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WHEEL OF FORTUNE
Operational Benefits of Product Wheel
Scheduling
Peter L. King – Zinata
Alan Nall - Zinata
2 #APICS2017
APICS 2017 Session Evaluation
Visit www.apics.org/Mondayor
download the APICS2017 app
3 #APICS2017
BS Electrical Engineering – Virginia Tech
DuPont Company – 42 years
R & D – 9 years
Project management – 15 years
Lean manufacturing & supply chain consulting – 18 years
Lean Dynamics – 2007 to present
Consult with companies in process industries
Zinata – 2014 to present
Consult on Product Wheel design/implementation , Value Stream Mapping
Lean for the Process Industries – Productivity Press, 2009
The Product Wheel Handbook – Productivity Press, 2013
Value Stream Mapping for the Process Industries
– Productivity Press, 2015
Several articles in IE Magazine, APICS Magazine, Target (AME)
Frequent speaker at IIE, APICS, ASQ, OpEx conferences
PETER L KING [email protected]
4 #APICS2017
Why Product Wheels?
Product Wheel concept
Wheel Design Basics
Case study - vitamin pill packaging
Making it real – simplifying daily operation
Other prominent Product Wheel users
Q & A
AGENDA
5 #APICS2017
are caused by processes
outside the plant floor
IT HAS OFTEN BEEN SAID THAT …..
75% of the problems on the plant floor
6 #APICS2017
Production scheduling is often based on what needs to be
produced within the next planning period
Without any view of the full manufacturing system
Without an understanding of the full product line-up
Therefore opportunities for optimization are often missed
Opportunities to standardize schedules
Opportunities to standardize sequences
Opportunities to simplify changeovers
Opportunities to optimize frequency of low volume items
PRODUCTION SCHEDULING IS OFTEN THE
CULPRIT
7 #APICS2017
PRODUCT WHEELS
Allow you to optimize production scheduling
In an integrated, holistic design process
In a way that has enabled major manufacturers to save millions $$
Higher throughput – higher revenue
Reduced inventories – reduced working capital
Improved customer service performance
– increased market share
With increased stability – reducing the chaos
With increased predictability – better forward planning
THE SOLUTION
= $$
8 #APICS2017
PRODUCT WHEEL CONCEPT
A
C
B
D
E
FG
H
I
JK
PRODUCTS (SPOKES)
CHANGE-OVERS
A regularly repeating
sequence of the production of
the various products
The overall cycle time is fixed
o The cycle time is optimized
based on business
priorities
The sequence is fixed
o The sequence is optimized
for minimum changeover
loss (time or material)
9 #APICS2017
PRODUCT WHEEL CONCEPT
51381
19852
30282
13045
55347
3268913775
57601
30173
45211
53181
19955
380913412
46077
4162855412 19097 53124 53125 53129
LINE 3 - CYCLE 1
Spokes can have different lengths, based on the Demand for each product
The amount actually produced can vary from cycle to cycle, based on actual consumption
Some low-volume products may not be made every cycle
When they are made, it’s always at the same point in the sequence
Make-to-order and Make-to-stock products can be intermixed on a wheel
10 #APICS2017
ONE CYCLE,
ONE REVOLUTION
A
B
CD
E
F
G
H
BREATHINGROOM
PRODUCT A
PRODUCT F
CHANGEOVER
SPOKE,
. CAMPAIGN
CHANGEOVER
BATCHES
WHEEL TIMEPRODUCT WHEEL CONCEPT
11 #APICS2017
Product wheels can be applied to a single major piece
of process equipment
A resin reactor
A paint mixer
A vitamin tablet compression machine
A ketchup homogenizer
Or to an entire line
A shampoo bottling line
A potato chip packaging line.
PRODUCT WHEEL APPLICABILITY
12 #APICS2017
Product wheels support a Pull replenishment system
Each spoke is designed based on average historical demand
or on the forecast
What is actually produced on any spoke is just enough to
replenish what has been consumed from inventory
Low volume products won’t be made unless needed
Product wheels can be employed in a Make-to-Stock
(MTS) or a Make-to-Order (MTO) environment
MTS and MTO products can be made on the same wheel
PRODUCT WHEEL APPLICABILITY
13 #APICS2017
PRODUCT WHEEL
DESIGN
𝐸𝑂𝑄 = 2 ∗ 𝐶𝑂𝐶 ∗ 𝐷
𝑉 ∗ 𝑟 ∗ (1 − 𝐷𝑃𝑅
)
14 #APICS2017
PRODUCT WHEELS ARE BASED ON A
THOROUGH ANALYSIS OF …
Frequency
Lot Size
1 Car/Day
190 K #
Transp time 7 Days
SUPPLIER 1
SUPPLIER 2
SHEET CASTING
(3)
SLITTING
(3)
BONDING
(HEAT TREATING)
(3)
INSPECTION
(1)
WRAPPING
PACKAGING
LABELING 3 233
6
Order Lead Time
# SKUs
1 Week
4
Order Lead
Time
# SKUs
1 week
6
Invtry
Days
# SKUs
8.9 M #
50
2,000
Invtry
Hours
# SKUs
60 K #
8
1000
Invtry
Days
# SKUs
2.6 M#
15
100
Invtry
Days
# SKUs
3 M#
16
50
Invtry
Days
# SKUs
1.2 M #
5.6
6
CUSTOMERS,
DISTRIBUTORS
Quantity/time
TAKT
5.4 M #/Mo
7.5 K #/Hr
Lead time Exp 4 Days
Frequency
Lot Size
5 Trucks/Day
36 K#/Truck
