Asprova Fine Planning System - Usage Report from MAGNA Interiors Libáň

Ivan Marinec, Plant Manager MAGNA Interiors Libáň

Testimonials:

“The advanced Asprova system for planning complex production processes in
the automotive industry helps us to even better track and analyse our production data. There are numerous reports available in Asprova enabling us various visualizations.”

Ivan Marinec, Plant Manager Magna Interiors Libáň

Company profile:

The Magna Interiors Libáň division, manufacturing plastic parts for vehicles’ interior, is a member of the global automotive supplier Magna International Inc. since May 2009. Magna is located in 29 countries and employs more than 125 thousand people worldwide. Besides Libáň, Magna Interiors operates two more divisions in the Czech Republic - Liberec and Nymburk, and about 40 plants worldwide. Highly recognized by various automakers, Magna Interiors Liban provides door panels, instrument panels, arm rests and other parts for customers such as Skoda, Audi, BMW and Citroen.

Production plant: Libáň, CR
Sector: Automotive industry
Number of employees: 480 in Libáň
125 000 overall at Magna
Implementation partner: AIMTEC a. s. (http://www.aimtec.cz/en.html)
Employed solution: APS Asprova

More info at: www.magna.com

Project data and specification:

Phase 1: Analysing and optimizing internal processes
Phase 2: Creating a model and testing with real data
Phase 3: Designing and integrating enterprise information systems - SAP ERP, MES, APS Asprova


Initial situation:

The Management of Magna Interiors Libáň decided to further improve its production planning. All planning had been done within the enterprise wide SAP information system by then. Initially considering the implementation of the APS Asprova system for plan visualization purposes only, Magna Interiors has now implemented an advanced tool for the entire production planning and assessment for all three plants in the Czech Republic - Libáň, Liberec, and Nymburk. The chosen APS solution met also thecondition of available language mutations in order to have anoption to roll-out this solution to other Magna divisions.

 

MAGNA Interiors produces high-quality interiors for automobile manufacturers in Europe and worldwide.

 

Project challenges and risks:

  • Interface to the SAP ERP enterprise information system - collecting data on multiple forms from SAP. It was necessary to harmonize manufacturing procedures with requirements from customers
  • Integrating three systems - SAP ERP, MES, and APS Asprova - that communicate with each other tightly

 

Solution:

Asprova, a Japanese system for production planning and governing, met all requirements of Magna Interiors. The Asprova supplier on the Czech and Slovak markets is the Aimtec company. Aimtec has implemented the APS Asprova system together with Magna Interiors specialists according to actual needs and requirements of the manufacturing process. The project consisted of several tightly connected steps. Initial phase of the Asprova implementation included an analysis and optimization of internal processes. Creation of planning model and testing with real data followed after this. Next step brought connection of the APS Asprova interface to the SAP enterprise information system where the automotive supplier had had to prepare sufficiently accurate data. This was achieved by purpose-created reports enabling quick and effective modifications of necessary data. Asprova was connected also to the existing MES system. A complete integration of three enterprise systems took place - SAP, Asprova, and MES. With the Aimtec’s Asprova the planner has got an adequate tool for advanced planning of production. Every morning the data are read from the SAP system to Asprova. The planner creates a detailed production plan for next 2-3 days. At first the presses supplying the JIS assembling are planned, then
the critical presses, and finally the presses with overcapacity are planned. Capacity forecast for the next two or three weeks is prepared, including schedules for operators and adjusters. Thus created plan is exported to SAP and sent to terminals of the MES system at individual machines. Operators can see the job queues. The MES system downloads information on the particular manufacturing batch and proceeds with the manufacturing steps automatically. The results are displayed in a form of Gantt chart on LCD panels and are used for next planning steps. Loading data (stock levels, call-offs, production data) from the SAP enterprise system into Asprova takes about 5 minutes. The very planning run within Asprova takes 10 minutes. Loading data from SAP takes place in early morning hours and lasts 25 minutes.

Solution specifics:

Change to the internal processProduction steps check-outs take place directly in relation to the given production batch. Number of production batch is printed onto labels within SAP ERP and Asprova.

Publishing plan independently from the planner
Planner just puts a plan together within Asprova, confirms it and sends it to the SAP enterprise system. No need to take care of anything else. All related processes are running automatically. He creates a plan everyday and keeps updating it according to new facts.

Easy correction of errors

If a planner makes any error in Asprova he can, unlike in the SAP system, correct it easily and it will not be propagated further into the system or in related processes.

Easy simulation of production plans
In Asprova there are production data available with which one can make numerous simulations. No changes to data within the SAP system are performed and thus no damages to plan may occur. Those are simplified “what-if” analyses

Results:

  • Increasing efficiency of planners by 50–60 %
  • Higher supervision of plan using the Asprova tools
  • Lower stock levels for semi-finished and finished production
  • Master data clean-up
  • More precise calculation of a product total price
  • More exact information about operation of the whole plant
  • More effective planning of number of operators working at production
  • Effective publishing of plan
  • Lower administration at production
  • Checking production state online according to plan
  • Assessing plan for a specified period and its deviations from original planning scheme
  • Safe transition from JIT to JIS deliveries 



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