Production Planning with Asprova

Automatic synchronization of all Production Processes with the Orchestrating End-to-End Planning System from Asprova

A one percent inaccuracy means that the planning results are incorrect and need to be adjusted.

Even changing an order affects all subsequent and parallel orders. This changes all planning results.
Without the APS planning system, you have to go back to manual planning with Excel.

There is no middle way: the plan is either 100 % correct - or it is not.

Great Total Efficiency through Process Synchronization in Industrial Manufacturing

Full process synchronization is based on accurate planning, which entails assigning manufacturing orders in correct order to be processed on the correct resources. This is only possible with the help of Asprova APS software, whereby

  • there is only one production tact time for every team all production recources.
  • the orchestrator observes, controls and plans the factory from a bird’s eye perspective.
  • one production tact = tact time production = the bottleneck process established the production tact for all other processes.

Ideally, final assembly should be able to handle a total mix of products according to the delivery sequence!

All related and parallel processes e.g. subassemblies and the mechanical production line should handle products sequentially, according to final assembly tact, and in its sequence.

This is the basis of a well-synchronized production process, just-in-time-production with minimal lead time, and minimal inventory.

Lot sizes should be as small as possible. Together, machine setup time and production lot sizes reveal the grade of your just-in-time standard.

 

Mapping 100 % of the Production Process in Real Time for Exact Plans and Simulations

 

Just a small degree of inaccuracy becomes, with time, magnified exponentially. This makes it necessary to perform constant downstream adjustments to the plan, as, say, a change made to a customer order is going to affect all downstream processes as well as parallel processes.

Without an APS planning system, one has to resort back to manual planning with Excel.

There is only one way – completely correct planning. Every other way leads to exponentially growing inaccuracy.

Asprova APS has extensive capabilities:

  1. Several thousand standard parameters form a totally standardized functional basis to map the production process to a degree of one hundred percent with no compromises.
  2. Short-term, middle-term, and long-term simulations of optimized manufacturing scenarios with regards to cost, lead time, and inventory are possible.
  3. The planning department becomes able to instantaneously issue realistic delivery dates for new customer orders.
  4. Bottlenecks are made visible in advance, so that they may be circumvented through pre-emptive measures.
  5. In case of order prioritization changes, resultant changes to the rest of the plan become immediately apparent.
  6. The planning department issues feasible work instructions for every production resource.
  7. Production timing and flow become optimized with regards to production model, manufacturing restrictions, optimal purchase dates for materials (of internal and external suppliers), and preventive maintenance.
  8. The status of currently processed and future manufacturing orders is visualized close to real-time for continuous oversight and control.
  9. Immediate reaction in the case of deviations and disruptions; provision of alternative scenarios with likely no increase in overall cost and no delays in customer orders.
  10. Immediate reaction in the case of changes to order priority or in the event of rush orders; fast issue of delivery date information to the sales department and customers.

Digital Production Planning: Exceptional Increase of Total Efficiency Through Synchronization of Company Processes and Resources

The planning department acts as a conductor in directing all processes to achieve and maintain a great degree of process synchronization.

The factory, hereby, is observed and controlled from a bird’s-eye perspective. This allows the planner to issue manufacturing orders to each resource according to an optimized sequence, calculated by Asprova.

Making use of an advanced planning and scheduling system is the best method to greatly improve total efficiency.

Further advantages are that planning efforts are reduced to a fraction, and implementation only takes a few months!

 

Asprova APS/SCP is the Missing Link between the ERP System and EPS: Process Synchronization was Difficult to Impossible, Until Now!

Man’s Body as an Example for Process Synchronization

The midbrain is part of the brain stem and its function is to relay signals between the spinal cord and all other parts of the brain.

In a similar way, the Asprova APS planning system processes information in a back-and-forth, whereby the shop floor is kept running according to plan and likewise plan is updated according to circumstances on the shop floor. This is the corner stone for feasibility and realism between planning and execution.

Easy Integration into Your IT Environment; Connection with the ERP System Without Programming

Asprova communicates with common ERP systems seamlessly via interface.

All settings for mapping the entire production process are done through simple adjustment of existing standard parameters, without programming.

This makes establishing an interface with an ERP system and any other software such as a manufacturing execution system very easy.

Are You Ready to Cut Your Production Lead Time by 50 Percent?

Lead time consists of waiting time and stagnation

for the most part, which is non-value-added time.

