Would the PDCA cycle become faster when accuracy improves?

Make-to-Stock

Vibration-proofing products are the specialty of this Make-to-Stock (MTS) manufacturer that we will try to analyze in this article. There are two reasons why they installed Asprova mainly: to improve efficiency and to upgrade accuracy.

The Production schedule, before Asprova introduction, was made three times a month. Because the company needed a lot of help with their vulcanization processes, they wanted to focus on narrowing this out for it to be automatically scheduled. Scheduling only three times a month made it hard for them to do so. But, after Asprova installation, they were able to schedule every day and made the processes more efficient and accurate. After this event, the company plans to expand the use of Asprova in other aspects of their production processes.

Production Planning Enhanced

According to their managers, the improvement of efficiency in making production plans is one of the best effects after Asprova introduction. Another is the accuracy enhancement of production plans.

The use of Asprova does not end in just the aforementioned details. The company predicts that in the future, there will still be effects like great reduction in-progress inventories.

How a Synchronized MRP and Finite Capacity Scheduler Helped a Cosmetic Company?

MTO Manufacturer Still Using Excel

In a Make-To-Order cosmetic product manufacturing, checking material availability usually takes a long time, sometimes it takes too long, that customers would rather cancel the order instead. It is very hard to keep up with order changes and respond to when this happens often. A Japan-based company specializing in: powders, lip sticks, and cream—experienced this setback.

The company utilized an Enterprise Resource Planning (ERP) software as the core system  in the past. This proved to be incompatible with their production setting because it took them a long time to complete all their processes and it was simply unstable. They even  had  to manually schedule using MS Excel for their scheduling because of this issue.

Finite Capacity Scheduling

However, these matters were resolved through the installation of a Finite Capacity Scheduler (FCS) software called Asprova. The company wanted to combine the two concepts to form a process that would utilize both MRP and FCS. And they succeeded by overcoming many challenges in conceptualizing how this would work (for a more detailed explanation click here—case study 14).

After switching from ERP to FCS, the company experienced a considerable reduction in manual workload, precision in scheduling, realized functionality of MRP, and  realized the computation of synchronized MRP and FCS in only 6 minutes—now that’s a quick (and also accurate) response to frequent order changes.

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What are the Benefits of Synchronizing Sales Production Orders?

Manual Scheduling

We’re now going to focus on an international company which does Make-To-Stock (MTS) manufacturing. This company is known for supplying disks to aircraft engines. Like other companies, this one had problems in scheduling because of their manual approach. This often caused delay in production operations. They also had to respond to frequent order changes.

The company needed a high-speed production scheduling tool that can function well in a fast-paced production environment—and also promise results. They tried a lot of schedulers to solve this issue before, but among all the production schedulers they tried, there was  one who could perform better than others.

It was Asprova.

Synchronizing Sales and Production Orders

According to the manager of this company’s production department, they chose this production scheduling software because it has large parameters that can be assigned by the user. “There are particular conditions and requirements here that are unique to us. Asprova’s flexibility fills the bill in that regard,” he adds.

The software helped the company synchronize their sales orders as well as their production orders. With Asprova, they were able to attain a uniform production planning and created precise production plans. Another noticeable achievement after the installation of Asprova is the automation of the previously manual scheduling operations.

Production Scheduling Software: In-house VS Standard Packaged

Quick Response

Consumers look for certain traits in their service and/or product providers. Two of the many things that customers assess in manufacturers are these: a swift product delivery and a fast response to their orders or order changes. These have been continuing to stand as a firm production standard and have also taught as a management concept known to many as Quick Response (QR).

QR is a management concept created to increase consumer satisfaction and survive increasing competition from new competitors. It intends to shorten the lead time from receiving an order to delivery of the products and increase the cash flow.

Asprova, the product that aims to apply the QR concept on its clients has certainly proven itself to a well known international company that produces heavy electric machinery systems, industrial mecha-tronics, information and telecommunications systems, electronic devices, manufacturing and sales of home electric appliances, and more.

Production Scheduling

According to the company, even though they have developed their own in-house scheduler, it required a great deal of troublesome work in establishing a system. Scheduling took a long time when it is applied to actual use. In order to solve such problems, they considered the introduction of the packaged solution—Asprova.

The previous in-house made scheduling software is very simple but it was also very slow. When the company switched to Asprova, they experienced a shift from the 5-10 minutes scheduling to a 2 second scheduling. The scheduling implementation was reduced by 80% and drastically shortened the implementation overhead.

Also, one of the most notable improvements, the company said, is the fact that it enabled them to respond quickly and accurately to customer orders.