Advaned Planning and Scheduling
J.Skorkovský, KPH


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

Planning scenario
Demand
Forecast
Maintained System
System Objectives
Constraints
Space
Budget
Resources
Plan

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

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

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

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

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

Shop floor situation APS rescheduling
Cutting 1
Cutting 2
Welding 1
Welding 2
Lacquering
Labeling P9
Labeling P10
Final assembly
Packaging
P1
P2
P5
P6
P3
P4
P7
P8
P9
P10
P9  and P10
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 firstly due to bottleneck,
 one WO (P3,P5->P7) moved to W2 to decrease impact of bottleneck,
re-schedule workers for Labeling in order to cover lack of capacity of labeling P10.

Scheduling criteira (PlannerOne)



Bottlenecks analysis (PlannerOne)



Working Orders/Product-Gantt and delays