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  Planvisage solutions help manufacturing businesses to proactively respond to real-time supply chain problems.  
     
 

Configuring Planvisage Advanced Production Planning and Scheduling factory planning system

I was recently requested to review a competitor’s software product to find where Planvisage provided a competitive advantage. I soon learned that this competitive product was in fact no competition at all. The main selling point was the sizzle offered by the competitor, but absent was the steak. I found it alarming that they used all the required industry buzz words, and had the most colorful displays I have ever seen. In fact they recommended companies provide users with two monitors to house all the beautiful graphics, referred to as a planning “cockpit”. To determine a schedule was a laborious nightmare as the user had to duck and dive into many screens to see where the problems originated, and to then apply fixes in the hope of solving all the problems manually. As a consultant I recommend that if prospects wishes to compare 2 or 3 solutions that they first draw up a list of essential functions required to meet their desired business process and do a software comparison to their checklist. Next review a “day in the life” of a planner to see how many steps are required to establish a valid schedule. Since this is the fundamental design provided within the Planvisage solution, expect to see meaningful results after executing the plan. Eliminate solutions that call on users to figure out how to solve the scheduling challenge by reviewing a number of very colorful, or not so colorful screens. As you will see below, by effectively establishing planning criteria, Planvisage will do the hard work for the user, taking very many variables and constraints into consideration, and provide a valid schedule. Planvisage is relatively simple to use, but simultaneously a highly sophisticated solution.

Purpose and Benefits

Manufacturing facilities and management face numerous challenges in today’s marketplace with:

  • rapid changes in product mix,
  • shorter life cycles,
  • smaller and more frequent shipment quantities,
  • rising customer expectations,
  • increased global competition,
  • lead time constraints,
  • reduced margins, and
  • production operations that are more complex

Daily challenges encountered include:

  •  supplier delays,
  • cycle time variations,
  • material rejection, and
  • resource breakdowns, etc.
  • This scheduling challenge is exacerbated by due date and/or order quantity changes from customers. Realistic production plans may not be firm for more than an hour or two.

Planvisage APS addresses these issues for management through:

  • a robust value-added software application supporting management and planners
  • Determining priority planning and scheduling decisions to allocate scarce material, labor and constrained capacity to high-value customers
  • Provide Available to Promise (ATP) firm due date delivery commitments to customers
  • Optimize sourcing decisions for raw materials from suppliers, considering order quantities to meet real-time capacity constraints
  • Communicate real time production status to the marketing and sales team
  • Consolidation of all department data to provide timely and reliable reporting
  • Improve profitability through effective working capital management
  • increased inventory turns
  • reduced overtime
  • reduced operating costs
  • less waste and scrap
  • greater productivity of all resources including labor, materials, capacity
  • increased sales
  • increased profitability

Some of Planvisage’s APS salient features include:

Capacity Planning

  • Automatically allocates an alternate resource when primary resources are not available
  • Automatically schedules alternate routings when primary routings are not available
  • Planning consideration for machine break-down time, planned maintenance schedules, holidays, and overtime
  • Accommodates constraints including setup time, wait time, queue time and yield variations
  • Different resource types modeled including batch, pooled, aggregate, subcontract, or labor
  • Planning for additional resources such as tools or fixtures
  • Utilization percentages are factored in load calculations
  • Model sequence dependent setup time, e.g. color, width

Material Planning

  •  Automatically selects alternate item when primary item not available
  • Considers lot size constraints when generating production or purchase orders
  • Transfer batch quantity releases when processing material across operations
  • Optional multiple vendor split percentages across suppliers
  • Consolidation of purchase orders
  • Operation level consumption
  • Calculates safety stocks and triggers automatic replenishment
  • Plans capacity loading based on material availability

Other Features

  • Considers both finite material and capacity constraints simultaneously rather than sequentially
  • What-if analysis capability to determine if a new order can be satisfied, given a set of orders already scheduled in the system
  • Allocate constrained capacity & material to high priority customers
  • Predict due date of orders taking material and capacity constraints into account
  • Warning how work orders and sales orders are impacted when:
      • Suppliers delay shipments
      • Cycle time variation increases or decreases
      • Material is rejected
      • Resource or capacity breakdowns
  • Different strategies for planning minimum WIP or maximum resource utilization

