oracle production scheduling - · pdf filedistribution planning ascp global order promising...

Oracle Production SchedulingMaximize shop floor throughput and optimize resource utilization

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?

Typical Scheduling Challenges

Large amounts of work in process inventoryConstant expeditingPoor shop floor performance and poor delivery performanceUnpredictable manufacturing throughput timesNo visibility to future planned requirementsVulnerable to unplanned downtime

Poor visibility to changes, manual process, expedite everything

Poor visibility to demand and production plan, many disparate spreadsheets, rush everything

Long cycle times

Traditional Approach

Feasible schedules that respect manufacturing constraintsImproved utilization and minimal setup timeConsistent manufacturing cycle timesImproved schedule adherence and delivery performanceReduced work in process inventoriesSecure and integrated system

Feasible on-time schedules with improved throughput and utilization

Complete visibility to demand and production plan, secure integrated system, improved cycle time

Monitorperformance

Analyzeexceptions

Short cycle times

Better Approach: Production Scheduling

How

Delivers

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

Maximize shop floor throughput and optimize resource utilizationOracle Production Scheduling

Complete e-business planning solution

Collaborative Planning CP

Real-Time Sales and Operations Planning

From

det

ail t

o su

mm

ary

CP

From short-term to long-term

SC Exception Management

PSProduction Scheduling

ASCPDistribution Planning

GOPGlobal Order Promising

ASCPSupply Chain & Manufacturing Planning

IOInventory Optimization

DMDemand Management

SCISupply Chain Intelligence

DevelopMarketSellOrderPlan

Procure

Make

FulfillService

Maintain FinanceHR

ProjectsAll Product,Customer,& SupplierInformation

SNONetwork Design

Oracle Advanced Planning

* Integration with Oracle EBS (R11.I.10)

Increase bottleneck utilization up to 25%

Reduce work in process up to 25%

Reduce scheduling cycle time from weeks to minutes

Drive continuous improvement

Typical key benefitsOracle Production Scheduling

Maximize throughput and increase resource utilization

Improve shop floor performance

Determine the best schedule

Comprehensively plan and schedule production

Enables you to…

Oracle Production Scheduling

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

Easily create feasible schedulesMaximize Resource Utilization

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

Minimize lost utilization due to setup timeMaximize Resource Utilization

Sequence work on a paint line from light to dark paint to minimize changeover and cleaning times between color changes, assuming 10hours run per job

PAINT LINE

Time

Orders needing WHITE paint Orders needing BLUE paint Orders needing BLACK paint

Changeover time from white to blue

From To: White Blue Black

White 0 2 6

Blue 10 0 4

Black 10 10 0

Changeover Times (Hours)

Orders Total setup

Total Run Total Time

90 138

9690

Un-sequenced White, blue, black, white, blue, black, white, blue, black 48

Sequenced White, white, white, blue, blue, blue, black, black, black 6

Example: Sequencing

Live on Production Scheduling since September, 2005

Nampak, South Africa

CompanyGlobal manufacturer with 126 facilities in 19 countriesManufacturer packaging products

Planning problem solvedMoved from manually intensive spreadsheet schedules to daily schedules that respect all material and capacity constraintsInstituted standard scheduling practices across multiple facilities

Unique aspects of implementationHigh volume production of a diverse product mixVery complex changeover matrix with over 40,000 entriesMultiple 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





Enables you to…


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

Easily identify and resolve issuesImprove Shop Floor Performance

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

Seamlessly communicate current priorities to productionImprove Shop Floor Performance

Live on Production Scheduling since June, 2005

W. L. Gore and Associates

CompanyGlobal Manufacturer with revenue over $1.5 BillionManufacturer Gore-Tex fabrics used in many consumer products

Planning problem solvedDetailed scheduling of fabric lamination to improve throughput of critical bottleneck resources

Unique aspects of implementationComplex 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





Enables you to…


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

Quickly determine the most optimal shop floor scheduleDetermine the Best Schedule

Issue– Important demands are not going to

be met on time

Analysis– 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

Decision– Authorize overtime for the weekend– Release new schedule to the shop

floor– Get approval for cost of overtime

Example: evaluate and adjust schedulesDetermine the Best Schedule

Live on Production Scheduling

Toyota Racing Development

CompanyA subsidiary of Toyota Motor Sales USA.Produces high performance engines for the Toyota racing teams

Planning problem solvedMoved from 2 week long spreadsheet based scheduling process to daily schedulingAutomatically generate multiple what if scenarios each day to determine optimal staffing plans

Unique aspects of implementationExtremely complex manufacturing process with many operations andextremely tight tolerancesVery 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





