Advanced Planner The Next Generation in Planning

1. Advanced PlannerThe Next Generation in Planning Jim Simunek CISTECH Inc. www.cistech.net

2. What is Advanced Planner? • Advanced Planner is an alternative to Mapics MPSP, MRP and CRP • Uses an Access Database to create the plan • AVP uses color coded graphs and charts that makes it easier to manage the master schedule process. This includes material and capacity testing

3. How does AVP do this? • Planning information is downloaded from the AS400 creating an Access database on a PC or server • Planning run is done on the PC/server eliminating job conflicts on the 400 and decreasing processing time. This allows for “more” planning runs. • Quicker response time and minimized job conflicts!

4. How does AVP do this?Cont’d • Once plan is executed to the PC the user can interactively (in memory on the pc) plan production and purchase orders to meet forecast and customer demand while viewing load to capacity on facility… • Offloading • Alternate routing (if EPDM is installed) • Outsourcing • Pegging • Drill down • Exception visibility and filtering • “What if” • Drag and drop and Undo……

5. How does AVP do this?Cont’d • Once satisfied with plan AVP uploads back to the 400 populating the MRP files (PLNDORD, REQMTS) for execution or releasing of work orders/schedules using: • Order Based Production Management (OBPM) • Repetitive • MRP Recommendations (Green Screen)

6. AVP/MRP Similarities • Both use all the planning modifiers in the Item Balance/Plan record • Both use the MRP Execution Options for re-scheduling, auto-release, etc. • Both use the MRP Horizon Dates • Both have direct or indirect interface to Mapics Forecast module • Both use the Manufactured due date from the customer orders for planning

7. AVP vs. MRP • An MRP generation is performed by a BOM explosion and netting routine usually overnight • With Advanced Planner NO AS400 MRP generation is ever necessary. The AVP engine performs the multi-level planning function • MRP has multi-planning warehouse capabilities • With AVP you create a separate database for each warehouse that has a Planning run. Multiple warehouses can still be consolidated.

8. AVP vs. MRP cont’d • MRP/CRP uses Mapics calendars • AVP has its own calendar within the database. This calendar holds hours of operation per day. AVP allows for an unlimited number of calendars and you associate multiple work centers to a calendar • MRP has no easy “what if” capability short of a new MRP generation • AVP has powerful “what if” capability directly with the AVP access database on the PC

9. AVP vs. MRP cont’d • MRP interfaces with MPSP • AVP has its own Master Schedule Routine • MRP uses Lead Time to calculate start date • AVP uses backward scheduling and the times in the routing to calculate start date. If ‘Operation Where Used’ is entered in the BOM, material is planned based on the Operation Start Date.

10. AVP vs. MRP cont’d • MPSP uses the greater of Customer Order or Forecast • AVP nets the CO’s against the Forecast and plans with the CO’s and Net Forecast • MRP assumes infinite capacity • AVP plans the work load in each work center for capacity review prior to accepting the plan. Even though it will ‘overload’ a work center, the Master Scheduler can move load and AVP adjusts other work centers and material to accommodate the move.

11. AVP vs. MRP cont’d • MRP provides a warning if a planned order quantity exceeds the Maximum • AVP uses the Maximum to create multiple orders due on the same day for the Max quantity (or less) • MRP plans an order to be due the same day as the requirement • AVP plans an order to be due the day before the requirement

12. AVP vs. MRP cont’d • MRP plans orders to the day/date • AVP can plan to the hour and minute • MRP has no view for load on a workcenter • AVP shows the load each MO or Schedule will place on a work center or production line. If you move the load to a different day, AVP will re-schedule the upstream & downstream operations and re-plan the material (assumes “Operation Where Used” in the BOM is completed)

13. AVP Extras • Forecast consumption • Forecast can be consumed in three ways: • Individual Item: The sales of each item consume the item forecast • An item and its parents: If many possible finished product configurations exist, made from a small number of components, you can forecast at the component level rather than the finished product level. The sales of the item and any parent consume the item forecast • Planning bill: Identify an item as a planning bill item and enter forecasts for the item. Forecast is consumed by end item and matching configurations in the Bill of Material

14. Forecast Consumption This is the forecast consumption chart within AVP

15. AVP Extras • Config.ini settings to: • Calculate run time by flow or batch method • Uses RM Quantity (at the time of the RM transaction) or Operation Quantity Completed (from Labor Reporting) to calculate balance due • Can define horizon length values 1-999 days

16. AVP Extras • You can optionally update either or both • The promise date on the customer order • The manufacturing due date on the customer order

17. Advanced Planning Process

18. Advanced Planner Process • Downloading Data to the Engine • Pulls BOM, Route, Item, Item process, Item plan, Forecast, CO’s and/or Manual Requirements • Creates flat files that are pulled in to create access database