User Interface

  • Role based executable work flows
  • Excel style interface making data maintenance simple
  • Printing or forwarding email direct from any screen
  • Visual representation for Bill of Material and supply chain diagram
  • Color coding scheme for problem orders
  • Ability to customize menus, buttons, column headers, and labels
  • Graphical display of scheduled orders using a Gantt Chart
  • Scheduled orders can be dragged and dropped manually
  • Graphically see links between up- and downstream operations
  • Ability to create Bill of Material through drag and drop action
  • User authorization privileges

Additional benefits:

  •  Improved inventory management with purchases made at the right time and appropriate quantity
  • WIP is minimized as operations are productively sequenced
  • Reduced resource downtime waiting on material
  • Reduced cycle time by using alternate work centers
  • Higher on-time delivery customer service levels

Flexible configuration

Design flexibility supports the idiosyncrasies of each manufacturing facility. Planvisage software and application consultants working together with user management require an understanding of management’s business process and to configure Planvisage to meet the client company needs. With this in mind we address multiple options to allow Planvisage to work effectively for each client with a well-trained user community.

Controlling Parameters

Planvisage provides a large selection of parameters to help support each manufacturing facility within a corporate group. That implies that a corporation might have one division making a continuous process product and another a job shop metal cutting batch process operation. Planvisage must be setup to handle the specifics of each plant.

Pegging Parameters

  • All or no inventory (This parameter defines whether the demand should be fulfilled only if entire Inventory is available. If the parameter is set to true it should be fulfilled by a single order in the Inventory): true/false
  • All or no surplus (This parameter defines whether the demand should be fulfilled by a single work order or multiple work orders. If the parameter is set to true the demand should be fulfilled by a single work order): true/false
  • Consolidate interval (Consolidation interval specifies the time period up to which the supplies can be consolidated. e.g. the user might want to group all procurements for 1 week and batch the POs): quantity
  • Consolidate interval unit of measure: days, weeks, months, quarters, years
  • Pegging priority 1 (The order given in which the pegging has to be performed, with Pegging Priority 1 being considered first. See below for more detail):

Primary inventory,

  1. Primary existing orders,
  2. Primary new orders,
  3. Alternate inventory,
  4. Alternate existing orders,
  5. None
  • Pegging priority 2: Primary inventory, Primary existing orders, Primary new orders, Alternate inventory, Alternate existing orders, None
  • Pegging priority 3: Primary inventory, Primary existing orders, Primary new orders, Alternate inventory, Alternate existing orders, None
  • Pegging priority 4: Primary inventory, Primary existing orders, Primary new orders, Alternate inventory, Alternate existing orders, None
  • Pegging priority 5: Primary inventory, Primary existing orders, Primary new orders, Alternate inventory, Alternate existing orders, None
  • For example, the planning engine might first look for “Item1” in inventory if Pegging Priority 1 is specified as Primary Inventory. If “Item1” is present in inventory, and based on “All or No Inventory parameter”, the planning engine decides if it can take the existing inventory even though it cannot specify the entire demand. If all of the demand is not satisfied, then it looks for the next parameter – Pegging Priority 2. If this is set to Alternate Inventory, the planning engine looks for “AltItem1” in Inventory, also considering “All or No Inventory” value. If all of the demand is not satisfied, then it looks for the next parameter – Pegging Priority 3 possibly set to Primary Existing Orders. Thus the planning engine looks for any work orders for “Item1” that is being completed and assigns that to satisfy the demand, provided the demand can be satisfied on time. If all of the demand is not satisfied, then it look for the next parameter – Pegging Priority 4 set to “Alternate Existing Orders”. Thus the planning engine looks for any work orders for “Altitem1” that is being completed and assigns that to satisfy the demand, provided the demand can be satisfied on time. If all of the demand is not satisfied, then it looks for the next parameter – Pegging Priority 5 i.e. creates a new Work order for “Item1”, provided it can satisfy the order on time. In short, Planvisage software allows for sophisticated planning options, based on user defined choices.

