qad planning and scheduling workbenches: enhancements & strategy review

QAD Planning and Scheduling Workbenches: Enhancements & Strategy ReviewCarianne Nieuwstraten, QAD Product Manager

MWUG, March 20, 2012

Agenda

• MSW/PSW Benefits and Value• Enhancements Review• Strategy Review

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QAD Planning and Scheduling Workbenches: MSW/PSW

Master & Production Scheduling Objective• Establish an item’s most optimum build

schedule that meets customer demand.- Measurements :

• Improved Customer Service- On time deliveries- Reduced back orders

• Improved and Reduced Inventories- Inventory turns- Reduced inventory investment

• Stable Manufacturing Schedule- Increased production efficiency- Reduced set up costs/time- Reduced overtime costs


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Master Scheduler’s Challenge

ExecutivesROI must improve; the stockholders are not happy!

ManufacturingThere are too many changes! Provide fixed schedules and the correct parts and delivery will improve. Sales

Service levels are down. I need more inventory! Whatever it takes to keep the customer happy!

EngineeringThere’s a new product introduction scheduled for the fall! But we need more time for design!

FinanceThere’s too much cash tied up in inventory!

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Production Scheduler’s ChallengeManufacturingLabor / machine resources not available for 2nd shift – what are you going to do about this?

SalesDrops in a new high priority order due tomorrow, which order can be moved?

MaterialsYou can’t change the schedule on short notice and expect the materials to be available.

FinanceHigh variances to “plan” (extra setup, downtime, labor), you need to optimize your production schedule.

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Planning & Scheduling ChallengesQAD Planning and Scheduling Workbenches: MSW/PSW

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Capacity FrameDisplays capacity information per selected resource in the Schedule Grid- Balance your planned and required capacity.

Supply/Demand FrameProvides demand & supply information per selected item in the Schedule Grid.- Primary information used for scheduling decision making.

Schedule GridThe primary context of the workbench. - View and modify your production schedules for each item.

MSW – Master Scheduling Workbench

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MSW – Master Scheduling Workbench

Supporting PanelsEnables master scheduling action and decision making.

Represents over 30 maintenance programs and reports!

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Production Order Sequence GridSchedule and sequence production orders by item attributes

Production Order BrowseSearch & group data per user specification

- Drag & Drop the orders to the desired position on the Sequence Grid.

Production Order MaintenanceView and maintain all order details

PSW – Production Scheduling Workbench

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Production Scheduling Workbench (PSW)

Master Schedule Workbench (MSW)

Production Scheduling Release To shop Floor ExecutionMaster Scheduling

Months-Weeks-Days Day-Shift-IntervalsDays

Maximize production efficiency through

schedule optimization

Create a master schedule balanced to Supply /Demand /Resources

Click For Next Point

• Avoid costly downtime• Reduce costly expedites• Reduce late customer shipments

Component Available Check (CAC)

Release to production with verification of

available materials


Tying It Together

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Customer: Cascade Engineering– Multi-business manufacturer (automotive,

commercial truck & bus, solid waste & recycling, home & office)

– Leading provider of engineered plastics systems and components (plus growing number of sustainability-focused products and services)

– Headquartered in Grand Rapids, MI, USA– 7 Manufacturing Facilities in NA– 1 Manufacturing Facility in Europe– QAD 2008 SE, repetitive

Pain Points– Capacity visibility– Schedule changes

Live– Two plants; first plant live: April 10, 2011– Roll out to 4 plants in next 4 months

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Customer: Superior Essex– A global leader in the design and

manufacture of copper and aluminum round and rectangular magnet wire used in motors and transformers

– Headquartered in Fort Wayne, Indiana, USA

– 2008 SE, discrete Pain Points

– No master scheduling process in place– Limited to no capacity visibility– Homegrown scheduling system

Live– First plant: February 10, 2012– Roll out to 5 more plants in next 6 months

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New Workbench

Enhancements13

• Business Scenario: Maintenance department needs to schedule maintenance for a machine/line. Might impact production plan.

