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A Journey from Unconstrained to Constrained:. Implementing Manufacturing Scheduling and ASCP. At a Glance. Global leader providing mission critical time and frequency solutions Headquartered in San Jose, CA. Offices throughout the US, as well as the United Kingdom, Germany and Malaysia - PowerPoint PPT Presentation
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Kevin A. BrownSenior Business Analyst2006 NorCal OAUG Training [email protected]
A Journey from Unconstrained to Constrained:Implementing Manufacturing Scheduling and ASCP
At a Glance Global leader providing mission critical time and
frequency solutions
Headquartered in San Jose, CA.
Offices throughout the US, as well as the United Kingdom, Germany and Malaysia
Manufacturing in SF Bay Area, Massachusetts and Puerto Rico
FY05 revenue $181M
~800 employees
Markets We Serve
Government Communications
Space, Defense and Avionics
Enterprise and IT Networks
WirelineNetworks
Wireless Networks
A Sampling of Customers
Telecom
Government
Enterprise
Oracle Environment
Hosted by Oracle On Demand
E-Business Suite 11.5.10 CU1
Dell Servers running Red Hat Linux
Live since June 2001
Oracle Modules Financials
• AR• AP• GL• Projects• FA• Time&Labor• iExpense
Procurement• PO• iSupplier• iProcurement
Manufacturing• INV• WIP (Discrete)• ENG• BOM• MRP
Order Mgmt/CRM• OM• TeleService• Contracts
Miscellaneous• HR• ICM
Project Madison
Overall Project Goal• Project Madison will implement three distinct yet
interdependent modules of Oracle: Manufacturing Scheduling, Advanced Supply Chain Planning and Global Order Promising
Primary Project Goal• Provide accurate Ship Dates to our customers
quickly
Project Madison
Initial Rollout in our Aguadilla, PR facility• Includes about 80% of production
Focus on ASCP and Manufacturing Scheduling First• Fine tune GOP once ASCP and MS are stable
Use Internal Resources Primarily• Gain a deep understanding of products and
processes• Less Expensive• Longer Project Timeline
Selling It
Problem Mfg Scheduling ASCPSupply/Demand across organizations not visible in one screen (see total supply/demand for all orgs) XNo short-term resource capacity planning X XNo long-term resource capacity planning XMust open multiple MPS or MRP workbenches to release orders for multiple orgs X
Operations Challenges
Project Challenges
Dirty Data• PO & WO Dates not Maintained• Sales Order Ship Dates not Maintained• Short Orders Left Open (PO and WO)• Inaccurate Lead Times• Scrap not Scrapped
Systems and Application Issues Team Resources Change Management
Keys to Capacity Planning
Accurate Routings
Accurate Capacity for Machines and People
Routing Update
Existing Routings Primarily Supported Costing• Only contained Human Resources• Used “Transit” resource to simulate extended
machine time• Resources and Departments used legacy
nomenclature
Sample Routing Here
Routing Update
Rules of Engagement• Don’t Change Standard Costs• Don’t Interrupt WIP
Complex Process Steps to Model• Test Operations• Operator Attended and Autonomous Processes• Shared Resources• Batchable Resources• Variable Process Times
Routing Update
Example:
Test Fixture Example Here
Routing Update
>1000 Routings to Update• Map Old Depts and Resources to New Depts and
Resources• Insert Appropriate Machine Resources• Evaluate Scheduling Sequence for Depts with
People and Machines
Prioritization• Items Averaging > 1 Job per Month• Items with Planned Orders
Routing Update
Keeping Things Simple• All Updates Made on Spreadsheets
Item Seq Op. Desc.Dept Resource BasisUsage Inverse 24 HrsDisableSch SeqAssigned UnitsSched Std Rate46162 50 STAGE KITT050 T050 ITEM0.0001 10000 NO Y 0.04 YES YES46162 50 STAGE KITT_STAGE/ KT STORE ITEM0.0001 10000 NO 0.04 YES YES46162 150 SMT T160 T160 ITEM0.0583 17.15 NO Y 0.04 YES YES46162 150 SMT T_SMT MACH OP 2 ITEM0.0583 17.15 NO 10 0.04 YES YES46162 150 SMT T_SMT SMT 0.0583 1046162 300 2ND OP T350 T350 ITEM0.0666 15.02 NO Y 0.04 YES YES46162 300 2ND OP T_2ND OP ASSY 2 ITEM0.0666 15.02 NO 0.04 YES YES46162 999 QA T850 T850 ITEM0.0166 60.24 NO Y 0.04 YES YES46162 999 QA T_QA QA ITEM0.0166 60.24 NO 0.04 YES YES
Routing Update
More Simplicity• Use Standard Interface Tables and Processes• Insert Statements Created Using MS Word Mail
Merge Functionality -- to add new resourcesinsert into bom_op_resources_interface(RESOURCE_SEQ_NUM,ASSIGNED_UNITS,USAGE_RATE_OR_AMOUNT,SCHEDULE_FLAG,OPERATION_SEQ_NUM,ORGANIZATION_CODE,ASSEMBLY_ITEM_NUMBER,RESOURCE_CODE,SCHEDULE_SEQ_NUM,basis_type,EFFECTIVITY_DATE,PROCESS_FLAG,TRANSACTION_TYPE)values(10,1,0.001,1 -- need 1 or 2, 50,‘PRT',‘TT-T654/RB/GPS','STORE',NULL, 1 -- basis_type,to_date('07-SEP-2005','DD-MON-YYYY')+1/24/60,1 -- process_flag,'CREATE');
Production Cutover
Challenges• Lots of Work in Process• Reporting• Scheduling Process During Transition
The Plan• Leave WIP Alone (for now)• Ensure All New Jobs have Updates Routings• Tweak Capacity to Create ‘WIP Resistance’• After X Weeks Update any Open Jobs with Old
Routings
Open Issues
Production Control Reorg??• Currently Personnel Segregated by Product Family
Maintaining Capacity
Fine Tuning• Mfg Sched Time Fence vs. ASCP Time Fence• Use of Penalties• Capacity/Usage/Assigned Units
Lessons Learned
Separate Project for Routing Update
Allow Time for WIP to Fill with Updated Routings
Emphasize Clean and Well Maintained Data
Expect and Allow Changes to Standard Costs
What We Did Right
Used Mostly Internal Resources
Completely Revamped Routings
Started in Largest Plant
Questions?