Signing the Contract, Creating Data, Starting Operation and Maintenance

When your company formally decides to implement the system with Asprova, purchase the licenses for the required modules. You may refer to the “Modules and options” about the details for the modules. See table below.

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Make sure that a project team has been formed for Asprova implementation. The team should consist of one person, responsible for the whole project, and 2 or more responsible for the implementation.

For the people in charge of the actual implementation, please assign one or more people from your manufacturing site as they know well about the scheduling requirement and one or more people from your information systems department as they are well-experienced in system requirements.

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To ensure a smooth and successful implementation, it is very important to share the professional backgrounds and knowledge between the team members.

Estimated timeline of a project is usually 3-6 months – from kick off to project implementation.
It is an example of the required work during the implementation of a scheduling system for specific production.

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The very first step of implementing a project is to define the requirements together with the system coverage they provide. Please refine the requirements definition and make a “Fit&Gap analysis” for the scheduling requirements for each operation.

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The purpose is to sort out the priorities and corresponding actions. To be able to visualize your expectations with respect to the scheduling requirements, it is recommended to make a graphical representation for the assignment results. See sample below.

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The next step is the Data Preparation. This step makes up most of the implementation, in most cases. Delays may occur as it takes a lot of time for preparing, if the accuracy of parameters measuring is low, for example, for the production capacities. In such cases, it is recommend to ensure the accuracy of your data and improve it further during implementation. In addition, when constructing the “Scheduling parameters” and implementing the scheduling logic, it is recommend that you start with a small amount of data.

If you start it with all the data at the very beginning, it will take a lot of time not only for preparing all the data, but also for identifying the bottle necks. Please start with the data from the prototype first, and add to the amount gradually by 30%, 70%, and 100% of the total.

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Next, let’s consider the manufacturing and operation processes together with the study of related documentation, such as the various technology-related instructions.

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It is necessary to cooperate with external program systems with regards to data communications. To proceed with development of such new software, please specify the interfaces with them.

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Summarize the manufacturing methods in an operation manual.

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Check each table to confirm whether we can smoothly input/output the data during testing.

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Then prepare the test samples for the system test and test the parallel operation.

Besides the testing of the implementation of defined requirements, please test your specific scenarios, such as sudden changes of orders, etc.

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In particular, in most cases re-scheduling will be performed on daily basis, so to simulate this, let’s not forget to perform the transaction tests for the whole system. Make sure that problems do not occur in such cases as irregular changes of orders and master data, and also consider an execution time of scheduling.

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You also have to provide training for your staff, based on a study of the operation manuals. Check the operation manuals and update as necessary. Upon completion of the tests, stop the old system and officially launch the new system, based on the “Asprova” scheduler. After official launch, maintenance of the system is necessary in order to add or change the production items, manufacturing equipment, etc. Because of this, conclude a maintenance contract with the “Asprova” company in order to use Asprova for a long period time.

There are many specifics in every project implemented with Asprova, therefore only the common procedures are explained. The scheduler is just a tool and its essential task is to make a schedule fast. The effect will be different depending on the manner of implementation.

To succeed in implementation, make sure that you have the correct definition of the requirements, the relevant prototype and the proper test procedures.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 26.How to plan and conduct the introduction project.).

 

Creating a Prototype and Investigating Systematization

In this article, we will continue to use the details regarding the definition of the current situation and goals.

To gather proper requirements for planning, we need to specify the requirements e.g. define the periods, processes and cycles of the scheduling objectives.

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Since the items above are too broad, add or change them according to your needs.
Then define the requirements for the system.

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To have more clarity on roles, define also the relationships with the external systems. At this stage, it is also often difficult to make final decisions. In such cases, please take one step further and verify the prototype.

The analysis also becomes easier if the necessary data and input/output are specified.
In addition, we need to define the requirements for the orders, master data and the results.

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Make sure to align them with the contents of the “Diagnostic sheet” and their influence to future results.

If there is a need to define requirement for other items, you may just add a new sheet and define them.

Now, we create the prototype.

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We will be needing the data about the BOM of each item, manufacturing processes, working shifts and calendars, orders and inventories.

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You may refer to the Diagnostic sheet for the items which production is to be scheduled.

To make the verification process smoothly running, we suggest to start with a small amount of data.

To study how to create prototypes and input the data into Asprova, please refer to the previous articles: “How to make a prototype” and “User interface”.

After the prototype is created and the data is specified, check them for their conformance to the requirements.

  • Whether or not orders were registered as thought.
  • Whether or not operations are displayed as wanted.
  • Whether or not the mesh of the operations is too narrow.
  • Whether or not the scheduling results are the same as expected.
  • Whether or not the actual results can be reflected as thought.
  • Whether or not system cooperation works as expected.

Pay special attention to the mesh of the operations because it affects the complexity of scheduling and the whole system, so the mesh must not be too fine. The appropriate mesh of the processes is the target processes of the work instructions.

If it is not possible to implement with standard features, you can opt to do manual adjustments or the development of additional programs. Otherwise, avoid it.

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 26.How to plan and conduct the introduction project.).

 

 

Understanding the Current Situation and Setting Goals

First, let us analyze the current situation and the goals. You can further clarify them with the help of filling out the “Diagnostic sheet”.

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Here is a sample of the Diagnostic sheet – which covers all pertinent information to assess whether Asprova will be suitable for you or not.

