Aspen Plant Scheduler Family

Transcription

1 Aspen Plant Scheduler Family A family of products that provides optimal production schedule generation and analysis to simplify operation and reduce costs The Aspen Plant Scheduler Family is comprised of a three-tiered scheduling solution designed to address the varying degrees of scheduling complexity. Customers deploying these solutions realize significant benefits in the areas of increased throughput, reduced inventory and expediting costs, and improved customer service. Generate optimal production schedules Improve on-time delivery performance by up to 5% Increase throughout by 1-5% Decrease manufacturing cycle times Reduce expediting costs Aspen Plant Scheduler Provides basic finite capacity production scheduling with rapid implementation Aspen Plant Scheduler-Extended Automation (EA) Economically optimizes the production schedule Aspen Plant Scheduler-Extended Optimization (EO) Facilitates the adoption of dynamic supply chain management practices The Challenge: Adapting to Change while Staying on Schedule Process manufacturers are under pressure to maximize productivity from their assets, making optimal production scheduling a critical necessity to remain competitive. A number of factors must be considered simultaneously capacity and material limitations, dependencies of sequenced changeovers, and scheduling of preventive maintenance. All of this must be done while keeping inventories to their minimum and ensuring that customer orders are ready to ship on time. The AspenTech Solution: Simulate Production to Keep up with Reality Aspen Plant Scheduler Family is comprised of a three-tiered scheduling solution, utilizing finite capacity scheduling and optimization principles to manage both basic and complex manufacturing sites. Companies are able to effectively simulate production capacity and evaluate production scenarios for meeting total demand. Additionally, the ability to link multi-stage production activities and customer orders provides real-time visibility of demand and manufacturing levels.

2 Scalable, Flexible Solution that Grows with You An important feature of Aspen Plant Scheduler Family is its ability to reconcile the inevitable differences between production plans and reality. The solution set reconciles planned versus actual for customer orders, receipts of raw materials, and production activities. It can also reconcile high-level corporate production plans with actual events occurring on the shop floor, sending the information back to corporate for global planning. Aspen Plant Scheduler Family integrates easily with ERP and in-house systems as well as other AspenTech applications, simplifying deployment and reducing total cost of ownership. Each solution builds upon the previous, so as the business complexity changes or as people move throughout the organization, the flexibility of the solution supports a right-fit for the current situation. Aspen Plant Scheduler-EA generates detailed plant production plans using advanced heuristics and solvers, creating an optimal short-term schedule of operations. While minimizing changeover, production, and inventory costs, Aspen Plant Scheduler-EA determines the precise timing and sequence of production activities throughout the plant. It works in finite capacity, so the production plans generated are feasible from both a capacity and material flow perspective, and are consistent with the strategic production plan. A prerequisite to creating optimal production schedules and sequencing is an understanding of a plant s supply and demand balance. Aspen Plant Scheduler-EO utilizes this unique perspective to create the optimal short-term plan and schedule of operations in the midst of numerous bottlenecks and constraints. Using both Mixed Integer/Linear Programming (MILP) optimization and advanced heuristics and solvers, Aspen Plant Scheduler-EO allows for the consideration and tradeoffs needed to deliver an economically optimal plan within the physical constraints of a particular production facility. Aspen Plant Scheduler-EO generates an optimal short-term schedule for unit production that is consistent with the longer term group production plan in order to address the inevitable variability in actual versus forecasted customer orders. The solution is developed at the end-item level (e.g., a shippable, billable item), scheduled by start and stop times, or shift, day, or other finite time period. Planned Production Optimization Results 2

3 Optimization Center Aspen Plant Scheduler-EA and Aspen Plant Scheduler-EO include an optimization center that quickly determines the ideal production schedule and sequence. The optimization center will analyze and determine the feasibility of an existing schedule and sequence considering both inventory and capacity dynamically determining timing requirements across multiple stages of production and linking inventories and production activities to customer orders and net forecast. For non-feasible situations, the optimization center will recommend a feasible solution. Often a scheduler will use the analysis components of the optimization center to identify improvements to a schedule that can be made by reducing changeover and inventory holding costs, or increasing effective capacity. Additional Features: Cost factors for early or late production, setup, and production cost Optimize an entire line or a user-selected portion Ability to run the optimization off-line and then post to schedule when ready Stacked bar graph depicts cost breakdown of best solution vs. current solution Optimization of the directly scheduled products or facilities of the production stage Planning Framework In Aspen Plant Scheduler-EO, the planning framework synchronizes the planning model with the real-world situation inside your organization by importing data from various sources that describe your current operating conditions. Data import uses standard integration to the Aspen Supply Chain Data Repository and collects items such as inventory status, current production, open orders, and schedule status. Bill of Materials (BOMs) and production routes are optimally selected based on numerous constraints such as purchasing or material costs at various levels, production cost variations, energy consumption, and labor costs. Aspen Plant Scheduler Function Basic finite capacity production scheduling with rapid implementation Addresses scheduling problems with simple material flow, intermediate inventory storage, static BOMs, simple sequencing rules, and feed constraints Easy-to-use Gantt chart and Inventory Profile Advanced simulation to track production activities, capacity consumption, and inventory productions Benefit Quick user acceptance and time to benefit Provides advanced scheduling starting point for many production processes Master scheduling and interactive Gantt chart framework for a steady state supply chain Base-level scheduling solution that provides visibility, reporting, and simulation capabilities 3

