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.

In this sample, the Resource class is set as Furnace resource (spec 1).

asprova1

This means that orders with the same resource class set as spec 1 will be assigned at the same time.

asprova2

In the order table, the Spec 1 of orders 1 and 3 is high.

asprova3

The Spec 1 of orders 2 and 4 is low.

asprova4

Run the Reschedule button.  You will notice that the orders 1 and 3 are assigned to produce at the same time and so are orders 2 and 4.

asprova5

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

 

Reschedule Again – Change Scheduling Basis Time

In this sample, we will create a new schedule with the result input and change it to scheduling layout for confirmation.

Go to View tab, then Layout Setting, select Scheduling.
asprova1To change the scheduling basis time, drag and drop the scheduling basis time to November 3rd.
asprova2

You will see that some operations were assigned in the past by moving the date.
asprova3

The progress of the operation can be seen through the slant line. You will notice also that a part of the operation 3:10 with no slant lines was also assigned in the past and is delayed.

asprova4

Next is to reschedule and reflect the results and re-assign the operations. The scheduling results will be changed and will be seen near the scheduling basis time. Run the reschedule button. You will see that the released operations that were not started are shifted to a future time.

asprova5

The 3:20 operation now matched the delay of the previous process and shifted to a future time since the previous process 3:10 was delayed with the original plan.

asprova6

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 23. User Interface).

 

 

Enter Result – Resource Gantt Chart

In this sample, we will input the result from the Resource Gantt Chart. Right-click on Operation 01:10 and select Operation, then Results.

Asprova1

This operation is done, so we will change the status to Completed. Click Ok.

Asprova2

A gray underline will be displayed in the operation and the slant lines will show the progress of the operation.

Asprova3

Do the same for operation 3:10 and input the result. Let’s assume that this operation has been delayed from the plan. Enter the reported start time as 2016/11/1 13:00. Input 7,000 in the reported quantity. Then, click Ok.

Asprova4

The result input is done.

Asprova5

You can also input the result from the Operation table aside from the Resource Gantt Chart. If you enter the result to some operations, you may use the Operation table.

Asprova6

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 23. User Interface).

 

User Interface: Change Calendar – Resource Gantt Chart

From the previous article, if manual adjustment does not address the delay in the order, maybe there is not enough time for the operation to assign. We can try to increase the working time and see if this eliminates the delay.

In this sample, we will change Nov 5, a Saturday as a working day. Left-click on Nov 5 while holding down the shift key.

Asprova1

Right-click the cell which is highlighted and then choose Day shift.

Asprova2

You will see that the shift of Nov 5 has changed to a Day Shift.

Asprova3

Run the reschedule button and you will see that operations will be assigned on Nov 5.

Asprova4

You can look at the message window and confirm that there is no more message about the delay. This means that the delay was eliminated.

Asprova5

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 23. User Interface). You may also refer to the online help for more details on Calendar settings.

 

Single Processing Schedule

In the initial screen view of Asprova, go to the File option and select New. The screen below will appear.

1.

Go to the View option and change operation mode to Basic.

2.

Then, go to the Schedule option, click Project settings and select the tab Time periods. From there, you can set a specific date on the Scheduling basis time option.

From the Table View option, go to the Integrated Master Editor to register master information. This is where the item is set up and all other related parameters such as process code, resource to be used and production time.

3

This is also where the order information is set up such as order code, item ordered, due date, order quantity and priority. Note that numerous orders can be registered with different quantities or same due dates. Just ensure to input the priority code so that the system know which order to schedule first.

4

After all the master information are setup, you are now ready to make a schedule. Just click the Reschedule button to see Asprova’s output.

5

In this sample, you will see the two orders scheduled one after the other based on the priority code registered. As the order quantity of order code 2 is 600 and the production time is 1mp (1 minute per item), it will take 600 minutes (or 10hours) to produce the order.

It is important that the correct information are setup in the system as the schedules are run based on the parameters we register. On the other hand, changes can be done easily by just editing the master information and clicking the re-schedule button. The system will re-run the schedule and make the necessary changes.

