Manual Production Scheduling’s Flaws
Scheduling is a key factor in any kind of production. It affects the entirety of processes and can either make or break the company’s daily production routines. As the company expands, demands change. Orders transform from a sizable few to a frantic many, which undoubtedly affect the daily production process and require upgrades in the system’s mainframe. A Japanese Auto Parts Company experienced this kind of ordeal.
It is of utmost importance to cite the several problems that gave the company quite a dilemma. First, there was inadequacy in the data processing capability of their current scheduler. This led to a point where they had to limit the number of products being produced. Second, the existing scheduler was unable to restrict colors in each facility. This problem led to manual schedule modification with the help of an experienced schedule manager. Third, and lastly, when they resorted to manual scheduling, it incurred a number of errors.
If we would analyze these critically, we could deduce a conclusion that their main problem lies in their custom-made production scheduler. Anybody would notice, and suggest, that the most plausible solution would be to upgrade their scheduling system. They did this. In fact, they thought of ways to improve the existing custom-made scheduler. However, their own managers agreed that it was better to search for a scheduling package than to upgrade the existing one.
Introduction of Asprova
They initiated efforts on finding a package that would be enough to satisfy their needs. It seemed hopeless at first, but then, persistence prevailed and they discovered Asprova. A demonstration was immediately requested. After learning more about Asprova’s functions through the use of a trial version of the software and attending a training seminar, they decided to switch to Asprova.
Asprova offers standardization. According to Wikipedia, Standardization means “the process of developing and implementing technical standards with the goals that can help with the independence of single suppliers (commoditization), compatibility, interoperability, safety, repeatability, and/or quality”. Standardized scheduling work by codifying their human scheduler’s know-how into Asprova made it easier for the company to make production schedules of bigger data and in a very short time.
After incorporating Asprova in their production scheduling, there were noticeable improvements: it enabled all products to be scheduled simultaneously, scheduling of data larger than their previous data size in the same amount of time needed, reduced schedule adjustment work due Asprova’s ability to restrict colors in each facility, and achieved standardization in most of the scheduling work by transferring the scheduling data into Asprova.
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