Planning Parameters

  • Time horizon (how far into the future do you wish to plan?): quantity
  • Time horizon unit of measure: days, weeks, months, quarters, years
  • Frozen horizon (how far into the future do you wish to firm the plan to restrict changes?): quantity
  • Frozen horizon unit of measure: days, weeks, months, quarters, years
  • Manufacturing type: continuous, discrete
  • Decimal places (Number of decimal places to consider rounding off if the manufacturing type is continuous.): quantity
  • Clean up in planning (Database acts as repository for all production related data to carry out planning, execution and also to maintain history. During planning; distribution, procurement and work orders are generated. When plan is run again, all the generated orders are deleted except those Work Orders which are released or scheduled, Procurement or Distribution Orders which are ordered, shipped or received, User locked the quantity or locked the pegging Orders falling within frozen horizon. Now new orders and pegging’s are generated based on the changed conditions.): true/false
  • Clean up tolerance percentage (Specified to cleanup any value greater than the parameter, and provide a cleaned-up plan): quantity
  • Resolve type: Material and capacity shortage, Material shortage, None
  • Order late limit (How much a sales order can be delayed while trying to resolve material or capacity shortage): quantity
  • Order late unit of measure: days, weeks, months, quarters, years
  • Fix cross feeds (During planning of sales orders, it might happen that earlier supply would be pegged to later demand and vice versa. After planning of all the sales orders, fix cross feeds will resolve the problem and re-assign the pegging): true/false
  • Number of days in week: quantity
  • Order date format: yy, yy-mm, yy-mm-dd, mm, mm-dd, none
  • Order suffix (this allows the user to select how many digits they wish to show after a sales, work, or purchase order has been generated. e.g WO_0001 if = 4, or PO_00000001 if 8): 2,3,4,5,6,7,8

Schedule parameters

  • Maximum wait time for earliest possible start time (Amount of time resource can wait to sequence the similar setups. This is used when there is sequence dependent setup time. If a resource is running Item A, and is expected to complete at 10 am, and there is another work order for Item A which is going to arrive at 11 am. If max wait time for EPST is 1 hour, then the resource will wait for 1 hour and then load Item A. If max wait time is 0.5 hour, the resource will not wait and will load Item whichever is available.): quantity
  • Maximum wait time for earliest possible start time unit of measure: minutes, hours
  • Maximum bucket span to schedule (Buckets are grouped based on these values. If value is 3, then 3 buckets are grouped together. Use of this parameter depends on the type of scheduling strategy, Bucket Based: Scheduling is done first on a bucket group for all resources and then moves to next bucket group and so on. Pull-Push: Orders are scheduled based on priority within the bucket group. Suppose there is priority 1 and 2 orders within a group, priority 1 orders are scheduled and then priority 2 orders. It then moves to next bucket group and repeats the process.): quantity
  • Resource availability while pulling orders: true/false
  • Scheduling strategy: pull-push, bucket based
  • Scheduling type: Just-in-Time, Resource Utilization
  • Buckets to schedule (Number of buckets to schedule if the scheduling is run from workflow): quantity
  • Setup time in non-working: true/false
  • Always consider setup time: true/false
  • Generate continuous schedule on non-working time (If running a continuous process, do you wish to ensure no gaps between operations): true/false
  • Generate continuous schedule: true/false

Problem Parameters

  • Problem tolerance percentage (The tolerance value states the percentage of tolerance, before flagging any problem as a problem. e.g. if a sales order is for 1000 and 999 is satisfied, and the problem tolerance is 10%, in the problem summary an “Order Short” problem is not created.): value

Cost Parameters

  • Labor cost: value
  • Labor cost unit of measure: hours
  • Overhead percentage: value

Capacity parameters

  • Bucket build ahead (The number of buckets to go back for capacity if the capacity is not available in the just-in-time bucket): value
  • Bucket build ahead unit of measure: days, weeks, months, quarters, years
  • Capacity priority: Alternate capacity—bucket build ahead, Bucket build ahead—alternate capacity
  • Short bucket (Size of buckets in the short term planning. This is based on the total cycle time to make a product. Short buckets are usually days): value
  • Short bucket unit of measure: days, weeks, months, quarters, years
  • Medium bucket (Size of buckets in the medium term planning. This will be size of buckets after the short bucket period is over. These are usually in weeks): value
  • Medium bucket unit of measure: weeks, months, quarters, years
  • Long bucket (Size of buckets in the long term planning. This will be the size of buckets after the medium bucket period is over until the end of the time horizon. These are usually in months): value
  • Long bucket unit of measure: months, quarters, years
  • Plant utilization percentage: value

Maintenance parameters

  • Time zone: select from a complete global list, none

Data Input/Output

Caution

If the client company is using the Planvisage Demand Planning solution: forecasting, replenishment, and distribution planning, then some of the requirements listed below may already exist in the database and since the solution is highly integrated, feeds will be provided to APS from Demand Planner.