Transp time 2 Days
Eff Capac 10.6
8.3TAKT
Utilization 78%
15 MinLead time
Yield 93%
85%Reliability
OEE 73%
50# SKUs
Batch size 1 roll
9 daysCYCLE
C/O time 1 hr
1 RollC/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
K #/Hour
Eff Capac 13.8
8.1TAKT
K #/Hour
Utilization 59%
18 MinLead time
Yield 98%
82%Reliability
OEE 74%
100# SKUs
Batch size 1 roll
13 daysCYCLE
C/O time 45 Min
~ 0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
Eff Capac 8.25
7.5TAKT
K #/Hour
Utilization 91%
15 MinLead time
Yield 92%
72%Reliability
OEE 55%
1000# SKUs
Batch size 1 roll
7 daysCYCLE
C/O time 5 Min
~ 0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
Eff Capac 18
7.5TAKT
Utilization 42%
6 minLead time
Yield 100%
100%Reliability
OEE 100%
1000# SKUs
Batch size 1 Slit Roll
N/ACYCLE
C/O time 0
0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
K #/Hour
Eff Capac 36
7.5TAKT
Utilization 21%
8 MinLead time
Yield 100%
70%Reliability
OEE 70%
2000# SKUs
Batch size 1 Slit Roll
N/ACYCLE
C/O time 0
0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
K #/Hour
Max Demo
Rate14.5
Max Demo
Rate18.6 Max Demo
Rate15
Max Demo
Rate18
Max Demo
Rate51
RAIL
CARS
Your process as an integrated system
15 #APICS2017
PRODUCT WHEELS ARE BASED ON A THOROUGH ANALYSIS OF …
ITEM FCST AVERAGE TABLET COLORBOTTLE
SIZEBOTTLE TYPE DESSICANT #
BOTTLE
COLOR
HOURS PER
MONTH
HOURS
PER 2
WEEKS
HOURS
PER
WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR 73.6 36.8 18.4
AB302 49303 N/A 500CC SHORT-PET D546 CLEAR 35.6 17.8 8.9
AB206 52234 N/A 500CC SHORT-PET NONE CLEAR 33.0 16.5 8.2
AB203 12447 N/A 400CC PET NONE LT BROWN 6.8 3.4 1.7
AA105 9500 N/A 400CC PET NONE LT BROWN 4.8 2.4 1.2
AC101 25796 N/A 400CC PET NONE GREEN 23.7 11.8 5.9
AD401 32821 WHITE 400CC PET NONE GREEN 22.7 11.4 5.7
AD221 41221 N/A 400CC PET NONE YELLOW 20.8 10.4 5.2
AC301 29888 N/A 400CC PET NONE YELLOW 20.7 10.3 5.2
AC201 27207 N/A 400CC PET NONE YELLOW 18.1 9.0 4.5
AB205 12792 N/A 400CC PET NONE YELLOW 7.0 3.5 1.8
AA101 3200 N/A 400CC HDPE NONE LIME 3.1 1.6 0.8
AA104 6462 N/A 400CC HDPE NONE LIME 7.8 3.9 1.9
AA103 5247 N/A 400CC HDPE NONE LIME 5.1 2.5 1.3
AA102 3407 N/A 400CC HDPE NONE LIME 3.3 1.7 0.8
AB207 25262 N/A 400CC HDPE NONE EGGSHELL 16.8 8.4 4.2
AD201 33992 N/A 400CC HDPE NONE BLUE 40.9 20.4 10.2
AC441 44016 N/A 400CC HDPE NONE BLUE 30.5 15.2 7.6
Your product line-up as an
interrelated group of things
with varying degrees of
similarity
16 #APICS2017
PRODUCT WHEEL DESIGN
Step 1 - Decide which assets would benefit
17 #APICS2017
SHEET FORMING VIRTUAL CELL GROUPING
Packaging
Roll Forming Machine 1
Roll Bonder 1
Chopper 1
Roll Forming Machine 2
Roll Forming Machine 3
Roll Forming Machine 4
Roll Bonder 2 Roll Bonder 3 Roll Bonder 4
Roll Slitting Machine 2
Roll Slitting Machine 3
Chopper 2
Chopper3
Packaging
CELL 1CELL 2
CELL 3
CELL 4
Roll Slitting Machine 1
18 #APICS2017
ASSETS THAT MIGHT BE SCHEDULED BY
PRODUCT WHEELS
Frequency
Lot Size
1 Car/Day
190 K #
Transp time 7 Days
SUPPLIER 2
SHEET CASTING
(3)
SLITTING
(3)
BONDING
(HEAT TREATING)
(3)
INSPECTION
(1)3 2
36
Order Lead
Time
# SKUs
1 Week
4
Invtry
Hours
# SKUs
60 K #
8
1000
Invtry
Days
# SKUs
2.6 M#
15
100
Invtry
Days
# SKUs
3 M#
16
50
Invtry
Days
# SKUs
1.2 M #
5.6
6
Eff Capac 10.6
8.3TAKT
Utilization 78%
15 MinLead time
Yield 93%
85%Reliability
OEE 73%
50# SKUs
Batch size 1 roll
9 daysCYCLE
C/O time 1 hr
1 RollC/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
K #/Hour
Eff Capac 13.8
8.1TAKT
K #/Hour
Utilization 59%
18 MinLead time
Yield 98%
82%Reliability
OEE 74%
100# SKUs
Batch size 1 roll
13 daysCYCLE
C/O time 45 Min
~ 0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
Eff Capac 8.25
7.5TAKT
K #/Hour
Utilization 91%
15 MinLead time
Yield 92%
72%Reliability
OEE 55%
1000# SKUs
Batch size 1 roll
7 daysCYCLE
C/O time 5 Min
~ 0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
Eff Capac 18
7.5TAKT
Utilization 42%
6 minLead time
Yield 100%
100%Reliability
OEE 100%
1000# SKUs
Batch size 1 Slit Roll
N/ACYCLE
C/O time 0
0C/O loss
Avail time 168 hr/wk
3 x 8 x 7Shift schd
K #/Hour
Max Demo
Rate14.5
Max Demo
Rate18.6 Max Demo
Rate15
Max Demo
Rate18
RAIL
CARS
19 #APICS2017
Step 2 - Analyze product demand variability
– consider MTO vs MTS
PRODUCT WHEEL DESIGN
20 #APICS2017
ANALYSIS OF DEMAND VAIABILITY –
PRODUCTS ON SHEET CASTING LINE 1
PRODUCT
WEEKLY
DEMAND
D (Rolls)
sD
(Rolls)
COEFFICIENT of
VARIATION CV
= sD/D
A 150 30 0.20
B 120 20 0.17
C 75 24 0.32
D 15 6 0.40
E 14 6 0.43
F 12 5 0.42
G 8 6 0.75
H 6 3.6 0.60
21 #APICS2017
AVERAGE DEMAND
22 #APICS2017
VARIATION IN DEMAND
23 #APICS2017
DECISION MATRIX –
VOLUME VS DEMAND VARIABILITY
B
A
C
G
D
E
H
F
MAKE TO ORDER (MTO) MTO? MTS?
MAKE TO STOCK (MTS)
MTO? MTS?
