PPC Sequencer for detailed planning   

 


01-seq-plan.png A detailed feasible production plan is an important basis for an efficient and transparent production. Detailed planning, which is employed in the short-term horizon, has the following relevant targets:

  • Just- in-time manufacturing
  • Einsparung von Kosten durch rüstoptimale Auftragssequenzen bzw. Kampagnenbildung
  • Cost saving by optimising the order sequences for minimum setup or by creating campaigns
  • Optimum workload on the resources

Detailed planning encompasses the aspects of the optimal sequencing of operations or orders and the detailed production capacity levelling within a short-term horizon.


The PPC Sequencer supports the day-to-day work of the planner: 

  • in the search of a gap for an operation/order on permitted resources (with graphical and tabular scheduling board)
  • in the scheduling and rescheduling of operation/order sequences for setup optimisation
  • in the summary of similar products for a joint production (creation of campaigns)
  • in the rescheduling of operations, e.g. due to machine failures or staff shortages

   

Benefits

  • Consideration of dependent operations/orders (multi-level possible as well)
  • Setup optimisation: Calculation of dynamic setup transitions (dependent on the sequence) using a setup matrix
  • No violation of the requirement dates considering the complete, multi-level production network
  • Combination of automatic and manual planning
  • Numerous planning strategies with flexible parameters that can be combined to represent the following scenarios:
       - Resources working at full capacity (gapless) 
       - Just-in- time scheduled operations as late as possible, without violating
         restrictions (e.g. requirement dates) 
       - Minimised setup times with the additional consideration of due dates


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Detailed planning overview: schedule with production orders in sequence and relevant detailed information, such as due date/requirement date, product characteristics (here: diameter), material, status, duration, quantity).


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Detailed planning overview: graphical planning board

 

Detailed planning can be carried out completely in the background or online using the corresponding function code in the PPC Sequencer.

Manual planning is possible as well. In this case, the responsible is assisted by the tool for an optimal realization of his or her decisions:

  • Drag-and-drop
  • Overview of all gaps, graphical and tabular
  • Display of setup times for available alternatives
  • Simulation possibilities
  • Indicators, such as the range of coverage or buffer to the due date

An advantage of the PPC Sequencer is the combination of automatic and manual detailed planning. The automatic scheduling offers a proposal for the planning allocation with all its consequences (derived indicators, exceptions). Afterwards, it is possible to fine-tune the results manually.


Process of semi-automatic detailed planning

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PPC Sequencer solutions

  • Automatic planning using configurable scheduling algorithms
  • Ability to shift (per drag-and-drop) to alternative bottlenecks (machines) in case of capacity overload
  • Prioritisation of operations on bottlenecks (resources)
  • Consideration of classification and configuration features in the sequence planning
  • Planning on order and operation level
  • Personnel planning
  • Tool planning
  • Simulations
  • Multi-level planning
       - Consideration of due dates on several production levels
       - Consideration of component availability across multiple production levels
       - Multilevel planning: top-down, bottom-up
       - Possibility of the integration of pegging


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Jump to super-/subordinate production levels for displaying the components or causing requirements (e.g. customer orders)

Solutions in combination with other modules of the Production Planning Cockpit

  • Sequencing at operation level with consideration of restrictions
  • Consideration of customer-specific restrictions when generating the production plan
  • Integration of alert management
       - Display of overloads (capacity)
       - Display of delays
       - Display of missing parts
  • Cost minimisation: Consideration of costs of different categories (storage, setup, delay) in the planning
  • Campaigns, blocks, reservations
       - Keep orders grouped during one or multiple levels of the production
       - Keep free capacity for key customers
       - Reservation of dates for campaigns