Oracle Production Scheduling. Maximize shop floor throughput and optimize resource utilization

Transcription

1 Oracle Production Scheduling Maximize shop floor throughput and optimize resource utilization

2 Typical Scheduling Challenges How can you: Sequence orders to best use your production resources? Offload production to alternate resources? Minimize the effect of unplanned production and down time? Evaluate the impact of a supply shortage on fill rates? Support revenue growth using existing production assets?

3 Traditional Approach Poor visibility to changes, manual process, expedite everything Poor visibility to demand and production plan, many disparate spreadsheets, rush everything Long cycle times Large amounts of work in process inventory Constant expediting Poor shop floor performance and poor delivery performance Unpredictable manufacturing throughput times No visibility to future planned requirements Vulnerable to unplanned downtime

4 Better Approach: Production Scheduling Feasible on-time schedules with improved throughput and utilization Complete visibility to demand and production plan, secure integrated system, improved cycle time Monitor performance Short cycle times Analyze exceptions Feasible schedules that respect manufacturing constraints Improved utilization and minimal setup time Consistent manufacturing cycle times Improved schedule adherence and delivery performance Reduced work in process inventories Secure and integrated system

5 How Delivers

6 Oracle Production Scheduling Maximize shop floor throughput and optimize resource utilization Maximize throughput of bottleneck resources Automatic detection of bottlenecks Minimize setup with intelligent sequencing Improve shop floor performance Minimize the effect of unplanned downtime Easy identification of issues What-if rescheduling Drag and drop Quickly determine the best schedule Fast easy simulation Scenario comparison and key performance indicators Implement quickly by leveraging out-of-the-box integration Integrated manufacturing planning and scheduling Fully integrated with Oracle E-Business Suite

7 Oracle Advanced Planning Complete e-business planning solution Supply Chain Intelligence SCI Network Design SNO Make Maintain Service Fulfill Procure Plan Order Finance HR Projects All Product, Customer, & Supplier Information Sell Market Develop From detail to summary Real-Time Sales and Operations Planning Production Scheduling Supply Chain & Manufacturing Planning Global Order Promising Distribution Planning PS Demand Management Inventory Optimization GOP ASCP ASCP IO DM SC Exception Management CP Collaborative Planning CP From short-term to long-term * Integration with Oracle EBS (R11.I.10)

8 Oracle Production Scheduling Typical key benefits Increase bottleneck utilization up to 25% Reduce work in process up to 25% Reduce scheduling cycle time from weeks to minutes Drive continuous improvement

9 Oracle Production Scheduling Enables you to Maximize throughput and increase resource utilization Improve shop floor performance Determine the best schedule Comprehensively plan and schedule production

10 Maximize Resource Utilization Easily create feasible schedules Determine a feasible schedule considering all your constraints Schedule and synchronizes multiple stages of production Automatically detects floating bottlenecks Considers all material and resource constraints Easily identify issues Exceptions highlight constraints Drill directly to root causes

11 Maximize Resource Utilization Minimize lost utilization due to setup time Minimize setup time Intelligent sequencing to minimize major and minor setups Recognizes last operation run Setup information comes directly from Oracle EBS Run optimization Plan for campaigns to optimize setup while respecting minimum run constraints Weigh on-time performance versus setup costs

12 Example: Sequencing Sequence work on a paint line from light to dark paint to minimize changeover and cleaning times between color changes, assuming 10 hours run per job Changeover time from white to blue Time PAINT LINE Orders needing WHITE paint Orders needing BLUE paint Orders needing BLACK paint From To: White Blue Black Changeover Times (Hours) White Blue Black Orders Total setup Total Run Total Time Un-sequenced White, blue, black, white, blue, black, white, blue, black Sequenced White, white, white, blue, blue, blue, black, black, black