PRODUCT DEMAND
PR
OD
UC
T V
AR
IAB
ILIT
Y
24 #APICS2017
PRODUCT WHEEL DESIGN
Step 5 - Calculate the most economic wheel time
25 #APICS2017
Step 5 - Calculate the most economic wheel batch size
𝐸𝑂𝑄 = 2 ∗ 𝐶𝑂𝐶 ∗ 𝐷
𝑉 ∗ 𝑟 ∗ (1 − 𝐷𝑃𝑅
)
Where
COC = Changeover Cost D = Demand per time period V = Unit cost of the material r = % carrying cost of inventory per time period PR = Production rate in units per time period.
PRODUCT WHEEL DESIGN
26 #APICS2017
0
2000
4000
6000
8000
10000
12000
14000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
TOTAL
COST
CHANGE-OVER
COST
INVENTORY
COST
CAMPAIGN LENGTH = WHEEL TIME
CO
ST
ECONOMIC ORDER QUANTITY – EOQ - CONCEPT
ECONOMIC
ORDER
QUANTITY
27 #APICS2017
OTHER FACTORS ….
Shelf life, obsolescence
Demand variability
Minimum lot size
28 #APICS2017
7. Determine the optimum sequence
PRODUCT WHEEL DESIGN
PRODUCTSHEET
WIDTH
BASIS
WEIGHT
POLYMER
TYPE423 J 12 3 J
403 L 10 3 L
403 J 10 3 J
423 L 12 3 L
426 J 12 6 J
406 R 10 6 R
406 L 10 6 L
426 R 12 6 R
406 J 10 6 J
409 L 10 9 L
409 J 10 9 J
489 J 8 9 J
429 L 12 9 L
489 R 8 9 R
489 L 8 9 L
429 R 12 9 R
PRODUCTPOLYMER
TYPE
SHEET
WIDTH
BASIS
WEIGHT489 J J 8 9
403 J J 10 3
406 J J 10 6
409 J J 10 9
423 J J 12 3
426 J J 12 6
489 L L 8 9
403 L L 10 3
406 L L 10 6
409 L L 10 9
423 L L 12 3
429 L L 12 9
489 R R 8 9
406 R R 10 6
426 R R 12 6
429 R R 12 9
29 #APICS2017
PRODUCT WHEEL DESIGN
Step 9 - Revise the scheduling process
Whatever production planning and
scheduling system the operation is using
SAP
Oracle
MIMI
Manugistics
Excel
Etc.
must be coordinated with the product
wheel design
30 #APICS2017
NATURE’S BOUNTY
VITAMIN PACKAGING
31 #APICS2017
Leading manufacturer/packager of vitamin tablets,
capsules, and gelcaps
Revenue ~ $3B
Five major manufacturing plants
Four packaging operations
32 #APICS2017
One of four NBTY packaging operations
700 packaged products
Several packaging lines
As many as 14 parameters may change
on any changeover
Bottle diameter
Bottle height
Allergen content
Cap type
Tablet coating
Etc.
DEERFIELD BEACH PACKAGING
33 #APICS2017
BLUE LINE
RACK
LOCATIONS
(24 HRS TO SEVERAL
WEEKS)
BULK
SUPPLYING
SITE
WORK ORDER
INFORMATION TO
COMPUTER TERMINAL ON
MEZZANINE
RAW MATERIAL
ORDERS TO MEET
NEEDS FOR NEXT 12
MONTHS
CAN GO TO ONE OF
SEVERAL PLACES
BASED ON THE
PROBLEM FOUND
BATCH PACKET
WORK ORDER HAS BEEN COMPLETED
(from all lines)
3PL
– MONTHS
BULK INVENTORY
1111
WAREHOUSE
(UP TO 3 MONTHS
OF INVENTORY)
PALLET TAG
PROCESS THE WORKBENCH
CHECK BULK, IFCs, LABELS, TRAYS, INSERTS, SHIPPERS
CAN I DO IT? MOVE TO OPEN ORDER
CAN T DO PUT A REASON ON WORKBENCH
PACKAGING LINE
TELLS GATE
KEEPER TO
RETURN
COMPONENTS
950cc
Can overwrap
Cannot bundle
COMPONENT
INVENTORY
SCHEDULER ASSIGNS EACH W.O. TO A PKG LINE
SCHEDULER WILL PUT IN THE SEQUENCE
ORDERS CAN BE PUT ON HOLD IF ALL MAT L NOT
AVAILABLE
A PLANNER CAN ENLARGE AN
ORDER TO CONSUME A
COMPLETE BULK LOT
RED LINE
CAPSULE
WORKS
DEERFIELD BEACH
VALUE STREAM MAP
Ver 10, MAY 30, 2016
SOLGAR
(N.J.)
BOTTLE
SUPPLIERS
CAP
SUPPLIERS
BLACK LINE
WHITE LINEHAZELTON,
PA
D.C.
SPRKS, NV
D.C.
BOCA RATON,
FL
D.C. 1297
DEMANTRAASCP
APS
AS 400PLANNER
PROCUREMENT
PLANNING
BOTTLES, CAPS,
CORROUGATED
THE BRAND:
COMMERCIAL,
MARKETING
SHIPMENT HISTORY
MARKET INTELLIGENCE
CURRENT ORDERS
FORECASTS
PROMOS & DISPLAYS
DEMAND
CONSENSUS
FORECAST
INVENTORY TARGETS
CURRENT INVENTORIES
BOMs
CYCLE TIMES (WHEEL TIMES)
CYCLE TIME INTERVALS
LEAD TIMES FOR EVERY
ROUTING
PLANNED ORDERS
FOR NEXT
12 MONTHS
BULK ORDERS
FOR NEXT
12 MONTHS
ORDER PRINTED COMPONENTS
LABELS
IFCs
SPECIAL PACKAGING
TRAYS, COUPONS, ETC.