19. Advanced Planner Process • Generating the Plan • Forecast Consumption • Nets the Requirements against on hand & on order (Load Project) using Access Database • Builds product structure network using the BOM and Routing • Plans Orders (PO, MO & Schedules)

20. Advanced Planner Process • Manipulate the Plan • View Load to Capacity Chart • View items on Load • Level Load both Material and Capacity • Time phased view • Drill down/up • Perform “what-if” planning

21. Load To Capacity Chart Process Hours; Setup hours; Capacity hours Red – W/C is overloaded Yellow – W/C has past due backlog Blue – Overload within one time period that can be corrected by re-scheduling, offloading, etc. Green – Plan is within capacity constraints Routing Facilities

22. Load To Capacity Drill Down

23. Work Center Timephased Load

24. Supply/Demand for an Item Planned Orders Required Date, Quantity and Source

25. Advanced Planner Process • Write Schedule Pass • When changes have been made to the work center load, Write Schedule Pass will update the access database without updating the AS400 • Useful if Multiple Schedulers are working on the plan and each wants to save their work before the upload to the AS400 files (REQMTS and PLNORD)

26. Advanced Planner Process • Upload to Mapics Files • Loads info into the MRP planning work files: • Requirements-unconsumed forecast and generated demand • Planned Orders-all supply orders, including open, firm planned and planned • Demand Ref-Demand information • Reschedule Activity-rescheduling actions

27. Advanced Planner Process • What happens? • Reschedules open MO’s/PO’s/Rep schedules according to set up • Updates the CO dates if specified in the upload options • Updates work center file in the MO/REP operations as specified during offloading • Loads the MRP planning files • Creates the Order Review file • Prints MRP reports as specified

28. Planning Execution • Once plan is saved • Release planned orders or expedite/defer released orders using OBPM • OR • Green Screen Order review and release • OR • Repetitive

29. Execute Plan using OBPM

30. Green Screen Execution

31. MRP Requirements inquiry

32. AVP DEMO

33. How has Advanced Planner helped our Customers?

34. SOCK Manufacturing

35. AVP Solutions for Socks! • Socks • Before • BPCS user • Offline Forecast file-not interfaced with system • Planners consumed forecast with orders manually and created work orders to drive knitting machines • Did not use MRP-everything scheduled manually

36. AVP Solutions for Socks! • Sock Manufacturer • Multiple knitting machines within 1 facility • Capacity constraints per knitting machine within each facility

37. AVP Solutions for Socks! • Challenge: • Sock Mfg. with multiple knitting machines • Need 1 MO/week/machine • If less than 1 week’s knitting is required, planned order quantity should be less than the week’s worth

38. AVP Solutions for Socks! • AVP • Any Planning Order Policy code with Max set to 50 • Requirement for 110 • 3 Planned orders, 2 for 50 and the third for 10 • MRP • Order Policy Code H with Max & FOQ equal to the same number • Requirement for 110 with Max & FOQ = 50 • 3 planned orders for 50 each

39. AVP Solutions for Socks! Quickly see the 2 Knitting machines overloaded

40. AVP Solutions for Socks! See the days where scheduled MO’s exceed the available capacity; take action from this screen to move to days with available capacity

41. CHAIRS

42. AVP Solutions for Chairs! • Situation • Current Mapics User • Does not use MRP • Forecast using spreadsheet by family • Schedule created manually

43. AVP Solutions for Chairs! • Steel chair Manufacturer • Many possible finished products • Many different finishes • Many different configurations • Upholstered • All steel

44. AVP Solutions for Chairs! • Made from a small number of components

45. AVP Solutions for Chairs! • Challenge • They Forecast in Families at the component level by excel spreadsheet • They perform forecast consumption manually with spreadsheets before planning each facility

46. AVP Solutions for Chairs! • MRP • Does not own Forecast module • Forecast today with excel spreadsheet • Consumption is performed manually • AVP • Set each item to forecast • Create interface from spreadsheet into the REQMTS file • Each item and it’s parents are consumed using AVP

47. AVP Benefits Realizing Your Quest for World-Class: • Improves capacity usage—maximize factory productivity • Increases revenue—the ability to consistently provide more accurate dates and deliver on time will attract more business • Streamlines purchasing an item that has an m-plan or s-plan order (outsourcing)

48. Benefits Realizing Your Quest for World-Class: • Reduces operation costs-running on a pc platform, AVP eliminates unnecessary server upgrades. • Expediting costs are lowered due to improved planning • Improves internal processing coordination—running your planning process quickly and more frequently will reduce material and/or capacity shortages

49. Benefits Realizing Your Quest for World-Class: • Catch changes and allow you to alert the shop floor and suppliers quicker

50. Summary • Alternative to traditional MPSP/MRP/CRP • Tight integration for quick implementation • Quick ROI from improved capacity planning • Improved Capacity usage • Decreased Lead time and inventory • Decreased costs