Introduction
- Addressing the top problems in the manufacturing industry – A customer orders 100,000 pieces of apparel. Manufacturer promises to deliver 2 months from the date of order. Due to challenges in the line, the request was not delivered on-time. The customer lost a week’s worth of profit and so does the manufacturer. This is just one problem usually encountered in the line. Would you like to know what the current top problems are in the manufacturing industry and how one system can help address them?
- Why is Production Scheduling Necessary? – Have you ever experienced coming across one of your employees burned out from scheduling one customer order to another? Do you know how tedious it is to change production schedules due to sudden changes in the production line? There are a couple of important reasons why production scheduling is necessary for your business but it does not have to be done manually. Take the time to learn more about the importance of production scheduling and how Asprova can help lessen the burden from your staff.
- How to Successfully Implement a Production Scheduling Software – Have you ever experienced implementing a new system and kept on encountering issues along the way? Do you ever wonder what it takes for a new system to be successfully implemented in your company? Please take the time to read the simple but important guidelines previous installations in ensuring success of a system implementation.
Modules and Options
- Asprova Modules and Options – Asprova is a lean-manufacturing solution that provides high-performance scheduling tool for manufacturers. It aims to aid manufacturers in planning the right schedule at the right resource, at the right quantity and at the right time, thus driving business growth and increasing customer satisfaction.
- Network Modules– There are two modules that can connect Asprova schedule: Network License Server (NLS) and Data Server (DS). Click on the link to know more about these network modules and how you can use them to manage your data schedules.
Try Out Sample Data
- Mixing-Packing-Inspection – Learn more about mixing, packing and inspection process and how this can be ran in Asprova. You can also watch this sample demonstration in Asprova’s e-learning video HERE.
- Mixing-Injection using Molds – This article covers plastic products, mixing-injection using molds process and how this can be run in Asprova. You can also watch sample demonstrations in Asprova’s e-Learning videos HERE.
- Metal Processing, Cyclic Long Processes – This article explains the operations and function of metal processing and cyclic long processes and how this can be run in Asprova.
- Mold Production, Assembly Process – This article will cover sample process of mold production and assembly and how this can be run in Asprova.
- Sales, Production and Purchase Scheduling – This article explains sample process of sales, production and purchase scheduling and how this can be run in Asprova.
Creating a Prototype
- Single Process Scheduling – Asprova is a production scheduling software that can quickly create production schedules for multiple items and processes. This article will show you a step-by-step guide on how to make a prototype and create schedules in Asprova.
- MRP – A manufacturer needs to know how much inventory it has to be able to commit on ordered quantity. It is critical that the company has an accurate record of inventory as any shortages may lead to delays in due dates. In this article, we will show you how materials are scheduled to avoid shortage on orders.
- Multi-Process – There are items that go through multiple processes before it is used as a supply into a different production or assembly process. In this article, we will show you how items going through multiple processes are scheduled and taken into account.
- Auto-replenishment – Inventory management is important in every company as this not only impacts cost but the company’s service as well. It is critical that you not only manage schedules but also knowing the availability and quantity of every resource and material. In this article, you will learn about Asprova’s auto-replenishment process and how it automatically fills orders to avoid inventory shortages.
- Sales Order Scheduling MTO – Make to order is a production strategy that only starts production of the product once the customer places the order. This article will explain how to register make to order (MTO) sales orders and how replenishments are automatically created through manufacturing orders.
- Sales Order Scheduling BTO – Build to order is a production strategy that is based on producing the customized product once the customer places the order. This is usually done for highly configured items such as computers, automobiles etc. This article will explain how to register build to order (BTO) sales orders and how replenishments are automatically created through manufacturing orders.
- Sales Order Scheduling MTS – Make to Stock is a production strategy that is based on anticipated demand. Customer needs are estimated in advance – this strategy is very cost effective if demand for the product is accurately forecasted. This article will explain how to register make to stock (MTS) sales orders and how replenishments are automatically created through manufacturing orders.
- Purchase Scheduling – Scheduling helps in deciding when to order or purchase materials intended for a sales order. It is used to allocate resources, plan production processes and purchase materials. This article will tackle purchase scheduling and how items are scheduled to be purchased automatically to support an order.