(LOGIC SOURCE)
CREATE
WORK ORDERS
AS 400 CHECKS BULK
AVAILABILITY AND LABELS
AND IFCs BEFORE
ALLOWING WORK ORDER TO
BE CREATED
SCHEDULER
BUYS
BOTTLES, CAPS,
CORROUGATED
LABEL ROOM
OPEN WORK
ORDERS
SCHEDULE
PINK LINE
ORANGE LINE
BOCA RATON
ORVILLE ROAD
CAMPUS
YELLOW LINE
2145
RONKAKOMA
GARDEN
GROVE
NBTY – CHINA
PLUS OUTSIDE
SUPPLIERS
IFCs
Heavily utilized, 92%
Gold Line is backup
Ordered by the
Advertising Team
SCHEDULER
REQUESTS BULK BE
MOVED FROM LOCAL
WAREHOUSE TO ON-
SITE STORAGE
BROWN LINE
GREEN LINE
GRAY LINE
LAVENDER
LINE
– 120cc
Fish Oils, 500 – 750cc
Can overwrap
– 150cc
Twin Packs
< 250cc
150cc &150cc-t
– 950cc
Can overwrap
400cc – 750cc
Can overwrap
150cc-t, 200cc, 300cc
Can overwrap
3 - 6 Months
< 1 Hour
1 - 8 Weeks 6 Hours 24 Hours1 - 2 Hours
YENNY TRIGGERS
THIS VIA A GTS
ASCP TRIGGERS BULK PRODUCTION
(From the Consensus Forecast, Current
Inventories, Planned Orders, etc.)
ASCP WORKBENCH
PLANNED ORDERS FOR NEXT
TWO WEEKS
REGENERATED WEEKLY
NEXT TWO WEEKS ORDERS
SHOULD INCLUDE PRODUCTION
NEEDED OVER COMPLETE
CYCLE INTERVAL DATA
VALIDATION
PROCESS
ERROR
LOG
PWT
SCHEDULER
OPEN WORK
ORDERS
NOTIFICATION THAT AS-400
HAS ACCEPTED THE
FIRMED ORDERS
FIRMED
ORDERS
REQUEST
BULK NEEDED
OVER NEXT 24
HRS
SCHEDULER
(YENNY)
STRETCH
WRAPPING
AREA
TRUCK LOADING
STAGING AREA
24 HOUR MAX
COPACKERS
& OTHER NBTY SITES
OFF-LINE
REWORK
BIG
OPPORTUNITY
(FROM ANY
PACKING LINE)
POMPANO
(OVERFLOW FOR 1111 OR 3PL)
INVENTORY ` 1 MONTH
SOME BULKS TO NY
PTRE-STAGING
(IN WAREHOUSE)
2 WORK ORDERS
~ 2.5 hr
STAGING
(AT BACK OF LINE)
3 WORK ORDERS
~ 4 hr
SHIPPER
SUPPLIER
PALLET
SUPPLIER
TRAY
SUPPLIER
LABELS
IFCs
SLEEVES
SUPPLIERS
# = 3
Inv = ~ 1 day
Lead Time = next day
# = 20
Inv = ~ 1 month
Lead Time = 6 weeks
# = 60+
Inv = ~ 3 – days
Lead Time = next day for some
6 weeks for Tray Shippers
(ordered by NY)
IFC # = 58
LABEL # = 600?
SLEEVE # = 12
Inv = ~ 3 months
Lead Time = 6 weeks
BOTTLE # = 54
Inv = ~ 1 - 3 days
Lead Time = 8 – hours
CAP # = 40
Inv = ~ 7 days
Lead Time = 8 – hours
QUALITY
DEPARTMENT
AS-400
BILL OF LADING
MATERIAL IS
RELEASED
GATE
KEEPER
SCHEDULE
TRANSACTIONS
COMPONENT
REPLENISHMENT
FOR REXALL WORK ORDER
PICK LIST
DC IS
IDENTIFIED
AS 400
PALLET BY PALLET
CLOSINGS
WORK ORDER
HAS BEEN
COMPLETED
(FROM ANY
DC)
DOCUMENTATION
ERRORS
10 Trucks / Week
2 Trucks / Week
10 Trucks / Week
60 - 80 Trucks / Week
INITIATE
MATERIAL
MOVEMENT
INTO PRE-
STAGING AND
INTO STAGING
LABELS &
SLEEVES
IFCs
GOAL IS TO STORE
GARDEN GROVE BULK
IN 1111 RATHER THAN
3PL TO REDUCE COST
COMPONENT
RETURN
AREA
UNUSED
COMPONENTS
M
E
Z
Z
A
N
I
N
E
BOTTLES
SEND MASTER
FOR LABELS
WORK
ORDER
WORK
ORDER
FIRM UP ORDERS
INITIATE BULK
TRANSFERS TO
FLORIDA
– 250cc
GTS
(General Transfer
System
transaction)
1111 + 3PL +
POMPANO
RACK
LOCATIONS
PRE-STAGING
AND STAGING TOTAL CYCLE TIME
FOR ONE BOTTLE
WAITING AT END OF LINE PLUS
LIFT TRUCK TRANSPORTATION
PACKAGING LINE TO STRETCH WRAPPER
STAGING AND TRUCK LOADING
WHY
PRE-STAGE?