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First step is to specify your tasks and goals. When setting up the concrete values and priorities, make sure that the goals are not ambiguous.

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In cases with ambiguous goals, it will become difficult to define concrete requirements later.
As a result, the system will not operate properly and the benefits of implementation may not be seen.

Specify a production scheduling method, and define the scheduling objectives and describe problems causing bottle-necks.

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Roughly enumerate all production processes to cover all the operations and the scheduling objectives.

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Consider the proper units for the production processes when creating the prototype.

In addition, provide the relevant information about the working shifts and the manufacturing equipment capacities, etc.

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Consider the orders to be handled, the statuses of the operations and the inventory status.

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Finally, check the status of the production management system.

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All the data filled in the Diagnostic Sheet will be used in the next step for scoping

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 26.How to plan and conduct the introduction project.).

 

Scenario 7 – Import Routing

In this scenario of import routing, we will teach you the following:

• Import the routing data from the TSV file
• Import the process number, resource, setup time, production capacity etc.

Please open the file 25.09 Scenario 7 – Import Routing.

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This is the [Data I/O table].

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You will see the Routing in the 3rd row. Please click on the Field mapping to see the format of TSV file for “Routing”.

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This is the imported TSV file. In this file, you will see the following fields: final item code, process number, process code, instruction code, item/resource code, setup, production, and teardown.

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The Import field in the Data I/O table is “Yes (differential)”. The Import property conversion expression is “Instruction Type = U”. The letter “U” here denotes “Use instruction”.

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Now, let’s open the Integrated Master Editor. You will see that it is still blank.

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Let’s import by clicking the File tab, and then Import. As a result, the imported integrated master data is as shown below.

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Please go to the Resource Gantt chart and then press the Reschedule button.
The resource has been assigned, based on the imported “Routing”.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 25. ERP Interface).

 

Scenario 6 – Import BOM and Material

In this scenario, we will show you how to import to Asprova the Manufacturing BOM and Items data.

We will use the file “25.08 Scenario 6 – Import BOM and Material”.

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This is the Data I/O table.

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The item code is connected with the Item name at the Material (Import).

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This is the actual Material (import) file. It includes the item code and item name.

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This is the data I/O setting for M-BOM. This is its TSV file. In this file, you will see its product code, process number, process code, instruction code, input item and the required quantity.

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Confirm the settings for Material and BOM in Data I/O table by checking the parameter setup below.

Verify that the Import column is set as “Yes (differential)” and Import property conversion expression column is set as “Instruction Type = I”.

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This means that the Instruction type will be automatically set as Input instruction as soon as you import the file.

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This is the Item table. You will see that the Item name is blank at the beginning. The Item name will be imported from the TSV file.

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This is the Integrated Master Editor. The Use instruction will be maintained in Asprova and the Input instruction will be imported from ERP.

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Let’s start importing the TSV files.

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Once completed, the item name will be displayed in the Item table and the Input instruction has been imported. See table below.

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Go to the Resource Gantt chart and press the Reschedule button to see the scheduling according to the imported BOM and items data.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 25. ERP Interface).

 

Scenario 5 – Export Purchase Requisition

In this scenario, we will export the “Purchase requisition”:

  • We will figure out the required quantities of purchasing items and auto-replenish the manufacturing orders
  • We will schedule the time to place an order and the due date.
  • We will export to the external file the scheduled due dates and quantities of purchasing items.

We will start with the last state of Scenario 4.Using the purchase item “X”, switch the Auto-replenish flag to “Yes” in the Item table. Set “Prefer to purchase” as Obtain method and “10000” as Purchase lot size MIN/MAX.

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Go to the Data I/O table and select the Field mapping of “Purchase requisition (Export)”.

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This is the format of the TSV file for purchase requisition.

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The due date is connected with the end time of the order.

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Let’s export the due date as the end time.

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Click on the Export filter expression to set the Export filter expression. Switch the Export to “Yes (all)” and set “Type==P” as [Export filter expression].

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Switch to the Order table and run the Reschedule button.

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You will then see that the purchase order has been auto-replenished with 10000 items of Item “X”.

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Go to the Resource Gantt chart to check on the purchase order.

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The lead time for purchasing is 24hours where the start time means the time to place an order and the end time means the due date. The due date for this purchase order is 10:40 on June 10th as stated in the box above.

Let’s export this. The file “25.07 Purchase Requisite (Export)” will be created and the data of the purchase order will be the output. It is the plan that will purchase 10000 items of “X” at 10:40 on June 10th.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 25. ERP Interface).

 

Scenario 4 – Export Production Orders

In this scenario, let’s export the production order including the start time and end time from Asprova. This can be done through ERP importing the TSV file for Production order and creating the purchase information by running MRP.

Let us open the Data I/O table from the final stage of the previous scenario (refer to Scenario 3 article) and confirm the Production order (Export).

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Open the Field mapping dialog by clicking on the cell of the same name.

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This is the format of TSV file for the production order.

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Switch the Export field to “Yes (all)” and set “Type=M'” as Export filter expression.

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Let’s export it. Go to the File tab and select Export.

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The TSV file for this production order will be created and the auto-generated manufacturing order will be its output. You will also see when you open the TSV file that the orders already include the start time and the end time.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and its e-Learning videos at http://lib.asprova.com/ (see 25. ERP Interface).