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 22. How to make a prototype).

ABC Analysis

© MIKI Yoshihito

Vilfredo Pareto (1848-1923), an Italian economist and sociologist, made the observation that a large proportion of national wealth tended to be under the control of a relatively small number of individuals. Pareto concluded that in any series of elements to be controlled a selected small factor in terms of number of elements (20%) almost always accounts for a larger factor in terms of effort (80%). Pareto subsequently developed this observation into a more defined 80:20 rule.

The Pareto principle serves as the basis for materials management value segmentation and in this context is more commonly referred to as ABC analysis. It is based on the concept that approximately 80 percent of the total value of stock items will be accounted for by approximately 20 percent of the items. In other words, just a few stock items account for a very large proportion of total stock value; these are the key items over which management control should be exercised.

Now the question that arises is how you will identify what stock value is attached to the stored materials. Well the answer is simple – Asprova. It has features that will display the usage value of each item, which will elevate the ABC analysis concept one stage further into three stock categories used extensively in stock control.

  • Category A items: The ‘vital few’. Small in number but high in usage value.
  • Category B items: ‘Normal items’. Medium in number, medium usage value.
  • Category C items: The ‘trivial many’. High in number, low usage value.

In the purchasing context the Pareto principle can be interpreted as 80% of spends being directed towards just 20% of the suppliers. This elementary form of segmentation can then be used to separate the critical few suppliers from the trivial many. In other words, more purchasing effort and energy needs to be focused on the category ‘A’ suppliers and the materials that are purchased from them.

Whilst the remaining items in other classifications cannot be neglected, appropriate ‘low maintenance’ replenishment controls should be considered. An example of low maintenance controls would be the use of Vendor Managed Inventory (VMI), a system by which responsibility for managing the stock is placed in the hands of the supplier, thereby minimizing the purchasing effort.

The powerful tools in Asprova will allow you to keep the entire stock at your fingertips. More precisely, our detailed production scheduling and visualization functions enable superior control of the critical category ‘A’ items. It ensures that the stock level of this particular class of items remain optimized the whole time through elimination of excessive buildup and/or abundant consumption, thereby reducing overall cost and improving customer service by avoiding stockouts.

 

 

Photo credit © MIKI Yoshihito

Asprova Scheduling: Mixing-Packing-Inspection Process

This article explains the operations and functions used from master setting to rescheduling with Asprova APS. In this sample, we will explain the mixing-packing-inspection processes in Asprova.

Graphical display

To be able to produce ProductA, it has to go through a series of processes:

  1. The materials for product A is set as ProductA-Material.
  2. ProductA-Material passes the mixing process first. There is a resource called Mixer 1 for the materials mixing process.
  3. Next step is the packing process. There are 2 packing resources – Packer 1 and Packer 2 for the packing process.
  4. Then, items produced in the packing process pass the inspection process. There is an inspector called Inspection Center 1 for the inspection process.
  5. Finally, ProductA will be produced.

This is the production process for Product A. All necessary equipment are called resources. All of these can be set up in Asprova – including set up and production time, resource or process output (e.g. mixing process outputs 1 unit etc), time constraint or waiting time and the order information. Order information includes product, order quantity, due dates and priority. Priority is set into two types – priorities 50-90 are called “Just in Time” orders wherein orders are scheduled in a backward direction from the due date and priorities 90-100 are called “Emergency” orders wherein orders are scheduled to start and finish as soon as possible.

With all these information set up in Asprova, we can run, adjust parameters and re-run schedule to meet the desired dates and quantity. For example, possible late deliveries can be adjusted to meet schedule on-time through opening weekends for operation. Asprova also has the capability to synchronize processes such that rush orders are scheduled sequentially with the just-in-time orders minimizing waiting time between processes. By doing this, it allows factories to schedule manufacturing with minimal lead time. As a result, size of production and work-in-progress inventories are reduced.

To learn more about this specific Asprova sample demonstration, you may visit Asprova’s e-Learning video HERE .