REDUCE
3PL
STORAGE
INVENTORY
ACCURACY
NEED
STANDARD
SPECS
REDUCE
PSDs
MOVES
MIS-
TRACKED
LABELER
DATE CODES
MANUAL INPUT
CREATES
ERRORS
DEERFIELD VALUE STREAM MAP
34 #APICS2017
PRODUCT ALLOCATION CONCEPT
PACKING #1
BREATHING ROOMPACKAGING LINE 2
BREATHING ROOMPACKAGING LINE 3
TIME
REPRESETATIVE OF 700 SKUs
BREATHING ROOMPACKAGING LINE 1
BREATHING ROOMPACKAGING LINE 4
BREATHING ROOMPACKAGING LINE 5
35 #APICS2017
STEP 1- PRODUCT GROUPING & ALLOCATION TO SPECIFIC LINES
Data shown is for illustration only and is not actual
ITEMFORECAST
AVERAGEBOTTLE SIZE
BOTTLE
TYPE
BOTTLE
COLOR
CAP
TYPECAP SIZE CAP COLOR BUNDLE QTY ALLERGEN
TABLET
COLOR
DESS
ICANTSIZE RUN RATE
AA356 22726 750cc PET ORNG CRC 53MM ORNG 6 D,U ORANGE NONE 500 20
AA378 18064 750cc PET ORNG CRC 53MM ORNG 6 NE,U N/A NONE 325 60
AA427 25331 750cc PET ORNG CRC 53MM ORNG 6 NE,U N/A NONE 500 50
AA502 62341 250cc PET ORNG CRC 53MM ORNG 6 NE,U WHITE 22-5700 500 50
AA503 52555 500cc PET ORNG CRC 53MM ORNG 6 NE,U WHITE 22-5700 500 50
AA532 16420 750cc PET ORNG FLIP 53MM ORNG 6 SE,NE,U BROWN NONE 500 50
AA756 14228 750cc PET ORNG CRC 53MM ORNG FULL WRAP NE,H,U GREEN 22-5700 375 50
AB112 1085 250cc HDPE SKY BLUE FLIP 45MM WHITE 3 OR NONE SE,NE,U N/A 22-5700 200 100
AB204 10301 750cc PET ORNG FLIP 53MM ORNG 6 SE,NE,HE,U ORANGE NONE 400 50
AB212 1058 200cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE SE,NE,U ORANGE NONE 400 100
AB306 2193 750cc HDPE BRN STD 53MM WHT 6 SE,NE,F,U N/A 22-5700 320 60
AB434 1018 250cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE U WHITE 22-5700 180 40
AC302 1166 250cc PET SKY BLUE FLIP 45MM WHITE 3 OR NONE SE,NE,FM,U PINK 22-5700 200 100
AC442 1103 200cc PET SKY BLUE CRC 45MM ORNG 6 NONE N/A NONE 120 40
AC518 1108 250cc HDPE SKY BLUE FLIP 45MM ORNG 6 SE,NE,LT,U PINK NONE 200 100
AC568 1991 250cc PET SKY BLUE FLIP 45MM WHITE 3 OR NONE SE,NE,U N/A NONE 200 100
AD256 1912 200cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE S,U WHITE NONE 120 40
AD348 1455 200cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE SE,NE,F,U N/A 22-5700 150 40
AD442 577 500cc PET BRN CRC 53MM BRN 6 SE,NE,F,U N/A NONE 250 100
AD512 1406 200cc HDPE ORNG FLIP 45MM WHITE 3 OR NONE SE,NE,U N/A 22-5700 130 40
AF244 1364 750cc PET ORNG CRC 53MM ORNG 3 OR NONE SE,F GREEN NONE 300 60
AF351 1235 750cc PET BRN CRC 53MM BRN 6 SE,F,U COBALT 22-5700 400 50
CHANGEOVER CRITERIA SORT PRIORITY
Bottle size 1
Bottle type 2
Allergen content 3
Cap type 4
Cap size 5
Bottle color 6
Dessicant 7
36 #APICS2017
REDUCTION IN BOTTLE COUNT PER LINE
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 11 12 13
REDUCTION IN BOTTLE SIZES RUN ON EACH LINE
TRADITIONAL BOTTLE COUNT JULY ALLOCATION
“Just this gave us 3 – points of OEE improvement!”
- Jaci Souza - Packaging Director – Nature’s Bounty
37 #APICS2017
DETERMINING THE:
WHEEL CYCLE TIME
FREQUENCIES FOR LOW VOLUMES
OPTIMUM SEQUENCES
38 #APICS2017
ITEM FCST AVERAGE TABLET COLORBOTTLE
SIZEBOTTLE TYPE DESSICANT #
BOTTLE
COLOR
HOURS PER
MONTH
HOURS
PER 2
WEEKS
HOURS
PER
WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR 73.6 36.8 18.4
AB302 49303 N/A 500CC SHORT-PET D546 CLEAR 35.6 17.8 8.9
AB206 52234 N/A 500CC SHORT-PET NONE CLEAR 33.0 16.5 8.2
AB203 12447 N/A 400CC PET NONE LT BROWN 6.8 3.4 1.7
AA105 9500 N/A 400CC PET NONE LT BROWN 4.8 2.4 1.2
AC101 25796 N/A 400CC PET NONE GREEN 23.7 11.8 5.9
AD401 32821 WHITE 400CC PET NONE GREEN 22.7 11.4 5.7
AD221 41221 N/A 400CC PET NONE YELLOW 20.8 10.4 5.2
AC301 29888 N/A 400CC PET NONE YELLOW 20.7 10.3 5.2
AC201 27207 N/A 400CC PET NONE YELLOW 18.1 9.0 4.5
AB205 12792 N/A 400CC PET NONE YELLOW 7.0 3.5 1.8
AA101 3200 N/A 400CC HDPE NONE LIME 3.1 1.6 0.8
AA104 6462 N/A 400CC HDPE NONE LIME 7.8 3.9 1.9
AA103 5247 N/A 400CC HDPE NONE LIME 5.1 2.5 1.3
AA102 3407 N/A 400CC HDPE NONE LIME 3.3 1.7 0.8
AB207 25262 N/A 400CC HDPE NONE EGGSHELL 16.8 8.4 4.2
AD201 33992 N/A 400CC HDPE NONE BLUE 40.9 20.4 10.2
AC441 44016 N/A 400CC HDPE NONE BLUE 30.5 15.2 7.6
LINE 4 - CYCLE 1
Data shown is for illustration only and is not actual
39 #APICS2017 Data shown is for illustration only and is not actual
ITEM FCST AVERAGE TABLET COLORBOTTLE
SIZEBOTTLE TYPE DESSICANT #
BOTTLE
COLOR
HOURS PER
MONTH
HOURS
PER 2
WEEKS
HOURS
PER
WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR 73.6 36.8 18.4
AB206 52234 N/A 500CC SHORT-PET D546 CLEAR 33.0 16.5 8.2
AB302 49303 N/A 500CC SHORT-PET NONE CLEAR 35.6 17.8 8.9
AL402 31325 N/A 500CC SHORT-PET NONE CLEAR 22.6 11.3 5.7
AR229 9415 DARK GREEN 500CC SHORT-PET NONE CLEAR 11.3 5.7 2.8
AR201 21841 N/A 500CC PET NONE CLEAR 26.3 13.1 6.6
AF221 33211 N/A 500CC PET NONE YELLOW 24.0 12.0 6.0
AF241 30496 N/A 500CC PET NONE YELLOW 22.0 11.0 5.5
AG330 13324 N/A 500CC PET NONE YELLOW 16.0 8.0 4.0
AL302 5568 N/A 500CC PET NONE YELLOW 4.3 2.1 1.1
AL302 5239 N/A 500CC HDPE NONE LIME 4.6 2.3 1.2
AF401 9823 N/A 500CC HDPE NONE EGGSHELL 11.8 5.9 3.0
AR217 5252 N/A 400CC HDPE D472 LIME 2.9 1.4 0.7
AR314 5034 N/A 400CC HDPE D472 LIME 2.8 1.4 0.7
AR112 2232 N/A 400CC HDPE NONE LIME 1.1 0.6 0.3
AL221 1046 N/A 400CC HDPE NONE LIME 0.7 0.4 0.2
AR514 991 N/A 400CC HDPE NONE LIME 0.5 0.3 0.1
AC441 44016 N/A 400CC HDPE NONE BLUE 30.5 15.2 7.6
AD201 33992 N/A 400CC HDPE NONE BLUE 40.9 20.4 10.2
