1 / 22

A Journey from Unconstrained to Constrained:

A Journey from Unconstrained to Constrained:. Implementing Manufacturing Scheduling and ASCP. At a Glance. Global leader providing mission critical time and frequency solutions Headquartered in San Jose, CA. Offices throughout the US, as well as the United Kingdom, Germany and Malaysia

toyah
Download Presentation

A Journey from Unconstrained to Constrained:

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. A Journey from Unconstrained to Constrained: Implementing Manufacturing Scheduling and ASCP

  2. At a Glance • Global leader providing mission critical time and frequency solutions • Headquartered in San Jose, CA. • Offices throughout the US, as well as the United Kingdom, Germany and Malaysia • Manufacturing in SF Bay Area, Massachusetts and Puerto Rico • FY05 revenue $181M • ~800 employees

  3. Enterprise and IT Networks WirelineNetworks Space, Defense and Avionics Government Communications Markets We Serve Wireless Networks

  4. A Sampling of Customers Telecom Government Enterprise

  5. Oracle Environment • Hosted by Oracle On Demand • E-Business Suite 11.5.10 CU1 • Dell Servers running Red Hat Linux • Live since June 2001

  6. Oracle Modules • Manufacturing • INV • WIP (Discrete) • ENG • BOM • MRP • Order Mgmt/CRM • OM • TeleService • Contracts • Miscellaneous • HR • ICM • Financials • AR • AP • GL • Projects • FA • Time&Labor • iExpense • Procurement • PO • iSupplier • iProcurement

  7. Project Madison • Overall Project Goal • Project Madison will implement three distinct yet interdependent modules of Oracle: Manufacturing Scheduling, Advanced Supply Chain Planning and Global Order Promising • Primary Project Goal • Provide accurate Ship Dates to our customers quickly

  8. Project Madison • Initial Rollout in our Aguadilla, PR facility • Includes about 80% of production • Focus on ASCP and Manufacturing Scheduling First • Fine tune GOP once ASCP and MS are stable • Use Internal Resources Primarily • Gain a deep understanding of products and processes • Less Expensive • Longer Project Timeline

  9. Selling It Operations Challenges

  10. Project Challenges • Dirty Data • PO & WO Dates not Maintained • Sales Order Ship Dates not Maintained • Short Orders Left Open (PO and WO) • Inaccurate Lead Times • Scrap not Scrapped • Systems and Application Issues • Team Resources • Change Management

  11. Keys to Capacity Planning • Accurate Routings • Accurate Capacity for Machines and People

  12. Routing Update • Existing Routings Primarily Supported Costing • Only contained Human Resources • Used “Transit” resource to simulate extended machine time • Resources and Departments used legacy nomenclature Sample Routing Here

  13. Routing Update • Rules of Engagement • Don’t Change Standard Costs • Don’t Interrupt WIP • Complex Process Steps to Model • Test Operations • Operator Attended and Autonomous Processes • Shared Resources • Batchable Resources • Variable Process Times

  14. Routing Update • Example: Test Fixture Example Here

  15. Routing Update • >1000 Routings to Update • Map Old Depts and Resources to New Depts and Resources • Insert Appropriate Machine Resources • Evaluate Scheduling Sequence for Depts with People and Machines • Prioritization • Items Averaging > 1 Job per Month • Items with Planned Orders

  16. Routing Update • Keeping Things Simple • All Updates Made on Spreadsheets

  17. Routing Update • More Simplicity • Use Standard Interface Tables and Processes • Insert Statements Created Using MS Word Mail Merge Functionality -- to add new resources insertinto bom_op_resources_interface (RESOURCE_SEQ_NUM,ASSIGNED_UNITS,USAGE_RATE_OR_AMOUNT ,SCHEDULE_FLAG,OPERATION_SEQ_NUM,ORGANIZATION_CODE ,ASSEMBLY_ITEM_NUMBER,RESOURCE_CODE,SCHEDULE_SEQ_NUM ,basis_type,EFFECTIVITY_DATE,PROCESS_FLAG,TRANSACTION_TYPE ) values (10 ,1 ,0.001 ,1-- need 1 or 2 , 50 ,‘PRT' ,‘TT-T654/RB/GPS' ,'STORE' ,NULL , 1-- basis_type ,to_date('07-SEP-2005','DD-MON-YYYY')+1/24/60 ,1-- process_flag ,'CREATE' ) ;

  18. Production Cutover • Challenges • Lots of Work in Process • Reporting • Scheduling Process During Transition • The Plan • Leave WIP Alone (for now) • Ensure All New Jobs have Updates Routings • Tweak Capacity to Create ‘WIP Resistance’ • After X Weeks Update any Open Jobs with Old Routings

  19. Open Issues • Production Control Reorg?? • Currently Personnel Segregated by Product Family • Maintaining Capacity • Fine Tuning • Mfg Sched Time Fence vs. ASCP Time Fence • Use of Penalties • Capacity/Usage/Assigned Units

  20. Lessons Learned • Separate Project for Routing Update • Allow Time for WIP to Fill with Updated Routings • Emphasize Clean and Well Maintained Data • Expect and Allow Changes to Standard Costs

  21. What We Did Right • Used Mostly Internal Resources • Completely Revamped Routings • Started in Largest Plant

  22. Questions? ? ? Questions?? ? ?

More Related