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Efficient Production Planning Strategies

Learn how to address critical manufacturing problems such as machine breakdowns, late deliveries, and exceeding capacities. Understand advanced planning and scheduling techniques to optimize resources, reduce delays, and improve production efficiency.

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Efficient Production Planning Strategies

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  1. Advaned Planning and Scheduling J.Skorkovský, KPH

  2. Critical manufacturing problems • Machine breakdown –lack of capacity • Components (from BOM) are not available in time • Sudden changes in orders and priorities • Late deliveries due to manufacturing delays • Missed sales due to exceeding capacities • Lost orders due to excessive WIP(Work in Progress) • High cost of delays due to long setup times • Difficult planning based on forecast (fluctuation of demand) • Overtime due to bad utilization of resources • Changeover operations are to often and too laborious

  3. Planning scenario SystemObjectives Demand Forecast MaintainedSystem Plan Constraints Space Resources Budget

  4. Very simple production • 4 machines : C1, C2 and W1,W2 (C=Cutting, W=Welding) • C1 can be used for cutting P1 or P2 and not vice versa (C2 can cut only P2) • W1 and W2 can be used for both lines (fully alternate resources) • Raw material (items P1..P10) • 1 product P11(P1..P10) using 2 lines (routings) • Workers • 6 operations : • Cutting • Welding • Lacquering (2 colours - one colours for P7-> P9 and P8->P10) • Labels • Final assembly • Packaging

  5. Bill of material P11 P10 P9 P7 P8 P5 P3 P6 P4 P1 P2

  6. Shop floor situation P5 P9 P7 P3 Labeling P9 Cutting 1 Welding 1 P1 Lacquering P4 Labeling P10 Welding 2 Cutting 2 P2 P10 P8 P6 P10 and P9 Packaging Finalassembly P11

  7. Shop floor situation after (3 orders) P5 P9 P7 P3 Labeling P9 Cutting 1 Welding 1 P1 Lacquering P4 Labeling P10 Welding 2 Cutting 2 P2 P10 P8 P6 P9 and P10 Packaging Finalassembly P11

  8. Shop floor situation- problems P5 Welding bottleneck P9 P7 P3 Labeling P9 Cutting 1 Welding 1 P1 Lacquering P4 Labeling P10 Welding 2 Cutting 2 P2 P10 P8 Label worker : absence from work Setup time problem machine was setup for coloring P7 Machine breakdown P6 P9 and P10 Packaging Finalassembly P11 Material shortage- awaiting labeled P10

  9. Shop floor situation APS rescheduling P5 P9 P7 P3 Labeling P9 Cutting 1 Welding 1 P1 Lacquering P4 Labeling P10 Welding 2 Cutting 2 P2 P10 P8 P6 P9 and P10 Packaging Finalassembly P11 Work order (P2->P4) moved to C1, some of 3 orders moved from W1 to free W2 (see green remark) Lacquering setup changed to color P8 firstlydue to bottleneck, one WO (P3,P5->P7) moved to W2 to decrease impactof bottleneck, re-schedule workers for Labeling in order to cover lack of capacity of labeling P10.

  10. Scheduling criteira (PlannerOne)

  11. Bottlenecks analysis (PlannerOne)

  12. Working Orders/Product-Gantt and delays

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