LINE 4 - CYCLE 2
40 #APICS2017
ITEM FCST AVERAGE TABLET COLORBOTTLE
SIZEBOTTLE TYPE DESSICANT #
BOTTLE
COLOR
HOURS PER
MONTH
HOURS
PER 2
WEEKS
HOURS
PER
WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR 73.6 36.8 18.4
AB302 49303 N/A 500CC SHORT-PET D546 CLEAR 35.6 17.8 8.9
AB206 52234 N/A 500CC SHORT-PET NONE CLEAR 33.0 16.5 8.2
AB203 12447 N/A 400CC PET NONE LT BROWN 6.8 3.4 1.7
AA105 9500 N/A 400CC PET NONE LT BROWN 4.8 2.4 1.2
AC101 25796 N/A 400CC PET NONE GREEN 23.7 11.8 5.9
AD401 32821 WHITE 400CC PET NONE GREEN 22.7 11.4 5.7
AD221 41221 N/A 400CC PET NONE YELLOW 20.8 10.4 5.2
AC301 29888 N/A 400CC PET NONE YELLOW 20.7 10.3 5.2
AC201 27207 N/A 400CC PET NONE YELLOW 18.1 9.0 4.5
AB205 12792 N/A 400CC PET NONE YELLOW 7.0 3.5 1.8
AA101 3200 N/A 400CC HDPE NONE LIME 3.1 1.6 0.8
AA104 6462 N/A 400CC HDPE NONE LIME 7.8 3.9 1.9
AA103 5247 N/A 400CC HDPE NONE LIME 5.1 2.5 1.3
AA102 3407 N/A 400CC HDPE NONE LIME 3.3 1.7 0.8
AB207 25262 N/A 400CC HDPE NONE EGGSHELL 16.8 8.4 4.2
AD201 33992 N/A 400CC HDPE NONE BLUE 40.9 20.4 10.2
AC441 44016 N/A 400CC HDPE NONE BLUE 30.5 15.2 7.6
ITEM FCST AVERAGE TABLET COLORBOTTLE
SIZEBOTTLE TYPE DESSICANT #
BOTTLE
COLOR
HOURS PER
MONTH
HOURS
PER 2
WEEKS
HOURS
PER
WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR 73.6 36.8 18.4
AB206 52234 N/A 500CC SHORT-PET D546 CLEAR 33.0 16.5 8.2
AB302 49303 N/A 500CC SHORT-PET NONE CLEAR 35.6 17.8 8.9
AL402 31325 N/A 500CC SHORT-PET NONE CLEAR 22.6 11.3 5.7
AR229 9415 DARK GREEN 500CC SHORT-PET NONE CLEAR 11.3 5.7 2.8
AR201 21841 N/A 500CC PET NONE CLEAR 26.3 13.1 6.6
AF221 33211 N/A 500CC PET NONE YELLOW 24.0 12.0 6.0
AF241 30496 N/A 500CC PET NONE YELLOW 22.0 11.0 5.5
AG330 13324 N/A 500CC PET NONE YELLOW 16.0 8.0 4.0
AL302 5568 N/A 500CC PET NONE YELLOW 4.3 2.1 1.1
AL302 5239 N/A 500CC HDPE NONE LIME 4.6 2.3 1.2
AF401 9823 N/A 500CC HDPE NONE EGGSHELL 11.8 5.9 3.0
AR217 5252 N/A 400CC HDPE D472 LIME 2.9 1.4 0.7
AR314 5034 N/A 400CC HDPE D472 LIME 2.8 1.4 0.7
AR112 2232 N/A 400CC HDPE NONE LIME 1.1 0.6 0.3
AL221 1046 N/A 400CC HDPE NONE LIME 0.7 0.4 0.2
AR514 991 N/A 400CC HDPE NONE LIME 0.5 0.3 0.1
AC441 44016 N/A 400CC HDPE NONE BLUE 30.5 15.2 7.6
AD201 33992 N/A 400CC HDPE NONE BLUE 40.9 20.4 10.2
CYCLE 2
CYCLE 1
Data shown is for illustration only and is not actual
41 #APICS2017
DEERFIELD BENEFITS
12 point improvement in OEE
35% increase in throughput
Same capacity on 20% fewer lines
Operating savings = 15% of direct labor
Extrapolating to other NBTY packaging operations
Similar savings are being realized
Have begun designing wheels for manufacturing operations
"The process addressed our real concerns and involved us in the solutions. We felt
committed to using each new change because it fixed a real issue.“
Jaci Souza – Packaging Director – Nature’s Bounty
42 #APICS2017
Eli Lilly & Co, The Procter & Gamble Co., DuPont – 28 years
Plant Systems Manager
Production Systems Integration
Project & Program Manager
CI Manager
Supply Chain COE Lead
Verrico Associates – 2009 to present
Consulting with Responsible Care chemical companies
Zinata – 2010 to present
Process improvement, Change managements, project management
Leadership team alignment and direction
Product Wheel design/implementation , Value Stream Mapping
Career has been about improving the way the supply chain and its
manufacturing component work - Whether intervention is a system, a process or
the basic ways things get done
ALAN H. NALL [email protected]
43 #APICS2017
DEERFIELD BEACH SUCCESS FACTORS
A well defined, well understood need
Low OEE (< 50%)
Frequent schedule breaks
Illogical run lengths
Too many changeovers
A well defined process for improvement
A design method that was flexible for changing needs
A strong cross-functional team
44 #APICS2017
Tools to integrate the wheels with our existing ERP and
scheduling systems
A simple, straightforward process for schedulers to
follow on a daily basis
Presents new orders assigned to the proper line
Presents new orders at proper point in wheel
sequence
Allows scheduler to make changes if needed
Tool capability enhanced to address concrete needs
Strong coaching and follow-up from the consultants
DEERFIELD BEACH SUCCESS FACTORS
45 #APICS2017
DAILY WHEEL OPERATION
Scheduling can be a complex task with a large # of SKUs
One packaging plant has > 4,000 packaged SKUs
They are packaged on more than a dozen lines
The Oracle system generates hundreds of orders per day
Wheels make this simpler to manage, but it can still be
complex and time consuming
We have Excel-based execution
accelerators to help the scheduler
- the “Product Wheel Accelerator”
46 #APICS2017
PRODUCT WHEEL ACCELERATOR CONCEPT
PIT
TIME
PIT
TIME
PITTIME
PIT
TIME
PIT
TIME
SWING LINE
PACKING LINE #3
PACKING LINE #5
PACKING LINE #2
PACKING LINE #4
PACKING #1
51381
19852
30282
13045
55347
3268913775
57601
30173
45211
53181
19955
380913412
46077
4162855412 19097 53124 53125 53129
51381
19852
30282
13045
55347
3268913775
57601
30173
45211
53181
19955
380913412
46077
4162855412 19097 53124 53125 53129
PWT – Excel Macro AcceleratorsWheel Based Schedule By Line
Open Orders - Extract
Current Prod Schedule - Extract
Production Schedule Prim.: L04-Black-CWheel
Item DescriptionSelected
Line Status WO#
D.A
.