13 Nampak, South Africa Live on Production Scheduling since September, 2005 Company Global manufacturer with 126 facilities in 19 countries Manufacturer packaging products Planning problem solved Moved from manually intensive spreadsheet schedules to daily schedules that respect all material and capacity constraints Instituted standard scheduling practices across multiple facilities Unique aspects of implementation High volume production of a diverse product mix Very complex changeover matrix with over 40,000 entries Multiple implementations each with unique manufacturing constraints Significantly reduced scheduling cycle time Increased utilization of bottleneck resources and reduced setup time Increased manufacturing flexibility by moving to daily scheduling

14 Oracle Production Scheduling Enables you to Maximize throughput and increase resource utilization Improve shop floor performance Determine the best schedule Comprehensively plan and schedule production

15 Improve Shop Floor Performance Easily identify and resolve issues Exceptions and alerts highlight issues Identify potential late demands Alerts identify the root cause of the issue Easy drill directly to the problem area Fast simulation and drag and drop rescheduling Enables scheduler to quickly asses potential corrective action

16 Improve Shop Floor Performance Seamlessly communicate current priorities to production Publish schedule directly to execution Reschedules of existing work orders Release of new production Assignment to alternate resources Publish dispatch list with detailed schedule and priorities Easily view list of operations on a resource Clear and up-to-date priorities for production

17 W. L. Gore and Associates Live on Production Scheduling since June, 2005 Company Global Manufacturer with revenue over $1.5 Billion Manufacturer Gore-Tex fabrics used in many consumer products Planning problem solved Detailed scheduling of fabric lamination to improve throughput of critical bottleneck resources Unique aspects of implementation Complex scheduling problem with floating bottlenecks Reduced work in process inventory by more than 25 percent Reduced scheduling cycle time from 1-2 weeks to minutes Reduced overtime and expediting

18 Oracle Production Scheduling Enables you to Maximize throughput and increase resource utilization Improve shop floor performance Determine the best schedule Comprehensively plan and schedule production

19 Determine the Best Schedule Quickly determine the most optimal shop floor schedule Easily compare multiple scenarios Unlimited what if scenarios Seeded key performance indicators to assess schedule quality Evaluate schedule on multiple metrics Delivery performance (late days, late orders) Cost Inventory performance Easily implement the approved schedule Release approved schedule directly to execution

20 Determine the Best Schedule Example: evaluate and adjust schedules Issue Analysis Decision Important demands are not going to be met on time One resource is the bottleneck and is completely consumed All production on this resource is required for critical production Working weekend overtime would enable all demand to be met on time Authorize overtime for the weekend Release new schedule to the shop floor Get approval for cost of overtime

21 Toyota Racing Development Live on Production Scheduling Company A subsidiary of Toyota Motor Sales USA. Produces high performance engines for the Toyota racing teams Planning problem solved Moved from 2 week long spreadsheet based scheduling process to daily scheduling Automatically generate multiple what if scenarios each day to determine optimal staffing plans Unique aspects of implementation Extremely complex manufacturing process with many operations and extremely tight tolerances Very highly constrained by complex automated machining centers Reduced scheduling cycle time from two weeks to minutes Reduction in time loss due to retooling Increased ability to react to engineering changes

22 Oracle Production Scheduling Enables you to Maximize throughput and increase resource utilization Improve shop floor performance Determine the best schedule Comprehensively plan and schedule production

23 Out-of-the-box Scheduling Scheduling for planners, not programmers Make better decisions faster by choosing alternatives Automatically detects floating bottlenecks Offloads to alternate resources Enforces all capacity constraints including materials, resources, and tools Start quickly Planners define the problem to solve Seamless integration with Advanced Supply Chain Planning and Oracle E- Business suite Leverage existing setup data

24 Comprehensive Manufacturing Planning and Scheduling Solution Complete, integrated Manufacturing Planning and Scheduling process SUPPLY PLANNING (ASCP) Production Plan Week 4-15 Production Plan Week 3-14 Production Plan Week 2-13 Production Plan Week 1-12 Planned orders Firm work orders Schedule Week 2 Schedule Week 3 Schedule Week 4 Schedule Week 5 Schedule Week 6 FIRM Schedule Week 1 Schedule Week 2 Schedule Week 3 Schedule Week 4 Schedule Week 5 PLANNED Schedule Week 0 Schedule Week 1 Schedule Week 2 Schedule Week 3 Schedule Week 4 PRODUCTION SCHEDULING (PS)

