Guidelines for the APS Selection Process


•The advanced planning system serves as the backbone and brain of a manufacturing company. All the other company organs are organized around the production schedule and carry out their tasks just-in-time for maximized efficiency. If the planning is incorrect this creates the most expensive type of waste.

•Employing an effective production scheduling system is of critical importance.

•The following guidelines for selecting an APS are based on functionality.

100% mapping of process rules and restrictions, without programming

The software should be capable of mapping product specifications, process rules and process restrictions 100 percent.

  • Inaccuracy of a single percentile means that scheduling results (Start-/End timing) will be incorrect and need to be adjusted manually. A change to just one order affects all proceeding and parallel orders. Thus all the planning results become unrealistic and the planner is forced to go return to manual planning in Excel.
  • In production planning results there can be no middle way: they are either one hundred procent correct…..or not.
  • Programming should not be necessary; it is time-intensive and its functions cannot be guaranteed to be work consistently with other parameters. An APS with a large array of standard parameters circumvents the need for programming.

Multi-Level Finite-Capacity-Planning

  • Being able to oversee the availability of all resources and sub-resources is of great importance, because production cannot commence if a single factor is unavailable.
  • In most cases, multiple levels of sub-resources must be considered, such as: machines, molds, jigs, tools, work stations, operators, etc.

Simultaneous Consideration of Resources and Material Availability

  • Availability and fluctuations of raw materials, as well as its consumption, incoming dates and timing must be monitored and considered for realistic scheduling.
  • The same foes for Semi-finished goods.
  • And finished goods and fluctuations.

Customizable Planning Logic

  • Today, product manufacturing processes including their many variants are highly complex. Optimal planning results are not attainable by means of a simple planning logic that is merely capable of forward scheduling and/or backward scheduling.
  • To synchronize processes, which results in shorter lead time and lower inventory, a highly-customizable and individualized planning logic is necessary.
  • The planning logic should be customizable and tailorable to your requirements without any need for programming, in this way you will be able to consistently and actively achieve optimal planning results.

Simulation

  • Using simulation it should be possible to reliably issue realistic delivery dates.
  • What-if Scenarios: you should be able to compute alternative scenarios in the cases of late raw material income, machine breakdown, rush orders, delivery date changes or order volume changes,
  • The effects that dynamic simulations and changes to the original plan have on the entire production process should be immediately apparent.
  • Simulations that are based on various parameter settings should highlight variations in inventory changes and their effects on production.

Future KPI

  • Many companies document KPI to evaluate productivity, lead time, costs, inventory, etc. from the past. But such have little influence on the future.
  • Future KPI afford the advantage of simulating various business scenarios and production strategies, and assists top-management in making profitable decisions for the future.
  • You gain foresight into the future and with that, the ability to control it.
  • The APS should provide the ability to look into the planning months and even years ahead.
  • Future KPI should be available for manufacturing costs, production lead time, value-adding time, non-value-adding time, setup time, resource productivity, inventory and many more:
  • For the entire planning horizon, including all orders for months and years in advance.
  • Periodic KPI for specific time periods
  • Products KPI for specific time periods
  • Resource KPI for specific time periods
  • Customer KPI for specific time periods

Computing Speed

•Business circumstances that change daily require the planner to make simulations to find the best planning results possible. It is important that this not take several hours, preferably this should be completed within minutes or seconds.

Visualization

  • As the saying goes: „one picture is worth more than 1000 words“, and this is based on the scientific research.
  • The brain processes visual information 60.000 times faster than textual information.
  • Around 40 percent of all the brain‘s nerve cells are connected to the retina (eye).
  • Visual data accounts for almost 90 percent of all information processed by the brain.

Visualization

  • As the saying goes: „one picture is worth more than 1000 words“, and this is based on the scientific research.
  • The brain processes visual information 60.000 times faster than textual information.
  • Around 40 percent of all the brain‘s nerve cells are connected to the retina (eye).
  • Visual data accounts for almost 90 percent of all information processed by the brain.

Flexible Interface to the IT-Environment

•Allows for access to multiple systems, including the ERP system, MES, data acquisition system, etc.

  • Überblicken Sie Auftragsstatus und Durchlaufzeiten für Monate im Voraus.
  • Beobachten Sie gegenwärtige und geplante Produktionsaufträge. (Visualisierung)
  • Engpässe werden frühzeitig ermittelt, sodass „Feuerwehrtätigkeiten“ vermieden werden können.
  • Visuelles Management ermöglicht zum „Blick in die Zukunft“. Dies ermöglich wiederum Frontloading-management und Ermittlung des kostengünstigsten Planungsszenarios.

White Box instead of Black Box

  • A black box does not, as the name implies, allow for study of the inner mechanisms. For an APS, this means that the logic between parameters of all levels and planning results cannot be traced! For realistic planning results, the logical consistency between parameters and the planning logic must be transparent and understandable.
  • On this foundation you would be able to educate your own APS-experts, who are then capable of making adjustments and improvements on their own, without the need for programming or support from the vendor!
  • A white box advises the planner and the manager on how to improve factory results, helping them to choose the best planning scenario!

Software License Cost

  • The planning system has a great influence on:
  • Production lead time
  • Inventory levels
  • Cash flow
  • Resource productivity
  • Manufacturing costs
  • License and implementation costs:
  • The choice of an APS should not be based only on the direct software price.
  • With a APS tool that is able to improve all 5 points the ROI is quickly recovered – often within one year and several times over. If a decision is made based only on direct software costs then the danger exists that after a few years there will still be no improvements or cost reductions.
  • The most important aspect of APS is that it contains the software functionality that will help reduce manufacturing costs.