Sales Order Scheduling – BTO

In this sample, scheduling a BTO production will be explained. Using the same sample in the previous article Sales Order Scheduling – MTO, switch the Auto-replenish flag of item “A” to “Yes” and set its production lot size Min/Max to 1000. By doing this, the production of item “A” is changed to “Make to Stock” production and will produce based on the set production lot size.

Assu1

Run the Reschedule button and switch view to Order table. You will see that three production orders were created automatically. The order quantities 300 and 500 of item “AX” are replenished for each sales order of “AX”. You will also notice that the production order quantity of item “A” is 1000, this is because we have set the lot size as 1000.

Assu2

Looking at the result in the Resource Gantt chart. The sales order quantity is set to 300 and accordingly the manufacturing order quantity of item “AX” is 300 (see Assembly1 bar). The blue bar shows that item “A” is being produced in 1000s as specified in the lot size.

Assu3

In this chart, we can also input inventory of item “A” and see how it is scheduled based on sales orders.Input “Inventory “A”” as Order code and select Inventory (absolute) as Order type. Set the due date and order quantity accordingly. Run the reschedule button to see the result in the Resource Gantt chart.

Assu4

You will see that the manufacturing order of item “AX” is replenished from Inventory where 300 items from inventory “A” are supplied to the manufacturing order of “AX”. Looking at its inventory level, the beginning on-hand is 400, then drops to 100 after replenishment to order “AX”.

Assu5

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).

 

BTO and the Need for High Level Scheduling

Kobayashi Create

Prescale Film

Manufacturing recording papers is the specialty of this featured BTO Japanese company. Due to the innovations brought about by Information Technology and the digitalization of printing, the pressure to supply complete solutions to respond speedily to market demand increased. This made communication between different departments an important issue that should not be overlooked. To realize seamless communication and to quickly respond to customers’ needs, the production management of this company decided to set up a collective management system. However, their scheduler at that time was unable to adapt to the integrated system that they wanted. This led them to find another scheduler that actually can.

A flawless connection

To simultaneously take a lot of factors into consideration and keep delivery dates in check, an advanced scheduler was needed. Asprova is widely known throughout Japan and the company immediately called for its help. By utilizing this Finite Capacity Scheduling software, making optimized production plans became an easy task. With its help, they were able to connect to the ERP they used and it became possible to reduce lead times substantially. “The existing scheduler was not able to connect systems and to create an overall optimized schedule. One reason for selecting Asprova was that it can flexibly be connected to peripheral systems. This made it possible to improve same day delivery responses from 20% to 80%,” says the production management team members.

Progress visualization

To monitor the progress of the production, the scheduling managers used Asprova MES. This greatly reduced the number of inquiries from other divisions as it made the progress available for every department.

After the success of the company in integrating Asprova to their system, the company plans to use Asprova on their other businesses. This company placed their trust on our production scheduler. It’s time for you to discover why!