Data Fields

The following addresses the data portion used for input to Planvisage APS. Please note that many data fields requested below are optional and there to support the user administrator with helpful information. Of equal importance is if fields have not been suggested, Planvisage permits each client company to add fields to support the way they wish to process and manipulate data.

How will data be imported into Planvisage?

The preferred method is either a database to database transfer in any of Microsoft SQL, Oracle, or IBM’s DB2. However in most circumstances ERP systems are rightly protective of their databases and will rather create an output file that can be imported into Planvisage. The reverse is equally true, database to database hookups are frowned upon to export information from Planvisage back to the host system. Planvisage can flexibly process Excel (xls or xlsx versions), text (txt), data (dat), Comma Separated Values (csv), Open Database Connectivity (ODBC) or SQL formats.

How will data be exported to the host system?

The same rules apply as stated in import above.

Users

Each user must be entered into the system with a User Identification, Password, Description, First and Last Name, Address, City, Phone, Email Address, and Alert Intervals

Roles

Roles are established for a group of users requiring an Identifier, Description, Type, Customer or Supplier Identifier—if applicable

Role Information

Each role is controlled within the application as to which data screens the role may access and if the Role Users are granted permission to: Add, Edit, Delete, and/or View Only data

User Role

This is where the users are linked to Roles

Role Alerts

This is where Alerts are assigned to Roles

 

At a high level Planvisage requires the following master data files:

  • Plant Master
  • Product/Item Master
  • Customer Master
  • Vendor or Supplier Master
  • Location Master
  • Bill of Material
  • Bill of Material By Products
  • Bill of Material Alternate
  • Unit of Measure Master
  • Location Calendars
  • Open Purchase Order Transaction
  • Open Production Order Transactions
  • Open Customer Order Transactions
  • Resource Master
  • Routing Master
  • Operations Master
  • Additional Operations Resource
  • Sequence Dependent Setup Time
  • Factory Parameters (these were discussed above)

Plant Master

  • Plant Identifier
  • Plant Description
  • Default User
  • Default User Role
  • Password

Product/Item Master

  •  Location ID
  • Product Code/ID
  • Product Description
  • Product Group
  • Product Group Description
  • Unit of Measure
  • Product Type
  • Saleable Product Flag (Yes/No)
  • Holding Cost
  • Ordering Cost
  • Cost Unit of Measure
  • Primary Location Flag (Yes/No)
  • Lot Order ID
  • Lot Line ID
  • Quantity Available

Customer Master

  •  Customer ID
  • Customer Description
  • Customer Address 1
  • Customer Address 2
  • City
  • State
  • Country
  • Customer Contact
  • Customer Telephone Number 1
  • Customer Telephone Number 2
  • Customer Fax
  • Customer Email
  • Approved Product ID
  • Approved Location ID
  • Approved Routing ID
  • Approved Item Group
  • Approved Customer Location
  • Approved Customer Item

Vendor or Supplier Master

  •  Supplier ID
  • Supplier Description
  • Supplier Address 1
  • Supplier Address 2
  • Supplier City
  • Supplier State
  • Supplier Country
  • Supplier Contact
  • Supplier Telephone Number 1
  • Supplier Telephone Number 2
  • Supplier Fax
  • Supplier Email
  • Approved Product ID
  • Approved Item Group
  • Approved Location ID
  • Lead Time
  • Lead Time Unit of Measure (days, weeks)
  • Run Time
  • Run Time Unit of Measure
  • Maximum Lot Size
  • Lot Size Increment
  • Variable Cost
  • Priority
  • Vendor Share Percentage
  • Order by Days
  • Order Specific

Location Master

  •  Location ID/Name
  • Location Description
  • Location Type

Bill of Material

  •  Bill of Material ID
  • Parent Product ID
  • Child Product ID
  • Quantity Per
  • Routing ID
  • Minimum Lot Size
  • Lot Size Increment
  • Maximum Lot Size
  • Operation ID
  • Priority
  • Attribute
  • Consider Alternate
  • Order Specific
  • Check Material
  • Valid From
  • Valid To

Bill of Material by Products

  •  Bill of Material Id
  • Item
  • Routing ID
  • By Product
  • Portion

Bill of Material Alternate

  •  Bill of Material ID/Name
  • Item
  • Alternate Item
  • Quantity Per
  • Routing ID
  • Operation
  • Priority
  • Check material
  • Valid From
  • Valid To