User Interface
- Creating Project and Setting up Scheduling Period – Asprova APS provides a rich array of features that allows you to perform various operations such as to display and modify scheduling results and edit data visually on the screen. This article will explain how to create projects and setup scheduling period in Asprova
- Integrated Master Editor table and Column Settings – The Integrated Master Editor is a feature for maintaining master data. It combines master settings and related properties in a table that is useful for creating and editing the master data. This article will explain how to update and edit the Integrated Master Editor table and its column settings.
- Display Settings Style – Style of the display settings can be setup separately for each style of charts and tables. This is the set style capability. This article will explain how to register multiple display settings in Asprova.
- Setup Shift, Calendar and Display Resource Gantt Chart – In Asprova, you can setup calendars and shifts for the system to use as working time pattern for a certain resource on a certain day. This article will explain how to setup shift, calendar and display settings in Asprova.
- Add Order 1 – Create User Property – In Asprova, you can also add new properties based on your specified requirement. This article will explain how to setup those properties in Asprova.
- Add Order 2 – Copy and Auto Fill – In Asprova, you can also copy and paste cells in table and properties windows, data between Asprova and other applications such as Excel. This article will show you how to copy and paste cells or data in Asprova tables.
- Reschedule – Message Window – In Asprova, the message window displays the contents of the events that occurred. This article will show you how to check these messages in Asprova.
- Layout Settings – In Asprova, you can register multiple records of information about the position, docking state, and applied style of charts and tables and use the settings later. This article will show you how to set up this layout settings feature in Asprova.
- Check Lateness – Order Gantt Chart – The Order Gantt Chart is a table time chart whose table view displays orders. This chart will help you understand how each order and operations are assigned, as well as its status. This article will show you how to check delays or lateness in the Order Gantt Chart.
- Check Operations – Resource Gantt Chart – The Resource Gantt chart is a table time chart whose table view displays resources. This helps you understand how operations are assigned to each resource. This article will show you how to check and move operations in the Resource Gantt chart.
- Change Calendar – Resource Gantt Chart – One resolution to address delays is sometimes related to work hours. In this article, we will explain how to change a calendar which specifies shifts for each resource and day to increase the working time in the production floor.
- Change and Move Operations – Dispatching View – In the dispatching view, the order of the use instruction and the assigned resource can be changed. The sequence order can also be customized.
- Resource Load Graph – The load graph is a table time chart that shows load on each resource. It shows how much load is put on each resource in graphical and numerical format. This helps us check whether a resource is overloaded or not and enables users to take necessary actions.
- Inventory Graph – The inventory graph is a table time chart that shows inventory quantity of each item in graphical and numerical format. This will help enable the user to project future inventory levels and take necessary actions.
- Pivot and Grouping – Pivot is used to summarize data from an existing table according to specified rules. In the same manner, grouping is also available if you want certain properties arranged in an aggregated order. This article explains how these functions are run in Asprova.
- Changing Status to Release – Status represents which state each operation is in. There are different values for the status flag. This article will help explain what these statuses are and how they can be changed in the system.
- Entering Result in Resource Gantt Chart – In Asprova, you can input results to scheduled operations and create a new schedule taking into account the results inputted. In this sample, entering results will be discussed.
- Reschedule Again – Change Scheduling Basis Time – If you reschedule operations for which results has not been input will be pushed in the future. Rescheduling again and changing scheduling basis time will be the topic of this article.
- Reschedule Modify Order – There are instances where orders will be asked to be moved to an earlier due date – this can be done in Asprova. This article will help explain how orders can be modified in Asprova.
Scheduling Logic
- Shift and Calendar – In this article, we will show how to register and change the working time and day in Asprova – setting up shift and calendar and assigning resources based on the calendar.
- Command – The Scheduling parameters determine the processing that takes place when rescheduling is run and this is made up of Commands. In this article, we will explain how commands define different kinds of data processing thru the contents of default scheduling parameter.
- Parameter – In Asprova, settings of scheduling parameters can be changed with regards to rescheduling. This article will explain parameters that can be adjusted to get order of assignment, assignment direction and resource evaluation
- Status – Represents which state each operation is in. This article will explain how to fix operations and set status as Released, Frozen, or Completed and how to input results after adjustment.
- Resource Quantity – The resource quantity can be used if you want a resource that can process multiple operations all at the same time. In this article, we will show you how this process is done to be able to shorten production time.
