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Precision Castparts Corporation Manufacturing Planning Systems

Precision Castparts Corporation Manufacturing Planning Systems. Summer 2004 Gordon Edwards Portland State University. Presentation Outline. Problem Statement Project Definition Project Methodology Analysis Process/Project Development Comparison Study First Second Current Status

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Precision Castparts Corporation Manufacturing Planning Systems

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  1. Precision Castparts CorporationManufacturing Planning Systems Summer 2004 Gordon Edwards Portland State University

  2. Presentation Outline • Problem Statement • Project Definition • Project Methodology • Analysis Process/Project Development • Comparison Study • First • Second • Current Status • Next Steps • Questions

  3. Problem Statement The PCC Large Parts Campus wishes to implement a decision support tool which will enable the organization to plan and control its in-house manufacturing processes (less Steel Manufacturing) and integrate these activities with outside processing steps as well as company business processes.

  4. Project Definition • Project Scope • Planning and execution of Titanium Manufacturing • All LPC activities less Steel Manufacturing • Understand the process – don’t change it • Didn’t include cost or implementation effort • Constraints and Limitations • COTS product with limited modification • Consistent with the Theory of Constraints • Interface with existing ERP system • Timeframe – 14 June to 17 September • Not to include Business Optimization

  5. Project Methodology • Analysis of initial statement of work and problem definition • Stakeholder Interviews • Functional Analysis of system requirements (FRAT) • Search for suitable commercial systems • Filtering of potential solutions • Weighting of selection criteria • Scoring of candidate systems: • Confirm they meet mandatory requirements • Assess strengths and weaknesses

  6. Stakeholder Interviews • Planners • Engineering Teams • Sales & Marketing • Titanium Manufacturing • Managers • PCC MIS • OSP Companies - surrogate

  7. Boundary Planning Tools Project Boundaries • Engr Svcs • Tooling & Fixture Design • Tooling & Fixture Procurement • CAD • Calibration/Repair Process Engineering Part Estimating Purchasing (OSP Contracts) Other Dept Ti Casting • Engr Svcs • Tooling & Fixture Availability • Tooling & Fixture Capacity • CMM • Layout • Targeting • Planning • Master Scheduling • Customer Svc • OSP Capacity/ • Scheduling • Dispatch • Materials Testing SLA Transportation/ Shipping • Engineering • Development • Production • Trial • Router Information Core Facility Titanium Manufacturing • MIS • Visibility Interface • Infrastructure • Information Security Check Film Quality & Process Control Statistical Analysis Legend: Sales & Marketing OSP Venders Information Steel Manufacturing Heat Treating Material

  8. Essential Requirements • 29 essential requirements defined • Examples/nature of requirements: • ERP Interface • User Interface • Capacity Planning capability • Flow Analysis/Bottle neck identification • Planner ability to conduct “what if” scenarios • Sales ability to assess orders on the road • Etc

  9. } essential } desirable First Comparison Study • Assessed 24 potential systems • Aim to reduce the list to a manageable number for detailed assessment • Based on a sub-set of requirements: • Data Management • Constraints • Flow Analysis • Operating System • Database Requirement • Statistical Analysis • Selected six as appearing to meet all requirements

  10. Second Comparison Study • Six candidate systems

  11. Second Comparison Study • Essential Requirements • 29 requirements total • 23 requirements scored/assessed • 6 requirements not scored – hands on • Must meet all assessed requirements (minimum required functionality) • Desirable Requirements • 10 requirements total – all assessed • Weighted for value • Method to differentiate between suitable candidate solutions

  12. Tooling Data Statistical Analysis Adv Constraints Engineer Planning Work Load Planning Consider tooling and fixture data in scheduling Ability to conduct statistical analysis The ability to manage scheduling through fifteen constraints "what if" analysis by people other than just planners Work Center work load planning Desirable Requirements

  13. Engineer Review Production Monitoring OSP Reports Work Orders Database Requirement Automatic notification of pending tasks Management oversight of schedule vs. actual production status Ability to report OSP loading schedule Load work orders in Visibility Compatibility with current systems in use Desirable Requirements

  14. Requirement Weighting

  15. Requirement Weighting

  16. Current Status • Four systems fully assessed: • Production Modeling Corporation/ASPROVA • Matrikon/MxSuite • RSS Solutions/NaView • Quinn & Associates/Preactor • Waterloo Manufacturing Software/TACTIC • Not responded: • MAPICS/SCM

  17. Current Rating

  18. Next Steps • Select system(s) to trial: • Risk vs. Reward • Address cost as a requirement • Address investment in implementation • Planning/manufacturing process definition • Get quotes/arrange demonstration & trial • Other Foundry ERP systems: • B&L Information Systems Inc/Odyssey • Guardian Software Systems/Foundry

  19. Questions

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