Increase Profits with a Production Planning Scheduler

~Introduction to the Production Scheduling System Asprova~

Chapter 01 - What is a Production (Planning) Scheduler?

Birth of the Advanced Planning and Scheduling System (APS)

The first generation of the Asprova Advanced Production Scheduler continued to be a best seller in Japan through nine years of updates after first being introduced to the market in 1994. Design of the second-generation scheduler was begun in 2001. The first generation production scheduler was software for creating schedules of the production process.

The second-generation production scheduler has been transformed from a tool that schedules production processes to one that schedules sales, orders and shipping, from a tool that creates short-term schedules to one that creates medium- and long-range schedules. We call this tool the Advanced Planning and Scheduling System (APS ).

Scheduling the production processes allows us to shorten production time. However, lead-time indicates the entire picture from purchase to production and delivery. An Advanced Planning and Scheduling System schedules everything from purchase to production and delivery and, as a result, achieves reductions in total lead time first reducing purchase lead time, then production lead time and then delivery lead time.

A production scheduler creates short-term schedules. But, companies plan their schedules in the sequence of long-term, mid-term and short-term. The Advanced Planning and Scheduling System prepares schedules in the long-term, mid-term and short-term providing overall support to the companies planning administration.

The Advanced Planning and Scheduling System has the following functions.

Schedule production

Performs finite capacity scheduling that takes into consideration the capabilities of plant, equipment and personnel. Uses finite capacity scheduling to create work instructions that can be implemented at the plant site.

Related article : Production Scheduling

Necessary quantitative calculations

We calculate required quantities of parts and raw materials from manufacturing orders and BOM (parts lists). Based on this data, we make a proposed schedule for production of necessary parts and create needed data for orders of raw material.

Related article : Visualizing Material Requirements

Scheduling of orders received

Scheduling the orders received links manufacturing orders and inventories. That creates a production schedule allowing orders received to be shipped just in time.

Related article : Scheduling Orders

Purchase scheduling

This schedule takes purchase lead-time into consideration. Calculates timing of orders for just-in-time purchases by finite capacity that are impossible in MRP.

Related article : Scheduling Purchases

Mid-term scheduling

This is scheduling for the next three months, approximately. Mid-term scheduling is calculated using more accurate estimates of demand from those you are doing business with, taking the process load into consideration and calculating the required quantities and then calculating the material quantities and timing necessary.

Related article : Mid-Term Scheduling

Long-term scheduling

Long-term scheduling creates a schedule one-year into the future and is based on demand forecast data and sales plans. This makes it possible to plan fiscal year costs, profit calculations, production strategies and plant and equipment.

Related article : Long-Term Scheduling

KPI (Key performance indicators) and cost accounting

The KPI are calculated from the results of short- mid- and long-term schedules. KPI consist of such items as order KPI, resources KPI, product KPI and period KPI. This allows cost accounting for each item.

Related articles :

Visualizing KPI

Visualizing Individual Costs

The Advanced Planning and Scheduling System has evolved from "a tool to aid the human production scheduler" to a "tool that contributes to raising profits for the manufacturing industry". This book explains how the Advanced Planning and Scheduling System (APS) makes that contribution to raising profits.

Next Problems Common to Manufacturing and How to Solve Them

Previous Speed is Critical to Production Scheduling