aps production scheduling v2.1

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Oracle Production Scheduling

Presenter’s NamePresenter’s Title

Maximize shop floor throughput and optimize resource utilization

CONFIDENTIAL: All capabilities and dates are for planning purposes only and may not be used in any contract

The following is intended to outline our general product direction. It is intended for information purposes only, and may not be incorporated into any contract. It is not a commitment to deliver any material, code, or functionality, and should not be relied upon in making purchasing decisions.The development, release, and timing of any features or functionality described for Oracle’s products remains at the sole discretion of Oracle.

Safe Harbor Statement


Globally…

#1 in Database

#1 in Supply Chain Mgmt

#1 in Customer Relationship Mgmt

#1 in Human Capital Mgmt

#1 in Industries

- Retail

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- Public Sector

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• 275,000 total customers

• 220,000 database customers

• 30,000 applications customers

• 19,000 SMB apps customers

• 30,000 middleware customers

• 17,700 partners

• 60,000 employees

• 14,000 developers

• 7,000 support staff

Founded in 1977. Headquarters in Redwood Shores, CA with operations in 145 countries.

Oracle At-a-Glance


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 inventory• Constant expediting• Poor shop floor performance and poor delivery performance• Unpredictable manufacturing throughput times• No visibility to future planned requirements• Vulnerable to unplanned downtime

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

Long cycle times

Traditional ApproachPoor visibility to changes, manual process, expedite everything


• Feasible schedules that respect manufacturing constraints• Improved utilization and minimal setup time• Consistent manufacturing cycle times• Improved schedule adherence and delivery performance• Reduced work in process inventories• Secure and integrated system

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

Monitorperformance

Analyzeexceptions

Short cycle times

Better Approach: Production SchedulingFeasible on-time schedules with improved throughput and utilization


How

Delivers


Oracle Advanced Planning Solution

Future *

IntegratedPlanningFunctions

Products

Platform

E1 EBS …Legacy

ERP* *

Real-Time Sales and

OperationsPlanning

DemandManagement

and AdvancedForecasting

Predictive Trade

Planning and Optimization

InventoryOptimization

AdvancedSupply Chain

Planning

ProductionScheduling

Global Order

Promising

CollaborativePlanning

WFL Common planning data model

Connectors

NetworkDesign Demand Sensing

And Shaping PostponementOptimization Holistic

Supply Planning

Promise,Distribute, and

ReplenishExecute to plan

Embedded Analytics

Role-based Portals

Preconfigured Worksheets and

Workbenches

Operational Excellence

Real-Time S&OP

Demand drivenadaptive planning

Multi-EnterpriseCollaboration

Trading Partners

Best in classBusinessProcesses

StrategicNetwork

Optimization

Supply ChainRisk Management

Complete, best-in-class e-business planning process platform


• 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

Oracle Production SchedulingMaximize shop floor throughput and optimize resource utilization


• Increase bottleneck utilization up to 25%

• Reduce work in process up to 25%

• Reduce scheduling cycle time from weeks to minutes

• Drive continuous improvement

Oracle Production SchedulingTypical key benefits



Enables you to …

Maximize throughput and increase resource utilization

Improve shop floor performance

Determine the best schedule

Comprehensively plan and schedule production


• 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

Maximize Resource UtilizationEasily create feasible schedules


• 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

Maximize Resource UtilizationMinimize lost utilization due to setup time


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

OrdersTotal setup

Total Run

Total Time

Un-sequencedWhite, blue, black, white, blue, black, white, blue, black 48 90 138

SequencedWhite, white, white, blue, blue, blue, black, black, black 6 90 96

Example: Sequencing


Live on Production Scheduling since September 2005

Nampak, South Africa

Company• Global manufacturer with 126 facilities in 19 countries• Manufacturer packaging products

Planning problem solved• Moved from manually intensive spreadsheet schedules to daily schedules that respect all

material and capacity constraints• Instituted standard scheduling practices across multiple facilities

Unique aspects of implementation• High volume production of a diverse product mix• Very complex changeover matrix with over 40,000 entries• Multiple 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

Improve Shop Floor PerformanceEasily identify and resolve issues


• 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

Improve Shop Floor PerformanceSeamlessly communicate current priorities to production


Company• Global manufacturer with revenue over $1.5 Billion• Manufacturer Gore-Tex fabrics used in many consumer products and apparel

Planning problem solved• Detailed scheduling of fabric lamination to improve throughput of critical bottleneck

resources

Unique aspects of implementation• Complex scheduling problem with floating bottlenecks

Live on Production Scheduling since June 2005

W.L. Gore and Associates, US

• 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

Determine the Best ScheduleQuickly determine the most optimal shop floor 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

Determine the Best ScheduleExample: evaluate and adjust schedules


Company• A subsidiary of Toyota Motor Sales USA.• Produces high performance engines for the Toyota racing teams

Planning problem solved• Moved from 2 week long spreadsheet based scheduling process to

daily scheduling• Automatically generate multiple what if scenarios each day to

determine optimal staffing plans

Unique aspects of implementation• Extremely complex manufacturing process with many operations and

extremely tight tolerances• Very highly constrained by complex automated machining centers

Live on Production Scheduling

• Reduced scheduling cycle time from two weeks to minutes

• Reduction in time loss due to retooling

• Increased ability to react to engineering changes

Toyota Racing Development, US



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

Out-of-the-box SchedulingScheduling for planners, not programmers


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

Schedule Any Mode of ManufacturingDetailed schedules for all Oracle execution processes


Achieve Incremental Value

Production Scheduling

E-Business Suite Advanced Planning

Inventory Optimization

StrategicNetwork

Optimization

AdvancedSupply Chain

Planning

DemandManagement

Real-TimeSales and

Operations Planning

Collaborative Planning

TradePlanning &

Optimization

Demand forecast

Utilization trends

• Items and categories• Bills of material• Routings• Resources• Production costs• Organizations• Customers• Calendars and Shifts• Units of measure• WIP discrete jobs• OPM process batches• OPM complex routings and

recipes• OSFM lot-based jobs

Plannedorders,Safety stock

Implement additional Advanced Planning components quickly by leveraging the same foundation


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Summary


• Feasible schedules that respect manufacturing constraints• Improved utilization and minimal setup time• Consistent manufacturing cycle times• Improved schedule adherence and delivery performance• Reduced work in process inventories• Secure and integrated system

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

Manageperformance

Analyzeexceptions

Oracle Production SchedulingFeasible on-time schedules with improved throughput and utilization


• Maximize throughput and increase resource utilization

• Improve shop floor performance

• Determine best schedule

• Comprehensively plan and schedule production

Enables leading edge and transformational business processes …


Best in class, proven production scheduling solution

Integrated manufacturing planning, scheduling, and execution

Designed for planners, not programmers

Integrated performance management

Why Oracle!

aps production scheduling v2.1

Documents

secure integrated

process inventories

schedule comprehensively

improved cycle

oracle production

integrated

production

improved throughput