Relationship between ERP and Asprova

Asprova can be integrated with any ERP system. It is ready to be interfaced with SAP, Oracle EBS, JD Edwards, Dynamics AX, QAD and legacy systems.

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The table below shows how Asprova is integrated with an ERP system – the data can be interchanged using Tab Separated Value (TSV) files.

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There are several data tables in ERP, such as: Planned independent requirement, Customer requirement, Planned order, Production order or Process order, Purchase requisition, and Inventory. For master data, there are Material, BOM (input items and quantity), and Routing.

In Asprova, there are 3 corresponding data tables related to an ERP System – Order, Item, and M-BOM (Manufacturing Bill of Materials).

There are several types of orders, such as Sales, Manufacturing, Purchase and Inventory.

There are 2 types of instructions in M-BOM: Input and Use instructions. Input instruction includes input items and its quantities as it relates to an ERP system’s master data BOM. Use instruction includes usable resource and production capacity of each process as it relates to an ERP system’s master data Routing.

It is necessary to prepare the interface program for the ERP side.The typical interface program for SAP is BAPI interface. In Asprova, data import/export is implemented by the DBIO feature. Thus, in most cases, there is no need to develop the software from Asprova’s side.

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).

 

Set up 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.

In this sample, we will produce item “AX”. Press 1 will be used as a main resource. Mold 1 and Mold 2 will be used as a sub resource.

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Let’s register in the Resource setup table a 120m-setup-time to switch Mold 1 to Mold 2 on Press 1.

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In addition, let’s set a 20m-setup-time to switch Mold 2 to Mold 1.

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Press the reschedule button to see the result. At the Resource Gantt chart, you will see that there is a 120m-setup-time on Press 1 when Mold 1 to Mold 2 is switched. Subsequently, there is a 20m-setup-time on Press 1 when we change Mold 2 to Mold 1.

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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).

 

 

Scheduling Logic: Status

When we move operations at the Resource Gantt chart, we can fix them so they can be as stuck as possible. It is also possible to set their status as released, frozen or completed. In this article, we will study the progress for inputting results after moving and adjusting operations.

If we move the operations at the Resource Gantt chart, the mark indicating fixed under the operation bar will be displayed.

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If you do not move the fixed operations, this will draw the other operations nearer to shorten the waiting time. When you don’t want operations to be drawn near to each other, you can set Forced forward or Forced backward as the Assignment direction from the Scheduling Parameter Settings.

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It will be leveled down when overlapping and will be assigned back or forward when there is no time to operate.

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To prevent such movements, we can freeze the operations by right-clicking on the operation and select Status, then Freeze.

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You can do this when you don’t want operations to be absolutely moved as they are frozen.

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If we input the results, it will change to Started. Go to Operation option and select Results.

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Input the corresponding results in the table below.

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The uncompleted part will be pushed to the right side of the scheduling basis time and other operations will be pushed back.

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In Asprova, it is possible to make scheduling in consideration of delays or advances. When the result is less than the planned production quantity, the quantity of the next process will be adjusted automatically in consideration of the previous process.

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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).

 

Sales Order Scheduling – MTS

In this sample, scheduling a Make To Stock (MTS) production will be explained. Using the same sample in the previous articles, go to the item table to set parameters: set item “AX” auto-replenish flag to “Yes”, set production lot size Min/Max to 500 units.

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In the Order Table, set the current inventory of item “AX”. Use “Inventory (absolute)” as order type and input 300 as order quantity.

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Run the Reschedule button to check the output. The order requires 500 items of “A” to be able to produce 500 items of “AX”. Since we have set item “A” with 400 pcs inventory, a production order of auto-replenishment “A” is created with a quantity of 1000. Go to the Resource Gantt chart to check the output. You will see that the sales order requirement for item “AX” is 300 and its current inventory is also 300. Therefore, no more production is created. For the second sales order of 500 “AX”, 500 items of “A” are necessary. Since the 400 items of “A” were used already from the first order, manufacturing orders of 1000 pcs each are generated automatically.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos and see 22. How to make a prototype.