• Planner Objective: Understanding of maintenance plans ahead of time allowing Planner to communicate with maintenance department to schedule best date/time for maintenance with minimal impact on production plan, where possible.

1. EAM Order Visualization

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EAM Orders Created• No WB

visualization

• No consumption of WB capacity

Maintenance work starts

• No change on WB

EAM Orders Scheduled•

Visualization on WB

• No impact to capacity on WB

Order Closed•

Scheduler can see work is complete and see history if desired

Visualize EAM OrdersQAD Planning and Scheduling Workbenches: MSW/PSW

EAM Detail | Summary - Details

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Repair Tech Schedules

(firms) EAM order

WB alerts scheduler request for acceptance

Scheduler reviews EAM Repair Order

Scheduler speaks with

Repair Tech if there is a conflict

Repair Tech makes changes

to order as needed


EAM Detail | Date/Time

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I can see the planned start and end time and estimated down time

impact

If this is not acceptable, I can speak with

Maintenance Dept. to reschedule it!


EAM Detail|Resource Relationships

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I can visualize the relationship of the

production line to the work centers.


• Business Scenario: Process generates more than one product - examples:- Injection molding - Metal stamping

• Planner Objective: Manage the various products as a joint structure.

2. Co-\By-Product Support

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• Solution: - Integration of existing standard co-\by-product

capabilities into MSW/PSW- ….with additional benefit that co\by functionality can

now also be leveraged in repetitive environments when using the workbenches


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• Business Scenario: Customer increases demand for end item already scheduled for particular due date; multiple BOM levels- Causes schedule increase for end item- May require increase of one or more lower assembly

schedules to meet short-term demand increase

• Planner Objective: Quickly gauge impact of demand increase/change across all BOM levels

3. Product Structure Filter

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3. Product Structure Filter

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• Workbenches – General:- eB2.1 SP4 and Up, add-on- 2010.1EE+, core

• Availability – New Enhancements- 2012 EE except for co\by- EE Package – target: mid-April- SE Package – target: mid/end of May

• Documentation- Install, user and training guides

Availability and Documentation

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Vision/Strategy

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Master Schedule

Material Plan

VisionQAD Planning and Scheduling Workbenches: MSW/PSW

Load-Leveling Constraint-

Based Master Scheduler

Master Scheduling Workbench

Material Requirements

Planning

Production Scheduling Workbench

Finite Capacity Production Scheduler

• Are tied to the goals of the Master Scheduler being:- Create a level schedule

• Level by Volume and Mix - Load, Setup, other - Meet customer delivery expectations

• Make to Order, Make to stock, Manage Backlog- Business Interests

• Manage Inventory, (Safety Stock, Seasonal, Customer service levels, Buffer)

• Manage Number of Setups • Customer/Item Priorities• Reduce expediting, overtime, etc.• Other

Business Drivers

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Calculates a level loaded (constraint based) Master Production Schedule

over a user defined period of time for a site or group of production lines.

MPS Leveling CalculationPlanning / Scheduling

Time

Volu

me

Demand

Level Production

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Master Schedule

Material Plan

VisionQAD Planning and Scheduling Workbenches: MSW/PSW

Load-Leveling Constraint-

Based Master Scheduler

Master Scheduling Workbench

Material Requirements

Planning

Production Scheduling Workbench

Finite Capacity Production Scheduler

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Learn More: www.qad.com/explore

http://www.qad.com/explore

• Carianne Nieuwstraten- Phone: 503-236-0025- E-mail: [email protected]

Contact Information

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qad planning and scheduling workbenches: enhancements & strategy review

Documents

scheduling workbenches

production schedules

scheduling decision

sequence production

demand qad planning

schedule optimizationcreate

customer demand

optimum build schedule