General scheme of production management-

Introduction to COSMOS Tooling

Plan

Working capital : Construction of production efficiency

Planning and Gantt chart

o Business Predictive Management

o Predictive Management : CBN, MRP, MRPII

o Synthesis : optimizations / risks

o Comparative

Summary MRPII COSMOS (1, 2 and Impact on the working capital)

Working capital

The production efficiency is characterized by the significant reduction in the financial immobilizationattached to each production by the combined action of :

A cost price calculated at the fairest. An optimization of the supplier item (price / time negotiation). An optimization of the customer item (billing and collection). An intelligent mechanism for scheduling supplies and manufacturing :

o The material and accessories supplies must be adjusted as closely as possible to theiruses (D-1 of the beginning of consumption).

o The availability of catalog products closer to commercial demand ( à D-1 of CMP* ).o Minimizing waiting times between each manufacturing stage (sequencing and overlap),

the productions must leave the workshops as quicly as possible.

* CMP : Commercial Master Plan

Planning and Gantt Chart

Planning is a process that sets after studies and prospective reflection, the objectives to be achieved, the core and necessary means, the stages of realization.

Gantt Diagram is a tool that visualizes in time the various tasks composing for one or more projects. It is a graphical representation of a connected tasks and intermediate realizations, evaluated and mesuared, wich makes it possible to graphically represent the scheduling.

Planning and Gantt Chart

Planning and Gantt Chart

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Two levels in production management

The company level where the lighting is put on the whole of the resources of production :

Business Predictive Management

Workshop level with focus on production lines in operation :

Operational management workshop

Business Predictive ManagementTemporality : - short term -

It is an essential phase for the organization of the plant, the whole of the resources is analyzed with astarget the best global scenario of production. Calculations often cover a horizon of several months, thefrequency of treatment is generally dependent on the firm periods for which the activity of the workshopsis fixed.

Operational management workshopTemporality : - daily -

This is a real-time monitoring of the activity of all resources mobilized at a time T. The actors, sectormanagers and operators on the production lines, ensure the continuity of production by avoiding supplydisruption at the manufacturing stages that follow. The imponderables are managed to the best of thepossibilities of the moment.

Planning and Gantt Chart

Planning and Gantt Chart

Forecast and operational management

Most of the computer tools that take advantage of a « Planning & Gantt » function apply to theoperational phase in the workshop. In this context, the forecast phase is usually satisfied with aCBN calculation (calculation of the net requirements for material sourcing and manufacturing ofcomponents an finished products).

Some software products on the market offer a forecast phase based on a MRP or MRP II process.Both techniques include a temporal approach of the needs, essential information that is notdelivered by the CBN.

• MRP is improved CBN that temporally locates the needs from a standard capacity of eachresource needed regardless of availability.

• MRP II is an enhancement of MRP that provides an allocation of manufacturing resourcesaccording to all their capabilities.

Planning and Gantt Chart

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Synthesis : optimizations / risks

Planning and Gantt Chart

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summary

The MRPII in the forecast phase is therefore the most complete tool to ensure optimaloutput of production resources with reduced risks to imponderables and let situationunder control.

It must imperatively rely on the knowledge of the complete context of theproduction :

By a detailed description of the manufacturing processes By an exhaustive inventory of available resources By knowing the assignment possibilities through the different calendars attached to

the company and each resource or group of resources.

Planning and Gantt Chart-

Comparative

Planning and Gantt Chart

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Summary MRPII COSMOS

(1/2)

The COSMOS MRPII benefits from a mechanism totally dedicated to its main functionof « operational research » for the workshops gathered by site and betweencollaborative sites of production.

It is the first product on the market to extend its field of calculation to additionalfunctionalities impacting its own results :

Adaptation the capacity to the charge Maintenance interventions Production lines managed in Kanban

Its computation time performance allows it to be submitted at any time to the requestsof the operational and help them to make the best choices regarding the occurrence ofimponderables that make sometimes the daily of sectoral leaders reality.

Planning and Gantt Chart

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Summary MRPII COSMOS

(2/2)

The COSMOS MRP II , by its capacity to organize production, allows the simulation of amulti-year production and determines the forecast needs of each committed resource.

The results show up :

The utilization rate of each internal and external resource, and by deduction theirextension if necessary.

The volume of materials, products components and finishes. The average intensity of variable activity resources The manpower by qualification required The volume of operations of maintenance and the replacement of tools at the end of

their life. …

Planning and Gantt Chart

Impact on the working capital

Combined at : A cost price calculated in the most fair way. An optimization of the supplier item (price/time negotiation). And an optimization of the customer item (billing and collection).

COSMOS significantly reduces the financial immobilization attached to each production :

o The materials and accessories supplies are adjusted as closely as possible to their uses (D-1 of thebeginning of consumption),

o The availability of the products in the catalog are as close as possible to the commercial demand (at D-1of CMP* ).

o The waiting times between each production stage (linking and overlapping) are reduced to theirmaximum, the productions leave as quickly as possible from the workshops.

Estimated financial gains : 40 à 60%

* COM : Commercial Master Plan