Enables you to…


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

Scheduling for planners, not programmersOut-of-the-box Scheduling

Complete, integrated Manufacturing Planning and Scheduling processSUPPLY PLANNING (ASCP)

PRODUCTION SCHEDULING (PS)

ScheduleWeek 0

ScheduleWeek 1

ScheduleWeek 2

ScheduleWeek 3

ScheduleWeek 4

FIRM

PLANNED

ScheduleWeek 1

ScheduleWeek 2

ScheduleWeek 3

ScheduleWeek 4

ScheduleWeek 5

ScheduleWeek 2

ScheduleWeek 3

ScheduleWeek 4

ScheduleWeek 5

ScheduleWeek 6

Production Plan Week 1 - 12

Production Plan Week 2-13



Planned orders

Firm work orders

Comprehensive Manufacturing Planning and Scheduling Solution

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

Detailed schedules for all Oracle execution processesSchedule Any Mode of Manufacturing

Architecture

Reliable– All plan information resides in the

database – Hot backup and recovery– Leverages grid computing

infrastructure

Open and standards based– Deploy against legacy systems– XML, flat file support

Database-centric architecture

APIs

Oracle ERP

Legacy Systems

XMLFlat file

KPIs Workflows

Internet

PortalPortal

TRADING PARTNERS INTERNAL USERS

Advanced Planning Architecture

Plans and Schedules

OrderPromising

Engine

Scalable and Open Architecture

Supply Chain and Manufacturing Planning

Collaborative Planning

Demand Management DM

Inventory Optimization IO

Global Order Promising GOP

CP

ASCP

Sales and Operations Planning

Forecast

Customerforecast

Orderforecast

Constrained plans

Supplier capacity

Time-phased safety stocks

Forecast and demand variability

Supplycommits

Orderforecast

Network Design SNOForecast scenarios

Production Scheduling

Planned orders

Supply schedule

Sourcing rules

Sourcing rules

Leverage integration at incremental investment

PS

CUSTOMERS

PLANNING PROCESS

SUPPLIERS

Safety stock targets

Integrated, yet Modular

Oracle EBS / PS Integration

Production Scheduling Integration Description

Advanced Supply Chain Planning Production SchedulingPlan for multiple facilities

Which plant makes what products and when

Pre-builds based on capacity shortages

Alternate facilities, suppliers andprocesses

Schedule a single facility

Sequence Production to meetdemands on this facility

Account for detailed productionconstraints and come up with an executable schedule

Constrained dependent demands, Independent Demands, Planned Orders

Detailed Sequence of activities near term to constrain the medium / long term plan

Production Scheduling Integration Description

Scope of ASCP – Planning the entire Supply Chain

Scope of PS – Scheduling a single Plant

DC1

DC2

Customer X

Customer Y

Customer Z

Plant 1

Plant 2

Plant 3

Supplier A

Supplier B

Supplier C

Production Scheduling Integration Description – Logical Information Flow

ASCP

Planned OrdersPlanned Order DemandsSales OrdersForecasts

Production Scheduling

Source ERPWork Order ReschedulesNew Work Orders

ItemsBill of MaterialsRoutingsResourcesWork OrderSales OrdersOn Hand...

Production Scheduling Integration Description – Modes of Running PS

Running PS “Standalone” Running PS with reference to an ASCP Plan

Schedule work orders only Schedule work orders and planned orders

Forecast demands specified via Demand schedules

Forecast demands come in via the referenced ASCP plan

Inter-org demands included only via internal sales orders

Inter-org demands also include planned order demands from the ASCP plan

Items to be included in PS specified via specification of category sets / categories

Items to be included in PS derived from the items in the ASCP plan

No Forecast consumption Forecast consumption performed in ASCP is retained within PS

Production Scheduling Integration Description – System Information Flow

Client PC

Collections

PS

Browser

PS Model FilesSnapshot PS DataFrom Planning Server

Oracle ApplicationsLogin

Rescheduled / NewDiscrete Jobs / Lot Based

Jobs / OPM Batches

PlanningData

Repository

Define Schedule names and Options

Invoke Data Snapshot

Open PS Workbench

Publish Schedule from PS(Release Process)

EBSSource

Summary

Feasible schedules that respect manufacturing constraintsImproved utilization and minimal setup timeConsistent manufacturing cycle timesImproved schedule adherence and delivery performanceReduced work in process inventoriesSecure and integrated system

Feasible on-time schedules with improved throughput and utilization

Complete visibility to demand and production plan, secure integrated system, improved cycle time

Manageperformance

Analyzeexceptions


Enables you to…






Best in class, proven production scheduling solution

Integrated manufacturing planning, scheduling, and execution

Designed for planners, not programmers

Integrated performance management

Why Oracle!

oracle production scheduling - · pdf filedistribution planning ascp global order promising...

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