists and detailed process characteristics for each resource (human, machine, tool, material).
The additional input of rules on formula expressions enables the mapping of individual customer requirements.
The Graphical representation of the master data gives a quick overview and also allows for interactive editing process and master data.
Shift Table: In the Shift Table individual work times are stored and provided with a unique name (shift code).
Calendar Table: The Calendar Table references the shift and resources table. It allows a targeted allocation of working hours and shift patterns to certain resources.
Additional Properties: "Order" - individual prioritization of individual calendar entries
"Number of Resources" - Number of available resources (eg employees)
Order Table: In addition to the "classical" order data, the Order Table contains - e.g. custom property fields (in our example of passing the type of the tool modules) or the property "priority", with which each individual order can be prioritized. Construction contracts the job class "replenishment orders" are automatically generated by Asprova.
The 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.
Simple drag-and-drop allows individual operations to be moved, fixed, unfixed or released, always taking into account the planning parameters and rules.
The example shows a backwards planning of all orders. Custom styles allow for individual color schemes (single item, item categorization etc.)
A powerful tool is the Resource Gantt search function. It finds targeted operations and highlights them, including all linked tasks. So you can quickly and comfortably filter out individual processes, for clear visualisation and investigation.
Asprova informs the user in many ways over the planning result, eg:
-Features, news and object window (see below)
- Task bar and status bar text
- Tooltip and connecting line texts (on mouseover)
- Context Menus
The Order Gantt Chart shows the time course of the scheduled jobs, both in the general survey (intermediate products, inventory, replenishment and purchasing orders, outsourcing, etc.),...
... as well as in the specific details of individual orders.tc.)
The Load Graph: Asprova optimized 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: A wide variety of labor and machine time models can be simulated in just a few minutes and selected accordingly. 
The Work Instructions: Asprova generates work instructions for all orders, working stations, resources, processes and makes them available for export to other systems. Information content and level of detail are individually configurable.

Some of our customers: