Success through Optimum Synchronisation of Processes

Challenges faced in the planning of blockboard manufacturing

Challenges:

  • Process loops (e.g. process Pressing is carried out repeatedly for the production of an item)
  • Time constraints between processes (e.g. minimum of 5 days between grinding and the previous process) should be adhered to
  • If there are several factory halls existing, the processing should be planned on resources within one hall
  • When assigning orders to the core machines, machines, which previously processed the same or similar stem thickness, should be preferred
  • Purchasing items must be replenished in time 

Processes

The graphical display of the item structure illustrates the process flow and the merging of high-voltage coil (HV), medium-voltage coil (MV) and under-voltage coil (UV) as well as the core composition.

Integrated Master Editor Table: In the Integrated Master Editor Table routings in combination with BOM are managed (input instructions for individual operations). Every process has use instructions by which the required resources for this process are displayed. A resource group can also be deposited as a use instruction from which Asprova can select the appropriate/optimal resource.
Item Table: In the Item Table, specifications for individual items that are relevant for the planning can be stored.
Resource Table: Properties of each resource are specified in the Resource Table. 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 (so that the group can be used in the master data as resource). Furthermore, next resource constraints are defined for some resources.
Shift Table: In the Shift Table patterns are managed , which can be assigned to each resource. 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, in our case, for core wood, and in consideration of purchasing also replenishment purchase orders.
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. In woodworking, the challenge is that the process Pressing is partially repeated several times (process loop). Furthermore, a waiting time of at least 5 days between the processes Pressing and Grinding must be taken into account.
Orders on the diagram can be filtered, highlighted and zoomed.
The Order Gantt Chart shows the individual orders in their 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. change in the scheduling logic, adding an extra shift etc.).
The Load Graph: Asprova optimizes and levels out the utilization of all resources according to configurable rules. In the load graph, the utilization of each resource is represented over time course.
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.

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