Transcript Presentation Title

Revolutionize
Material and Production Planning
with
Advanced Planner
Deborah Vermillion, CPIM, CIRM
CISTECH Inc.
www.cistech.net
What is Advanced Planner?
• Advanced Planner is an alternative to XA MPSP, MRP
and CRP
• Windows based fast MRP that helps you to do
interactive planning
• Allows you to visualize load on the facilities (work
centers). AVP uses color coded graphs and charts that
makes it easier to manage the master schedule
process. This includes material and capacity testing
• Helps you to take appropriate decisions such as
offloading, outsourcing, level loading etc to meet the on
time delivery of your customer orders
• You can also estimate the labor requirements to support
your plant schedules
• Generates suggested supplies( both MOs and POs),
supply exceptions, detailed operation start times and
shipment delivery dates
How does AVP do this?
• Planning information is downloaded from the
AS400 creating an Access database on the PC
• Planning run is done on the PC eliminating job
conflicts on the 400 and decreasing processing
time. This allows for “more” planning runs.
Quicker response time!!!
AVP- Input Output
Demand
•Forecasts
•customer orders
•Replenishment policy
•inventory on hand
•shop orders and allocations
•Outside operations
•purchase orders
Product Structures
•part attributes
•Standard and workorder bills
•Standard and workorder routings
AVP Engine
Supply
Production Plan
•manufacturing order releases
•load vs. capacity
•workcenter schedules
Procurement Plan
•purchase order releases
•expedite; defer; cancel
Shipping Plan
•customer promise dates
Plant Structures
•Workcenters
•Labor
AVP/MRP Similarities
• Both use all the planning modifiers in the Item
Balance/Plan record
• Both use the MRP Execution Options for rescheduling, auto-release, etc.
• Both use the MRP Horizon Dates
• Both have direct or indirect interface to Mapics
Forecast module
• Both use the Manufactured due date from the
customer orders for planning
AVP vs. MRP
• An MRP generation is performed by a BOM
explosion and netting routine usually overnight
• With Advanced Planner NO AS400 MRP
generation is ever necessary
• MRP has multi-planning warehouse capabilities
• 6.1 Provides multi-warehouse planning
AVP vs. MRP
• MRP/CRP uses Mapics calendars
• AVP has its own calendar within the database.
This calendar holds hours of operation per day.
• MRP has no easy “what if” capability short of a
new MRP generation
• AVP has powerful “what if” capability directly
with the AVP access database on the PC
AVP vs. MRP cont’d
• MRP interfaces with MPSP
• AVP has its own Master Schedule Routine
• MRP uses Lead Time to calculate start date
• AVP uses backward scheduling and the times in
the routing to calculate start date
AVP vs. MRP cont’d
• MPSP uses the greater of Customer Order or
Forecast
• AVP nets the CO’s against the Forecast and
plans with the CO’s and Net Forecast
• MRP assumes infinite capacity
• AVP plans the work load in each work center for
capacity review prior to accepting the plan
AVP vs. MRP cont’d
• MRP provides a warning if a planned order
quantity exceeds the Maximum
• AVP uses the Maximum to create multiple orders
due on the same day for the Max quantity (or
less)
• MRP plans an order to be due the same day as
the requirement
• AVP plans an order to be due the day before the
requirement
AVP extras: Forecast Consumption
Forecast can be consumed in four ways:
– Individual Item: The sales of each item consume the item
forecast
– An item and its parents: If many possible finished product
configurations exist, made from a small number of
components, you can forecast at the component level rather
than the finished product level. The sales of the item and any
parent consume the item forecast
– Planning bill Family: Identify an item as a planning bill item and
enter shippable forecasts for the item (% based on qty per in
Planning Bill. Forecast is consumed by end item and matching
configurations in the Bill of Material
– Product Family: Does not use a Planning Bill. The ‘Base’ Item
is forecasted. Customer Order Demand for items within the
Product Family consume the ‘Base’ Item’s forecast.