Prod.
QTYIssue Date
Slat
#Forecast
Bott
le
Size
Bottle
TypeAllergen
Dusty
,
Sticky
BulkCap
Type
Bottle
ColorCap Color
Bulk
Type
Proposed
Line
Run
Rate
Anticipated
Run length
Anticipated start
dateOffset Cycle
Wheel
SeqIdeal Date
aa333 Product description aa333 N Running 1 0 35400 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 9.00 01/12/2017 00:00 44 Cycle 142795 01/24/2017 22:36
aa333 Product description aa333 N Printed 2 0 23142 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 5.89 01/12/2017 09:00 44 Cycle 142795 01/24/2017 22:36
hh111 Product Description hh111 N Printed 3 0 35000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 9.26 01/12/2017 14:53 0 Cycle 142751 01/12/2017 13:54
hh111 Product Description hh111 N Ready 4 0 28000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.41 01/13/2017 00:09 0 Cycle 142751 01/12/2017 13:54
hh111 Product Description hh111 N Ready 5 0 19705 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 5.21 01/13/2017 07:33 0 Cycle 142751 01/12/2017 13:54
hh111 Product Description hh111 N Ready 6 0 30171 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.98 01/13/2017 12:46 0 Cycle 142751 01/12/2017 13:54
hh333 Product Description hh333 N Schedule 101 0 2709 06/01/2016 0 29201 100CCPET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 0.67 01/13/2017 20:45 3 Cycle 142754 01/13/2017 15:12
hh333 Product Description hh333 N Schedule 102 0 11600 06/01/2016 0 29201 100CCPET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 2.87 01/13/2017 21:25 3 Cycle 142754 01/13/2017 15:12
dd765 Product Description dd765 N Schedule 103 0 96061 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 23.31 01/16/2017 00:17 8 Cycle 142759 01/16/2017 08:36
dd765 Product Description dd765 N Schedule 104 0 3441 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 0.84 01/16/2017 23:36 8 Cycle 142759 01/16/2017 08:36
dd765 Product Description dd765 N Schedule 105 0 50000 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 12.14 01/17/2017 00:26 8 Cycle 142759 01/16/2017 08:36
gg544 Product Description gg544 N Ready 7 0 24258 05/10/2016 0 64285 100CCPET Free 7892 STD GREEN WMLTYELLOW SG L04-Black 94 6.83 01/17/2017 12:34 9 Cycle 142760 01/16/2017 23:42
gg766 Product descritpion gg766 N Schedule 106 0 17788 06/03/2016 0 49077 100CCPET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 5.12 01/17/2017 19:24 11 Cycle 142762 01/17/2017 12:24
gg766 Product descritpion gg766 N Schedule 107 0 23926 06/03/2016 0 49077 100CCPET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.88 01/18/2017 00:31 11 Cycle 142762 01/17/2017 12:24
gg766 Product descritpion gg766 N Schedule 108 0 23765 06/03/2016 0 49077 100CCPET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.83 01/18/2017 07:23 11 Cycle 142762 01/17/2017 12:24
gg655 Product Description gg655 N Ready 8 0 29980 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 14:13 12 Cycle 142763 01/17/2017 19:30
gg655 Product Description gg655 N Ready 9 0 29999 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 22:56 12 Cycle 142763 01/17/2017 19:30
gg655 Product Description gg655 N Ready 10 0 29709 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.64 01/19/2017 07:40 12 Cycle 142763 01/17/2017 19:30
gg655 Product Description gg655 N Ready 11 0 4569 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 1.33 01/19/2017 16:18 12 Cycle 142763 01/17/2017 19:30
dd876 Product Description dd876 N Schedule 109 62 48070 05/27/2016 0 20266.66667 100CCPET Free Dusty 12610 STD AMBER YELLOW T L04-Black 112 11.35 01/19/2017 17:38 13 Cycle 142764 01/18/2017 09:18
ff234 Product Description ff234 N Ready 12 73 20000 6581 100CCPET Free 90 STD AMBER YELLOW C L04-Black 105 5.04 01/20/2017 04:59 15 Cycle 142766 01/18/2017 14:30
ee444 Product Description ee444 N Ready 13 118 2973 16421 100CCPET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.79 01/20/2017 10:01 19 Cycle 142770 01/19/2017 00:00
ee444 Product Description ee444 N Ready 14 118 2298 16421 100CCPET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.61 01/20/2017 10:48 19 Cycle 142770 01/19/2017 00:00
ee888 Product Description ee888 N Ready 15 42 23000 12077 100CCPET Free 29172 STD AMBER YELLOW SG L04-Black 71 8.57 01/20/2017 11:25 20 Cycle 142771 01/19/2017 04:18
ff456 Product Description ff456 N Schedule 110 26 17333 05/27/2016 300 6273 100CCPET Free 50402 STD AMBER YELLOW SG L04-Black 105 4.37 01/20/2017 19:59 21 Cycle 142772 01/19/2017 08:48
aa111 Product Descr aa111 N Schedule 111 71 22200 05/27/2016 9900 9296.666667 100CCPET Free 52714 STD AMBER YELLOW T L04-Black 109 5.39 01/23/2017 00:21 24 Cycle 142775 01/19/2017 16:00
bb111 Product Description bb111 N Schedule 112 93 7824 06/07/2016 0 9434.666667 100CCPET Free 16875 STD AMBER YELLOW T L04-Black 106 1.95 01/23/2017 05:44 25 Cycle 142776 01/19/2017 18:18
bb111 Product Description bb111 N Schedule 113 93 6886 06/07/2016 0 9434.666667 100CCPET Free 16875 STD AMBER YELLOW T L04-Black 106 1.72 01/23/2017 07:41 25 Cycle 142776 01/19/2017 18:18