25 Schedule Any Mode of Manufacturing Detailed schedules for all Oracle execution processes Discrete Manufacturing Simultaneous resources Minimum transfer quantities Sequence dependent setups Process Manufacturing Co-products and by-products Hard links Campaigns Changeovers Semiconductor Binning Network routings

26 Architecture

27 Scalable and Open Architecture Database-centric architecture TRADING PARTNERS INTERNAL USERS Portal Portal Internet Reliable All plan information resides in the database Hot backup and recovery Leverages grid computing infrastructure Oracle ERP Order Promising Engine Open and standards based Deploy against legacy systems XML, flat file support APIs XML Flat file Plans and Schedules Legacy Systems KPIs Workflows Advanced Planning Architecture

28 Integrated, yet Modular Leverage integration at incremental investment PLANNING PROCESS Safety stock targets Forecast scenarios Network Design SNO Sales and Operations Planning Demand Management DM Forecast and demand variability Inventory Optimization Forecast IO Sourcing rules Supply schedule Planned orders Time-phased safety stocks Supply Chain and Manufacturing Planning Constrained plans ASCP Sourcing rules Production Scheduling PS Global Order Promising GOP Supplier capacity Supply commits Order forecast Order forecast Customer forecast Collaborative Planning CP SUPPLIERS CUSTOMERS

29 Oracle EBS / PS Integration

30 Production Scheduling Integration Description Constrained dependent demands, Independent Demands, Planned Orders Advanced Supply Chain Planning Plan for multiple facilities Which plant makes what products and when Pre-builds based on capacity shortages Alternate facilities, suppliers and processes Production Scheduling Schedule a single facility Sequence Production to meet demands on this facility Account for detailed production constraints and come up with an executable schedule Detailed Sequence of activities near term to constrain the medium / long term plan

31 Production Scheduling Integration Description Supplier A Plant 1 Customer X DC1 Supplier B Plant 2 Customer Y DC2 Supplier C Plant 3 Customer Z Scope of ASCP Planning the entire Supply Chain Scope of PS Scheduling a single Plant

32 Production Scheduling Integration Description Logical Information Flow Source ERP Work Order Reschedules New Work Orders Items Bill of Materials Routings Resources Work Order Sales Orders On Hand... Production Scheduling Planned Orders Planned Order Demands Sales Orders Forecasts ASCP

33 Production Scheduling Integration Description Modes of Running PS Running PS Standalone Schedule work orders only Forecast demands specified via Demand schedules Inter-org demands included only via internal sales orders Items to be included in PS specified via specification of category sets / categories No Forecast consumption Running PS with reference to an ASCP Plan Schedule work orders and planned orders Forecast demands come in via the referenced ASCP plan Inter-org demands also include planned order demands from the ASCP plan Items to be included in PS derived from the items in the ASCP plan Forecast consumption performed in ASCP is retained within PS

34 Production Scheduling Integration Description System Information Flow Client PC Oracle Applications Login Define Schedule names and Options Browser Invoke Data Snapshot EBS Source Collections Planning Data Repository Open PS Workbench Rescheduled / New Discrete Jobs / Lot Based Jobs / OPM Batches Snapshot PS Data From Planning Server Publish Schedule from PS (Release Process) PS Model Files PS

35 Summary

36 Oracle Production Scheduling Feasible on-time schedules with improved throughput and utilization Complete visibility to demand and production plan, secure integrated system, improved cycle time Manage performance Analyze exceptions Feasible schedules that respect manufacturing constraints Improved utilization and minimal setup time Consistent manufacturing cycle times Improved schedule adherence and delivery performance Reduced work in process inventories Secure and integrated system

37 Oracle Production Scheduling Enables you to Maximize throughput and increase resource utilization Improve shop floor performance Determine the best schedule Comprehensively plan and schedule production

38 Why Oracle! Best in class, proven production scheduling solution Integrated manufacturing planning, scheduling, and execution Designed for planners, not programmers Integrated performance management

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