(introduced at AVP 6.1)
Forecast Consumption
This is the forecast
consumption chart
within AVP
AVP Extras
Config.ini settings to:
– Calculate run time by flow or batch method
– Uses RM Quantity (at the time of the RM
transaction) or Operation Quantity Completed
(from Labor Reporting) to calculate balance
due
– Can define horizon length values 1-999 days
AVP Extras
You can optionally update either or both
– The promise date on the customer order
– The manufacturing due date on the customer
order
Questions?
Advanced Planner Process
• Downloading Data to
the Engine
– Pulls BOM, Route,
Item, Item process,
Item plan, Forecast,
CO’s and/or Manual
Requirements
– Creates flat files that
are pulled in to create
access database
Advanced Planner Process
• Generating the Plan
– Forecast Consumption
– Nets the Requirements
against on hand & on
order (Load Project)
using Access Database
• Builds product structure
network using the BOM
and Routing
• Plans Orders (PO, MO &
Schedules)
Advanced Planner Process
• Manipulate the Plan
– View Load to Capacity Chart
– View items on Load
– Level Load both Material and
Capacity
– Time phased view
– Drill down/up
– Perform “what-if” planning
Load To Capacity and Time phased load :
Identify overload problem
Orders that can be
offloaded-Yellow
Planned Orders- Green
New Colors at AVP 6.1:
Firm Planned- Pink
Released- Light Orange
Load To Capacity Chart
Process Hours;
Setup hours;
Capacity hours
Routing
Facilities
Red – W/C is overloaded
Yellow – W/C has past due
backlog
Blue – Overload within one time
period that can be corrected by rescheduling, offloading, etc.
Green – Plan is within capacity
constraints
As decisions are taken you get instant feedback
Order waterfall view:
Identify what is needed when and the Critical chain
Advanced Planner Process
• Upload to Mapics Files
– Loads info into the MRP planning work files:
• Requirements-unconsumed forecast and
generated demand
• Planned Orders-all supply orders, including open,
firm planned and planned
• Demand Ref-Demand information
• Reschedule Activity-rescheduling actions
Advanced Planner Process
• What happens?
– Reschedules open MO’s/PO’s/Rep
schedules according to set up
– Updates the CO dates if specified in the
upload options
– Updates work center file in the MO/REP
operations as specified during offloading
– Loads the MRP planning files
– Creates the Order Review file
– Prints MRP reports as specified
Planning Execution
Once plan is saved
– Execute plan using OBPM
OR
– Green Screen Order review and release
OR
– Repetitive
Execute Plan using OBPM
Green Screen Execution
MRP Requirements inquiry
Questions?
AVP 6.1 New Functionality
• Planning Multiple warehouses in one planning run
• Saving the Schedules to database on the client
machine
• Support for SQL server and Oracle databases
• Time phased Labor loads
• Job-step information in the waterfall
• Automatic offload from one facility to other by
batch size
• Which customer orders to be pushed out
• Adjusting the operation start times of intermediate
operations thru Modifying the delay times
• Demand Prioritization
• Ability to handle negative on hand balances.
Waterfall with Job step information
Estimating the Labor Requirement
Which Orders to push out
New Commands show the
potential order list that
will be delayed based
upon the current
schedule.
Generated from within the Facility.
Lists supply orders where Supply
Due Date > Supply Suggested
Dated
Global Records not limited to within the Facility.
“Which Customer Orders..” lists only Customer
Orders where Demand Suggested Date > Demand
Due Date. Customer Orders pushed out will be
displayed from the “List of Customer Orders..”
AVP Benefits
• Improves capacity usage—maximize
factory productivity
• Increases revenue—the ability to
consistently provide more accurate
dates and deliver on time will attract
more business
• Streamlines purchasing an item that has
an m-plan or s-plan order (outsourcing)
AVP Benefits
• Expediting costs are lowered due to
improved planning
• Improves internal processing
coordination—running your planning
process quickly and more frequently will
• Catch changes and allow you to alert the
shop floor and suppliers quicker
AVP Summary
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Alternative to traditional MPSP/MRP/CRP
Tight integration for quick implementation
Quick ROI from improved capacity planning
Improved Capacity usage
Decreased Lead time and inventory
Decreased costs
Thank you!!
For additional assistance contact:
[email protected]
[email protected]
423-822-6499