Production Planning & Control: The Management of Operations Shop floor characteristics influencing the use of advanced planning and scheduling systems Shop floor characteristics influencing the use of advanced planning and scheduling systems (original) (raw)
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An overview of the Advanced Planning and Scheduling Systems
Independent Journal of Management & Production, 2014
Currently, the activities of the planning and control of companies are becoming increasingly complex and the managers of this area are constantly pressured to reduce operating costs, maintain inventories at adequate levels, to fully meet the demand of customers, and to respond effectively to changes that occur. The planning and scheduling task is important for most companies, so according to some authors, there is a need for further analysis of the practical use of production planning and control systems. Within the context of production planning and control systems development, in the 1990s were launched the APS systems, which represent an innovation when compared to their predecessors. This paper intended to provide through a literature review, the concepts, structure, capabilities, implementation process and benefits of using APS systems in the companies production planning and control. The main contribution of this research is to show a strong conceptual understanding regarding APS systems, which can be used as a solid theoretical reference for future researches.
i ii Advanced planning and scheduling systems in manufacturing planning and control processes Abstract An advanced planning and scheduling (APS) systems is defined as any computer program that uses advanced mathematical algorithms or logic to perform optimization, and/or simulation on finite capacity scheduling, sourcing, capital planning, resource planning, forecasting, demand planning and others. The expectations of APS systems have been high, both from academia and industry in the subject area of manufacturing planning and control. Relative the massive interest there has not been much written about how APS systems are used in practice and what effects an APS approach really results in. This thesis focuses on the use of APS systems in manufacturing planning and control (MPC) processes, and the research questions is to explore how APS can support these processes, which benefits that can be achieved and which prerequisites to consider when using APS systems. Three case studies have been conducted including seven case companies that use APS in different MPC processes. The results are presented in four appended papers. Empirical data from the case studies have mainly been conducted thorough interviews with actors involved in MPC processes.
Proceedings of the 17th LACCEI International Multi-Conference for Engineering, Education, and Technology: “Industry, Innovation, and Infrastructure for Sustainable Cities and Communities”
Choosing and designing production planning and control systems are critical tasks because they provide the means to translate the corporate strategy into direct shop floor actions. However, it is not always easy to find the correct systems for an application. This difficulty occurs if the company does not present the necessary criteria for the system, in which case the expected benefits may not be achieved. This study proposes a framework to support the selection or design of a production planning and control system (PPCS) based on the current characteristics of a company. Using relevant parameters, companies are categorized and posteriorly evaluated, identifying the negative and positive relations between the company characteristics and the principles of the evaluated PPCSs. To test the proposed framework, we apply it to determine a suitable system for Ecuadorian small and medium-sized enterprises. Simplified drum buffer rope (S-DBR) approach is found to be a suitable PPCS, and the framework suggested some necessary enhancements to resolve potential weaknesses that could arise during the application of S-DBR. Keywords-production planning and control systems, framework, PPCS selection, small and medium manufacturing enterprises, simplified drum buffer rope TABLE I CATEGORIZATION OF THE POTENTIAL RELATIONSHIPS BETWEEN THE CHARACTERISTICS OF THE COMPANY AND THE PRINCIPLES OF PPCS.
Using production data for improved planning and control
2011
With the purpose of coping with the global competitiveness between lead companies there is a need for systematic methods to provide shorter production time and higher quality of the resulting system. Currently, there is a tendency to focus on the solution instead of looking for the requirements and the production management don´t realize the severe consequences it has. According to the PPA studies of Swedish manufacturing companies, and some other studies, there is a significant gap between operation times in reality and in the planning systems. In order to solve this, it is installed a new level in the structure of MPCS (Manufacturing Planning and Control Systems) between the ERP/APS system and the shop floor level, called MES (Manufacturing Execution System). Through that, it is provided realtime information to the managers that help them to take decisions based on facts. The objective of the study is to analyze the present software existing in the MES level in the company Good Solutions and the corresponding model of disturbances and production times in order to improve the planning and control. That is developed with real production data and it is checked what can be modified and improved on it. A model for production disturbances is given as well as some proposals with the intention of automating the decision process.