- Furnace Resource – The furnace resource is a resource where multiple operations start and finish at the same time. This can only happen when all of the specs of the operations are set up the same. In this article, we will show how to schedule the resources with the batch processing capabilities.
- Sub Resource – Sub resources can be set as jig tools, molds or workers. They can be assigned the same time with the main resource or to the set up time. This article will explain how to generate a schedule with the sub resource workers.
- Setup Time (ItemSpec) – In addition to the Setup time settings specified in the Integrated Master Editor, it is also possible to register the setup time according to the items and related specs. In this article, we will show how to schedule the setup time when items and specs are switched.
- Setup Time (Resource) – In Asprova, it is also possible to schedule the setup time for changing molds and jig tools. This can be specified in the Integrated Master Editor. This article will show you how to generate a schedule setup by switching the main resource and the sub-resource.
- Material Requirement Calculation – In Asprova, the required quantity of items can be calculated and the input time from the manufacturing time to setup time can be moved. This article will explain how to register the requirement and time settings.
- Material Requirement Calculation (Yield, Scrap) – In Asprova, you can also take into consideration the yield and scrap when calculating the material requirement. This article will show you how to calculate the requirement when taking yield and scrap into account.
- Time Constraint – In this article, we will study the time constraint by which we can specify how to connect the previous operation with the current one given the time delays for each resource and item.
- Operation Split – Operation split can divide and assign operations based on the lot size. By doing this, a schedule in which two or more pieces of equipment that will work in parallel can be generated. In this sample, we will show how to assign the operations by equipment of lot size.
- Safety Stock Inventory MIN – Safety stock is used as an extra stock that is maintained in order to prevent stock outs. In Asprova, the order will be generated automatically to prevent from falling below the safety stock value.
- Auto-Replenishment – In any material requirement calculation, Asprova can check the inventory of a raw material and parts and generate automatic replenishment orders when needed. This article will show you the two ways of generating replenishment orders.
- Inventory Constraint – If you want to be able to know which and when the inventory of an item is about to run out, Inventory Constraint function should be set up. In this article, we will study how this is done in Asprova.
- Branched Process – Branching process function in Asprova allows you to branch a process in the middle of the production process. In this article, we will study how to use branching to schedule processes.
ERP Integration
- Relationship between ERP and Asprova – Asprova is set up in such a way that it is ready to be integrated with any ERP system. It will pull data from any flat files and will optimize processes and track utilization of resources. This article will explain how Asprova can be integrated with an ERP system.
- Scenario 1 – Import planned orders and production orders – This article will explain how to import planned orders and production orders from external files such as TSV files then schedule the imported manufacturing orders with finite capacity.
- Scenario 2 – Use MRP and Finite Capacity Scheduling – In this scenario, we will use MRP and Finite Capacity Scheduling of Asprova – how to import the manufacturing order for the production and inventory from TSV files and how to auto-replenish the manufacturing order for parts and schedules.
- Scenario 3 – Import Planned Independent Requirement and Customer Requirement – In this scenario, we will teach you how Asprova implements the MRP by importing data from external systems and scheduling sales orders.
- Scenario 4 – Export Production Orders – In this scenario, we will teach you how to export production order including start and end time from Asprova.
- Scenario 5 – Export Purchase Requisition – In this scenario, we will teach you how to export the purchase requisition generated by Asprova.
- Scenario 6 – Import BOM and Material – In this scenario, we will show you how to import to Asprova the Manufacturing BOM and Items data.
- Scenario 7 – Import Routing – In this scenario, we will teach you how to import the BOM, material and routing data from ERP to Asprova and then create a schedule.
HOW TO PLAN AND CONDUCT THE INTRODUCTION PROJECT
- Steps for Implementing an Asprova Project – In this article, we will introduce to you the step by step guide on how to implement Asprova project in your company.
- Understanding the Current Situation and Setting Goals – In this article, we will show you how to fill out Asprova’s Diagnostic Sheet. This will help you in creating a proper prototype to see whether Asprova is suitable for your factory or not.
- Creating a Prototype and Investigating Systematization – In this article, we will show you how to investigate systematization in implementing Asprova.
- Signing the Contract, Creating Data, Starting Operation and Maintenance – After you have properly filled out the Diagnostic Sheet and concluded that Asprova is suitable for your organization, the next step is to learn how to start implementing Asprova in your factory and the necessary manpower needed in smooth and successful Asprova implementation.