 

How to Successfully Implement a Production Scheduling Software

Flickr ©Scott

Flickr ©Scott

Every software implementation needs thorough preparation and planning to ensure success. Over the past years, Asprova has had its fair share of success and failures in the implementation of its Production Scheduling software. Based on actual experiences from our customers, here are important points to take note to be able to successfully implement a Production Scheduling software:

Set clear and in between ideal and realistic goals. To define these goals, understand first why your company needs a Production Scheduling software. Create a project plan that clearly articulates business requirements. Analyze the requirements and ensure to set goals in between realistic and ideal – be able to separate wish lists from the attainable ones. Lastly, goals have to be set with great focus on the company’s bottom line – PROFIT. For example:

1. Be able to answer quickly and accurately → Aiming at the increase of customer satisfaction and sales

2. Reduce inventory → Aiming at cutting costs

3. Shorten production lead time → Aiming at improving agility to respond to customer needs as well as cutting costs

• Build a prototype. Before implementation, it is recommended that a prototype be built first to be able to completely examine the functions of the system. This will help you decide whether the functions of the system will work for you or not.

• Keep additional software development to an absolute minimum. Too much customization may derail your implementation due to time constraints, possible bugs and uncontrollable costs. Take the opportunity to evaluate your processes first. Then, try to solve using the standard functions of the system.Taking into consideration all these important factors will help your company in successfully implementing a Production Scheduling software and in achieving your end goal of hitting profit plans.

Are you planning to implement a Production Scheduler in your factory? If so, we strongly recommend that you download the free trial version of Asprova and watch our e-Learning videos.

 

 

Photo credits: Flickr ©Scott

Push and Pull Manufacturing: A brief comparison

tug-of-warDifferentiating Push type and Pull type manufacturing is simple: Push type refers to Make-to-Stock (MTS), where production is NOT BASED on actual demand; on the other hand, Pull type refers to Make-to-Order (MTO), where production is BASED on actual demand.

Here’s another way of saying it:

MTS – A manufacturer producing items before orders are received. Now, you might be wondering where MTS manufacturers base the number of products that they produce over time. This traditional production strategy looks at the demand forecasts generated from data that they gathered. These will then be synchronized to the quantity of items to be made. The key to this type of manufacturing is to be as accurate as possible in making forecasts.

MTO – A manufacturer producing items after orders are received.

As you might have derived from the facts above, MTO manufacturers move right after an order is received. The usual case in this type of production strategy is that each order is unique—giving producers a hard time making them. The processes for every product, of course, vary from one another and this makes scheduling quite a handful.

The downside

In MTS, the biggest disadvantage falls into the forecasts itself. Here, inaccuracy will definitely result to losses producing high or excessive inventory ratings—where there are more products in the real demand and even stock-outs—when there would be a shortage of produced items when the demand is high.

In MTO, there are also many disadvantages and one of them is shortening lead time. If the company accepts many orders without having the ability to schedule them right, it will result to aggravating the consumers who, in that case, might be receiving their orders late or not receiving their orders at all. If the company refuses to accept orders because of certain issues, this results in loss of profit.

The Solution

In this blog site of Asprova, we can see a couple of examples regarding MTS and MTO. The article about Make-to-Stock clearly states that by using the Advanced Planning and Scheduling Software, a vibration-proofing manufacturer achieved great results. In short, using a production scheduler is the biggest factor that led to more accurate forecasts.

Also, in another article focusing on MTO manufacturing, the solution was the same: using a production scheduler that can cope with the flexibility needed in MTO. This enabled them to cut-off late deliveries in half.

To wrap this up, be it Pull or Push, there is a simple solution: Join the Winners!

Results of Integrating Asprova with ERP

pentelA Japan-based manufacturer, that has been a subscriber to Asprova Production Scheduler for 10 years, thought that they needed to replace Asprova with SAP. This is all due to the fact that other factories had been using SAP, and it was becoming a trend. To keep up with others, the company decided that they should replace their Asprova with SAP/R3. However, this did not happen.

Why?

The company found out that SAP/R3 cannot fully replace Asprova. This is because the scheduling function of Asprova continues to be a big asset to the company – you can try it out too for free. And because of its flexibility, Asprova can be used hand in hand with SAP/R3. With some tweaks, the company found out about a way to use Asprova together with SAP/R3.

How is this possible?

In production scheduling, Asprova was utilized because of its speed and accuracy. Plans created by Asprova are returned to SAP and SAP creates and issues instructions to each production sites.

As a result, they were able to dramatically decrease their inventory—unshipped items are decreased by 1/4~1/2. The accuracy of orders’ due dates went up to 97~98%! The Information Systems officer interviewed by Asprova claimed that “Optimal scheduling brings satisfaction to our clients”.

Asprova’s scheduling capacity remains undisputed. If you’re thinking of replacing Asprova, you should think twice before you do it because you might be able integrate it with the product that you want to use, for example, ERP. And, with proper systemization, you will be able to achieve outstanding results.