Location Calendars

  •  Shift Number
  • Start Shift Time
  • End Shift Time
  • Attribute
  • Pattern Name
  • Pattern Value
  • Working Shift Type

Open Purchase Order Transactions

  •  Purchase Order ID
  • Purchase Order Line ID
  • Supplier ID
  • Product ID
  • Location ID
  • Quantity Planned
  • Quantity Planned Delivery Date
  • Order Status

Open Production Order Transactions

  •  Order ID
  • Line ID
  • Product ID
  • Location ID
  • Quantity
  • Delivery Date

Open Customer Order Transactions

  •  Customer ID
  • Sales Order ID
  • Sales Order Line ID
  • Product ID
  • Location ID
  • Quantity Ordered
  • Requested Delivery Date
  • Order Status

Resource Master

  • Resource ID/Name
  • Resource Description
  • Resource Type
  • Number of Resources
  • Sequence Dependent Setup Time
  • Load Capacity
  • Resource Capacity
  • Schedule Priority
  • Sub Resource Shift
  • Sub Resource Shift Unit of Measure
  • Consider Location Calendar
  • Consider Calendar
  • Interruptible
  • Fill Gaps
  • Sub Resource
  • Aggregate Resource

Routing Master

  •  Routing ID
  • Routing Description
  • Operation
  • Resource ID

Operations Master

  •  Operation
  • Operation Description
  • Routing ID
  • Resource ID
  • Operation Sequence
  • Production Rate Per
  • Run Time
  • Run Time Per
  • Fixed Time
  • Fixed Time Per
  • Transfer Batch Quantity
  • Minimum Queue Time
  • Minimum Queue Time Unit of Measure
  • Setup Time
  • Wait Time
  • Campaign
  • Interruptible
  • Transfer Batch Quantity
  • Yield
  • Number of Units
  • Batch Type
  • Space Utilization Percent
  • Variable Cost
  • Labor Cost
  • Number of Pooled Resources to use
  • Load Percentage
  • Operation Maximum Time Gap
  • Sub Resource Shift
  • Sub Resource Shift Unit of Measure

Operations Resource

  •  Routing Name
  • Operation
  • Resource Name
  • Operation Sequence
  • Production Rate
  • Production Rate Per
  • Run Time
  • Run Time Per
  • Fixed Time
  • Fixed Time Per
  • Setup Time
  • Wait Time
  • Minimum Queue Time
  • Minimum Queue Time Unit of Measure
  • Campaign
  • Interruptible
  • Transfer Batch Quantity
  • Yield
  • Number of Units
  • Batch Type
  • Space Utilization Percent
  • Consider Alternate
  • Variable Cost
  • Labor Cost
  • Number of Pooled Resources to use
  • Load Percentage
  • Operation Maximum Time Gap
  • Sub Resource Shift
  • Sub Resource Shift Unit of Measure

Additional Operations Resource

  •  Routing ID/Name
  • Operation
  • Resource Name
  • Operations Sequence
  • Additional Resource ID
  • Usage Percentage
  • Number of Units

Operations Resource Alternate

  •  Operation Description
  • Routing ID
  • Resource ID
  • Operation Sequence
  • Production Rate Per
  • Run Time
  • Run Time Per
  • Fixed Time
  • Fixed Time Per
  • Minimum Queue Time
  • Minimum Queue Time Unit of Measure
  • Setup Time
  • Wait Time
  • Campaign
  • Interruptible
  • Transfer Batch Quantity
  • Yield
  • Number of Units
  • Batch Type
  • Space Utilization Percent
  • Consider Alternate
  • Variable Cost
  • Labor Cost
  • Number of Pooled Resources to use
  • Load Percentage
  • Operation Maximum Time Gap
  • Sub Resource Shift
  • Sub Resource Shift Unit of Measure

Sequence Dependent Setup Time

  •  Attribute Name
  • Attribute Description
  • Setup Time
  • Attribute Order
  • Sort ASC
  • Sort Type

In every situation we work with the client to determine the very best solution to meet their unique operating environment. We would never expect a client to have to read a list like that above and figure out how to get the desired results. It would be akin to visiting your doctor with an ailment and he tells you to find and read the appropriate book from his expansive library. We are there offering professional support.

 
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