This is true even for world class manufacturers that have high-grade just-in-time systems in place –
about one percent of their total lead time is value-added;
the rest is waiting time and stagnation

The main causes for waiting time and stagnation are:

Reducing Non-Value-Added Time by 50 Percent
with Orchestrating End-to-End Planning
from Asprova.

As an additional consequence:

+ WIP inventory reduction by 50 %
+ finished goods inventory reduction by 30 %
+ increased productivity and greatly reduced planning efforts
+ Minimized variable costs and minimized fixed costs

Inventory Levels Reveal Your
Just-In-Time Standard

Reducing variable costs and fixed costs through just-in-time production

Long lead times and excessive inventory stocks signify underlying problems.

Less inventory stocks and short lead times bring any such problems to the surface where they can be solved.

  • Turnover rate of 6 = material lead time of 2 months (reception until delivery)
  • Inventory turnover rate of 12 = 1 month “JIT Level”
  • Inventory turnover rate of 24 = 2 weeks “JIT Level”
  • Inventory turnover rate of 100 = 2.5 days “JIT Level”

Conclusion:

Reducing the lead time means
to reduce the inventory

Instead of capacity planning with Excel:

Visualizing the Production Process’ Situation for Fast Spotting and Acting

Visual presentation of scheduling results in the form of bar graphs (Gantt-Chart and others) perfects your grasp of and on the entire production process, from customer order to finished-good delivery. In this way, you have the ability to view and control everything weeks and months into the future and in seconds-accuracy.

Issues such as inbound order delays become apparent in advance, making them avoidable in the first place through pre-emptive plan adjustments. Additional information that is related to the order can be pulled up swiftly.

Advanced Visual Management and Planning

 

  • Depiction of all process connections
  • Highlight individual orders
  • Dynamic inventory monitoring (incoming, outgoing inventory; outsourcing)
  • Drilldown functionality
  • Filter functionality in all tables, charts, and diagramsn

 

  • Zoom functionality in all tables, charts, and diagrams
  • Window style customization (colors, properties, boundaries, toolbar, tooltip, and more)
  • Excellent usability: all tables, charts, and diagrams are accessed by switching to their tabs

Predictive KPIs (Key Performance Indicators)
Simulating of Varying Business Results in the Future for Evaluation

Most companies make use of KPIs that in their standard form denote performance of the past in terms of productivity, lead time, costs, inventory, etc. Evaluating these bears little in terms of improving future results, however.

Asprova features Predictive KPI for costs, lead time, value-added time, stagnation, setup time, resource productivity, inventory and many more according to four main attributes:

  • Periodic KPIs – for specified time periods
  • Product KPIs – for specified products
  • Resource KPIs – for specified resources
  • Customer KPIs – for specified customers

High-Speed Calculation in Planning and Simulating

  • Asprova features the fastest planning engine on the market.
  • Simulations of divergent, alternative scenarios can be done instantly.
  • Thus, realistic delivery dates for new orders/enquiries are issued quickly.

The World’s Fastest APS System

Up to 5,000 calculations are completed in three seconds, which makes Asprova the world’s fastest scheduler. A very complex production process, and including the complete supply chain, can be planned with minimal time investment. Of course, capacities are considered finite and material availability is checked for.

  • Manufacturing and supply chain processes are kept in a synchronized state through a thorough and holistic planning approach.
  • When simulating alternative scenarios, feasibility, costs, and delivery dates come out accurately for you to rely on with confidence.

Other schedulers require several hours of calculation time for a mere 100,000 operations;
Asprova handles that number in twenty seconds.

Whitebox Instead of Blackbox: The APS System with Total Transparency

Changes made in one place can have effects in many other places. As the title implys, the mechanisms and workings behind tables, charts, and graphs can be tracked and studied, so that you gain a complete and in-depth understanding of Asprova APS and Asprova SCP.

Armed with knowledge of the logical consistency between settings and scheduling results, there are no limits on how you use Asprova to positively manipulate your production process and supply chain!.

  • Train your own APS experts. Since there is no programming involved, they will quickly be able to effectively plan and keep improving in the planning process.
  • Your planners and managers receive consultation from Asprova’s transparent way of presenting scheduling results from all perspectives and angles to give you the full picture of the situation, and how to improve it.

The Asprova Production Planning Dream Team

Orchestrating End-to-End
Shop Floor Planning

APS (Advanced Planning and Scheduling)

Orchestrating End-to-End
Supply Chain Planning

SCP (Supply Chain Planning)

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