PLANSEE - Holding

Plansee Holding

High performance

materials

hard material

matters

Sintered steel parts

50%100% 100%50%

Tungsten and powder

CERATIZIT – structure / organigramm

CERATIZIT Italia - Segments

F1 – Cold heading dies F2 – Drawing dies

F3 – Fastening Industry F4 – special metal forming

Identified Dysfunctions

Not updated process standard times

High variability of processes due to lack of standardization

Not efficient estimation of the order delivery dates

Very low levels of capacity control

Long lead times

High values of tardiness

Low service levels

Estimation of order delivery dates

All orders are managed with highest priority

Due date

delay

standard

Release date

with priority

Release date Time Reduction

M

Queue time

machine

Lack of production control

The MRP in the company works assuming infinite production capacity

The MRP in the company assumes constant lead times

Lead times are not updated

No tool for shop floor control

Due date

fatherchildrenMRP

Shop floor

Capacity

Loading

Modified

Lead times

waiting times increase with the

machine loading

Production capacity control

What piece will make the machine produce

tomorrow ?

Code Description May June July August September October November December January

A1 Production flow analysis

A2 Data collection

A3Definition of production objectives and

constraints

A4Customization/development and testing of

the TPS optimization algorithms

A5 Customization of the TPS data base

A6 First installation

A7 Tuning and final installation

A8Re-engineering of production planning

processes

TPS Project

TPS project

release datesdue dates

production planproduction

available capacity

Central Staff

Periferic Staff

Strategic Process Owner

Process Owner

A0 - Business Unit Organisation

Le

ad

Tim

eA8 - Re-engineering of production planning process

Lean Organization Office

Job Enrichment

Job Enlargment

Reduction Hierarchical Levels

Reduction Lead Time

Production Planning,

Master Scheduling

Material Requirements,

Resource Capability

Scheduling

and Rescheduling

Dispatching

Shop-Floor

Management

Shop-Floor

FLOW

MANAGER

TEAM

LEADER

Schedule

Job LoadingData Collection

Detailed Scheduling

Shop Status

Schedule Performance

PLANNING

MANAGER

Schedule Constraints

Capacity Status

Shop Orders, Release Dates

Quantities, Due Date

Orders

Material Requirements

TPS

SAP + TPS

SAP

CUSTOMER

SERVICESAP + TPS

Le

ad

Tim

eDynamic ATP

A0 - Business Unit Organisation

TPS (APS)

Advance Planning Scheduling

SAP (ERP)

Enterprise Resource Planning

• Central Planner: assign the workload to centers (group of affine machines) on the basis of the due date, availabilities

and customer priorities. If some technological info is available also a specific machine is chosen

• Flow Manager: modifies the assignment made by the central planner between some predefined range (2 days)

Problems

The product information stored in the company ERP does not contain enough technological information

Machine operators are the only persons able to assign properly a product to a machine

Decision making: one central manager, local managers, flow managers

Solution: details

Customer priorities are assigned by the marketing staff (yearly)

Product & machine technological characteristics

Third suppliers of components & processes

Center modeling

Finite capacity machines

Batch working machines

Release dates

Finite number of tasks (of the same order) scheduled in a time window

Integration with the company ERP

Continuous update (15 mins)

T&P project

Goal: to derive a procedure for estimating standard times in Ceratizit processes

DIFF. EFF./STD.

Fre

qu

en

cy

1086420-2

350

300

250

200

150

100

50

0

Mean 0,3676

StDev 0,9522

N 660

Histogram of DIFF. EFF./STD.Normal

Goal: to derive a procedure for estimating standard times in Ceratizit processes

Da

taCODICE LUNGHEZZA

Operaz. standardOperaz. effettivo

*87654321*87654321

12

10

8

6

4

2

0

Boxplot of Operaz. effettivo; Operaz. standard vs CODICE LUNGHEZZA

Da

ta

CODICE DIAMETRO INT. / CHIAVE

Operaz. standardOperaz. effettivo

*87654321*87654321

12

10

8

6

4

2

0

Boxplot of Operaz. effettiv; Operaz. standard vs CODICE DIAMETRO

T&P project

Goal: to derive a procedure for estimating standard times in Ceratizit processes

T&P project