PPC Rough-cut Dispatcher   

 



Rough-cut planning is a levelling between capacity requirements and available capacity that occurs within predefined periods (e.g. month, week). The planning usually has a long-term focus, where MRP receipts can be created or adapted as required in the respective periods (“buckets”). At the same time, the capacities of ERP work centres are synchronised and periodic constraints are taken into account (e.g. maximum amount per day). Costs for production plans can also be calculated and optimised.

The PPC Rough-cut Dispatcher is a module fully integrated in SAP ERP and based on standard objects and functionalities. All major data for planning from the SAP ERP (e.g. planned and production orders) are invoked from the PPC Rough-cut Dispatcherwithout any interfaces. Planning is both manually (e.g. by drag and drop) and automatically (using planning algorithms) possible and a multi-level analysis ensures planning transparency in all cases.


Benefits

  • Periodic capacity overview (period is defined by user)
  • Real-time information about capacity workload in the plant
  • Real-time information on the feasibility of customer inquiries on yearly, monthly, weekly, daily and shift level
  • Central access to all major SAP ERP standard objects and capacity data
  • No interfaces
  • Flexible module that is quickly established
  • Review and consideration of restrictions: supplier delivery capacity, storage capacity, supply shortages, etc.


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Capacity overview: work centre workload in the respective production week (periods)

Use of a basis period, for example a day or a shift, depends on the customer requirements. The periodicity is selected corresponding to the business case, for instance:

  • During the strategic planning of the next financial year the buyer can gain an overview about required quantities of production resources. Required raw materials, machines and production tools are calculated based on the predicted demand volume of products. In this case a coarser granularity is to be chosen.
  • During operative planning, orders are prepared and daily or weekly programs are forwarded to the production controller or shop floor foreman, who plans manually based on their experience. A finer granularity is better suited in this case.

 

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The focus of rough-cut planning is not on the creation of a detailed sequence of planned orders. However, it can be an efficient and comprehensive preparation for the subsequent more detailed planning step.

 

The periodic planning ("bucket planning") covers several aspects of planning:

Planning

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Receipt quantities are created as required and modified to ensure availability for each period

Capacity

The rough-cut planning makes sure that required bottlenecks are available. On the one hand, this may be a matter of represented bottlenecks in the ERP capacity planning such as capacity categories of work centres. On the other hand, these can be modelled as any other bottleneck types, such as quantity restrictions due to storage space, supply capacity or supply constraints associated with component supply. Within the scope of rough-cut planning, ITeanova provides a lean and effective modelling alternative through the analysis of dynamic order networks formed by pegging.

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Capacity bucket planning: Jumping to the respective bucket shows the causes for overloads.
The result is an overview of orders with all required data. Dispatched orders are highlighted (blue)
as well as undispatched order (red).

 

Smoothing

A special feature is the periodic smoothing, which creates a production plan with an evenly distributed workload having taken all restrictions into account.

Constraints

Constraints that must be adhered to are taken into consideration for the creation of a final production plan. These include, for instance, time coordination of all production levels, correct positioning of all receipts relative to customer and pre-planning due dates, maintenance of a minimum stock as well as minimum and maximum offset between operations and orders.


Graphical planning

It is possible to display and change the planning result graphically. Orders can be moved easily by drag and drop. The graphical display offers a better overview of the planning situation for the user to optimise the planning data comfortably.


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Interactive graphic


Solutions of the PPC Rough-cut Dispatcher

  • Finite and infinite bucket planning (periodic capacity levelling)
  • Automatic and manual planning
  • Planning heuristics – predefined planning logics
  • Just-in-time planning (JIT planning)
  • As-soon-as-possible planning (ASAP planning)
  • Multilevel planning – simultaneous planning on several levels
  • Pegging – Assignment of receipts and demands
  • Production and demand smoothing
  • Personnel planning
  • Tool planning
  • Chief orders – orders that cannot be moved
  • Prioritised planning – e.g. according to demand (make-to-stock, make-to-order etc.)
  • Cross plant planning
  • Whatif analysis – simulation of various planning scenarios


Solutions in combination with other modules of the Production Planning Cockpit

  • Block planning – orders are grouped into blocks and produced jointly
  • Capacity reservation for key customers
  • Campaign planning – orders grouped based on specific criteria
  • Planning constraints – additional restrictions