Advanced Planning and Scheduling (APS) Systems: A Systematic Literature Review
Advances in Transdisciplinary Engineering
Planning and scheduling are important functions for industrial systems to operate effectively. Their principal aim is to detail how production resources will be used so that its demand is timely met. In literature, there are several works that propose mathematical models for production planning and scheduling for different production scenarios, accounting for different resources configurations and other limitations. However, it was only recently that advanced planning and scheduling systems (APS), making use of these models, started being more widely used and discussed. This work presents the results of a systematic literature review, developed by applying the ProKnow-C method, on APS systems. An overview of the main publications is provided, classifying them in new methods, models or approaches; heuristic approaches; Lagrangian relaxation techniques; and genetic algorithms. The future of APS systems is also discussed, particularly regarding difficulties such as human dependence, us...
The potential benefits of advanced planning and scheduling systems in sales and operations planning
2010
Purpose -The purpose of this paper is to explore what potential benefits may be achieved by using advanced planning and scheduling (APS) systems in the sales and operations planning (S&OP) process. Design/methodology/approach -The paper investigates benefits at the S&OP process level by interviewing APS experts and APS users. Several methods have been used; literature review, Delphi study, and a case study at a company in the chemical industry which uses APS system support in the S&OP process. Findings -Three types of potential benefits were found to be achieved when using APS systems in the S&OP process; benefits concerning decision support, planning efficiency and learning effects. The most common type was decision support benefits according to APS users and APS experts. The results from the case company showed that the benefits perceived in the different S&OP activities differed. In the activities concerning the preparation and generation of delivery plans, the perceived benefits mainly concerned learning effects. In the activities concerning the generation of a production plan, the benefits were foremost found in planning efficiency. In the S&OP meeting decision support benefits were highest valued. The reason for the different results can be explained by the aim of the activity, how APS was used in the activity, the user characteristics and the design of the model and access and quality of planning data.
The evolution of a production planning system: A 10-year case study
Computers in Industry, 2007
This paper describes the evolution of a production planning system (PPS) from a simple work sequence generation tool to a useful, sustained scheduling system. Three stages of evolution are described. In the first stage, a Gantt chart sequencing tool was converted to a scheduler's information system. This change was driven by the need to support the scheduler's daily task. The second stage of evolution was caused by an MRP-ERP conversion. The integration and conversion increased overhead and complexity in the job task and hence the tool, including the transformation of the previously integrated dispatching/scheduling task into separate dispatching and scheduling activities. The third stage of evolution has been small continuous improvements driven by management reporting requirements. PPS was developed in 1996 and has been fully operational since January 1997. Two major insights are discussed in this paper: the implications of supporting the scheduling task versus work sequence generation, and the software design requirements for evolutionary change as the software is used in an ever-changing situation.
Advanced Planning and Scheduling Systems: Modeling and Implementation Challenges
The paper summarizes the results of research on the modeling and implementation of advanced planning and scheduling (APS) systems done in recent twenty years. It discusses the concept of APS system – how it is thought of today – and highlights the modeling and implementation challenges with which the developers of such systems should cope. Some from these challenges were identified as a result of the study of scientific literature, others – through an in-depth analysis of the experience gained during the development of real-world APS system – a Production Efficiency Navigator (PEN system). The paper contributes to APS systems theory by proposing the concept of an ensemble of collaborating algorithms.
The Role of Production Planning in Enhancing an Efficient Manufacturing System – An Overview
E3S Web of Conferences
Every manufacturing system can only survive with a high level of system planning and budgeting. Production planning is a sequential ladder in the manufacturing setting to ensure that materials input (raw materials, men, money, and machine) is made available within a stipulated time frame, in the appropriate amount to produce the demanded output of goods and services based on the schedule specified. Production planning also helps in making available high quality of goods and services in the right quantities to the customer at the demanded delivery timing to attain higher degree of customer satisfaction. Through production planning, different departmental activities i.e., engineering, production, purchasing, sales, and marketing, as well as stock control department, and other units that may relate to production are coordinated to attain a regular, steady, and balanced flow of production thus, enhancing reduction in production cycle time. Production planning serves as an instrument whi...