4 Planning Board In all the Aspen Plant Scheduler Family of products, the schedule is readily viewed and manipulated via an interactive Gantt chart called the Planning Board. Drag-and-drop schedule modifications are accompanied by inventory projections and extensive exception reporting to assist the scheduler in visualizing the impact of changes, especially useful when dealing with non-routine events in real-time, such as unexpected spikes in demand, outages of raw material, or equipment breakdowns. The graphical user interface facilitates the intuitive grasp of the underlying operational model, greatly reducing the time required for users to become proficient. The Gantt chart allows for drag-and-drop re-scheduling, and displays scheduled activities by product, product family, setup criteria, rate, or JIT status via multiple color options. Customizable pop-up dialog boxes are used to notify the scheduler of activity, material flow, and alerts to problem conditions. The lower portion of the Planning Board shows a graph of material inventory levels and their changes as the production schedule advances. Planning Board Planning Board with Material Trace Material flows are easily traced because of the unique usage of color and arrows; setup/production times and excess capacity are easily viewed at a glance. Aspen Plant Scheduler EA Function Optimization capability layered on top of Aspen Plant Scheduler Addresses the wide range of scheduling problems such as alternate BOMs, simple shared resources, workcenter dependent sequencing rules, and more Capability to set inventory targets by customer, product, and location Benefit Adds value by economically optimizing the schedule Provides advanced scheduling starting point for many production processes that involve a higher degree of complexity Out-of-the-box scheduling optimization capable of addressing process complexity Optimize inventory levels based on safety, cycle, and threshold stock-level targets and desired customer service levels 4

5 Customizable Reports Aspen Plant Scheduler Family boasts powerful reporting capabilities. Template style reports are easily modified to meet organizational requirements. Report Examples: Capacity utilization by % and hours used in days, weeks, and months Material Balance Planned production by facility and product in days, weeks, and months Inventory report in days, weeks, and months Report generator for facility schedule reports Late orders report for early indication of problem orders Material balance report allows user to see the effects of purchases, production, transportation, external/internal demand on the inventory in daily, weekly, and monthly increments Capacity Utilization Report Planned Production Aspen Plant Scheduler EO Function Dynamic optimization capability layered on top of Aspen Plant Scheduler EA Addresses the wide range of scheduling problems including complex setups and transitions Supports event monitoring, detection, notification, and resolution from plant floor to supply chain Dynamic optimization scheduling capabilities Distribution scheduling capability linked to production scheduling Benefit Gain competitive advantage by adopting dynamic supply chain management practices Finite capacity scheduling framework to support dynamic supply chain practices Out-of-the-box scheduling optimization capable of addressing high process and scheduling complexity Ensures synchronization between the business processes for agility to respond to changing market conditions 5

6 aspenone Planning and Scheduling Aspen Plant Scheduler Family is a part of AspenTech s integrated aspenone solutions for Planning and Scheduling. AspenTech s aspenone solutions are designed to align with the key industry business processes, providing manufacturers the capabilities they need to optimize operational performance, make real-time decisions, and synchronize the plant and supply chain. About AspenTech AspenTech is a leading provider of award-winning process optimization software and services. AspenTech s integrated aspenone solutions enable manufacturers to reduce costs, increase capacity, and optimize operational performance end-to-end throughout the engineering, plant operations, and supply chain management processes, resulting in millions of dollars in cost savings. For more information, visit Worldwide Headquarters Aspen Technology, Inc. 200 Wheeler Road Burlington, MA phone: fax: info@aspentech.com EMEA Headquarters AspenTech Ltd. C1, Reading Int l Business Park Basingstoke Road Reading UK RG2 6DT phone: +44-(0) fax: +44-(0) ATE_info@aspentech.com 2008 Aspen Technology, Inc. AspenTech, aspenone, and the Aspen leaf logo are trademarks or registered trademarks of Aspen Technology, Inc. All rights reserved APAC Headquarters AspenTech - Shanghai 3rd Floor, North Wing Zhe Da Wang Xin Building 2966 Jin Ke Road Zhangjiang High-Tech Zone Pudong, Shanghai , China phone: fax: apac_marketing@aspentech.com