Discrete Manufacturing Production Planning Solution

Discrete Manufacturing

Production planning is a tool for achieving a high level of operational efficiency and customer service -- it allows for a systematic, efficient and reliable order fulfillment.

Goals of Discrete Manufacturing Planning Solution

An efficient planning process providing quality outputs needs to be supported by high performance tools for production planning and scheduling, capable of processing even tens of thousands of manufacturing orders and material items. Such tools naturally have to respect the business environment and provide quality outputs for efficient management of the order fulfillment process.

The LOGIS solution for discrete manufacturing is a set of tools for production planning and scheduling in the environment of machinery, engineering, electro-technical, automotive and other similar industries.

Capacity Planning

Capacity constraints are one of the most significant limitations companies must face when taking care of meeting the due date required by the customer. The key characteristic of a high performance solution is the ability to identify the dynamically changing bottlenecks and resolve capacity issues using optimization algorithms, taking those bottlenecks into account and propagating the result of capacity planning across the entire order hierarchy, while identifying the effect of the selected solution on all other accepted orders.

An efficient tool for capacity planning helps to achieve the following goals:

Goals of Capacity Planning

The result is the creation of capacity-feasible job queues for the limiting resources not only on the short-term horizon, but also in longer time periods. The final output is achieved by a combination of optimization algorithms and manual work of the planner. A capacity-balanced plan then becomes a valuable base material for creating a high quality production schedule, allowing for economically efficient and reliable order fulfillment.

Material Requirements Scheduling

Unavailability of a single material article of insignificant value can cause late producing of an order, whose timely production is a decisive factor for successful future of the enterprise. Therefore availability of all components of the final product must be taken into account when creating the materially feasible plan. The ability of flexible response to changes in material disposition is a necessity as well. Concurrently, unnecessary resources should not be bound to fulfilling the order – these resources can have significant value for larger companies.

Efficient planning and scheduling of material requirements has these effects:

Goals of Material Requirements Scheduling

Material availability is a hard constraint when creating a feasible production plan. The second limitation to be taken into account when creating a materially-feasible plan is the latest moment when the output component must be available to start the works, considering the defined lead time. Setting these boundaries for each item is essential for the next stage of the planning cycle to create a capacity-feasible production plan.

Production Scheduling

The environment of electro-technical industry, automotive, as well as other specific production processes of machinery and engineering require setting a sequence of orders in relation to various constraints – for example depending on quality and strength of material to be split or the setup time of the production resource between separate orders.

Setting an optimal sequence of orders on a resource leads to the following benefits:

Goals of Production Scheduling

An optimized production schedule is generated in seconds, or minutes at most, which allows for flexible responding to the dynamically changing production situation and to the changes from outside. The ability to quickly create optimized sequence of operations thus gives the planners time for manual modifications of the schedule and taking those constraints into account, that are not a part of the scheduling algorithms.

The complexity of production planning and scheduling issues often leads to deploying tools that combine the ability of scheduling material requirements and planning and scheduling production in parallel. In most cases, deploying such solution leads to achieving the main goals of the planning process itself – improving operational efficiency and achieving a higher level of customer service.

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