ff123 Product Description ff123 N Ready 16 77 36000 12325.66667 100CCPET Free 447 STD AMBER YELLOW T L04-Black 109 8.74 01/23/2017 09:25 26 Cycle 142777 01/19/2017 20:42
cc456 Product Description CC456 N Schedule 114 109 29070 06/07/2016 300 18488.66667 100CCPET Free 3860 STD AMBER YELLOW T L04-Black 120 6.41 01/23/2017 18:09 28 Cycle 142779 01/20/2017 03:00
ff677 Product description ff677 N Schedule 115 0 10016 06/03/2016 0 16874 100CCPET Free 50126 STD AMBER YELLOW T L04-Black 109 2.43 01/24/2017 00:33 29 Cycle 142780 01/20/2017 07:06
hh444 Product Description hh444 N Ready 17 0 43816 05/18/2016 0 24581 100CCPET Free 52385 STD GREEN WMLTYELLOW C L04-Black 120 9.66 01/24/2017 02:59 34 Cycle 142785 01/20/2017 20:54
ff789 Product Description ff789 N Ready 18 0 31392 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 6.75 01/24/2017 12:39 35 Cycle 142786 01/20/2017 23:36
ff789 Product Description ff789 N Ready 19 0 9022 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 1.94 01/24/2017 19:24 35 Cycle 142786 01/20/2017 23:36
ff789 Product Description ff789 N Ready 20 0 25444 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 5.47 01/24/2017 21:20 35 Cycle 142786 01/20/2017 23:36
bb777 Product Description BB777 N Schedule 116 0 23600 05/27/2016 0 25241 100CCPET Soy 2090 STD GREEN WMLTYELLOW SG L04-Black 120 5.20 01/25/2017 02:49 37 Cycle 142788 01/23/2017 04:54
gg433 Product Description gg433 N Ready 21 0 7473 05/18/2016 0 36986 100CCPET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 1.62 01/25/2017 08:01 38 Cycle 142789 01/23/2017 07:42
gg433 Product Description gg433 N Ready 22 0 16640 05/18/2016 0 36986 100CCPET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 3.61 01/25/2017 09:38 38 Cycle 142789 01/23/2017 07:42
cc234 Product Description cc234 N Schedule 117 0 75535 06/01/2016 0 30754 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 16.65 01/25/2017 13:15 40 Cycle 142791 01/23/2017 15:36
CC123 Product Description CC123 N Ready 23 0 6000 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 1.51 01/26/2017 05:54 41 Cycle 142792 01/23/2017 19:00
CC123 Product Description CC123 N Ready 24 0 25000 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.30 01/26/2017 07:24 41 Cycle 142792 01/23/2017 19:00
CC123 Product Description CC123 N Ready 25 0 24666 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.21 01/26/2017 13:42 41 Cycle 142792 01/23/2017 19:00
CC123 Product Description CC123 N Ready 26 0 8766 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 2.21 01/26/2017 19:55 41 Cycle 142792 01/23/2017 19:00
aa222 Product Descr aa222 N Ready 27 0 28960 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 6.96 01/26/2017 22:08 42 Cycle 142793 01/23/2017 23:24
aa222 Product Descr aa222 N Ready 28 0 24000 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 5.77 01/27/2017 05:06 42 Cycle 142793 01/23/2017 23:24
hh222 Product Description hh222 N Ready 29 0 39060 05/18/2016 0 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 9.94 01/27/2017 10:52 43 Cycle 142794 01/24/2017 08:42
hh222 Product Description hh222 N Ready 30 0 49163 05/18/2016 0 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 12.51 01/27/2017 20:48 43 Cycle 142794 01/24/2017 08:42
ff567 Product Description ff567 N Schedule 118 0 14409 05/26/2016 0 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 3.34 01/30/2017 09:18 45 Cycle 142796 01/25/2017 05:18
ff567 Product Description ff567 N Schedule 119 0 65232 05/26/2016 0 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 15.14 01/30/2017 12:39 45 Cycle 142796 01/25/2017 05:18
ff567 Product Description ff567 N Schedule 120 0 44382 05/26/2016 0 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 10.30 01/31/2017 03:47 45 Cycle 142796 01/25/2017 05:18
ff345 Product Description ff3454 N Schedule 121 0 18318 06/07/2016 0 15950.66667 100CCHDPE Free Dusty 1380 STD LIMEGRNGREEN T L04-Black 110 4.41 01/31/2017 14:05 48 Cycle 242799 01/25/2017 18:06
ff345 Product Description ff3454 N Schedule 122 0 10200 06/07/2016 0 15950.66667 100CCHDPE Free Dusty 1380 STD LIMEGRNGREEN T L04-Black 110 2.45 01/31/2017 18:30 48 Cycle 242799 01/25/2017 18:06
gg988 Product Description gg988 N Schedule 123 0 3232 06/01/2016 0 16121 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 0.71 01/31/2017 20:57 56 Cycle 242807 01/26/2017 18:18
gg988 Product Description gg988 N Schedule 124 0 39376 06/01/2016 0 16121 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 8.68 01/31/2017 21:40 56 Cycle 242807 01/26/2017 18:18
gg877 Product description gg877 N Schedule 125 0 5000 06/03/2016 0 1534 100CCPET Free Dusty 54801 STD AMBER WHITE T L04-Black 104 1.27 02/01/2017 06:20 63 Cycle 242814 01/30/2017 06:06
ee333 Product Description ee333 N Schedule 126 72 18000 06/01/2016 300 6808 100CCPET Free Dusty 1660 STD AMBER YELLOW C L04-Black 105 4.54 02/01/2017 07:37 64 Cycle 242815 01/30/2017 07:18
hh655 Product Description hh655 N Ready 31 130 8888 15543.66667 100CCPET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 2.03 02/01/2017 12:09 69 Cycle 242820 01/30/2017 18:30
hh655 Product Description hh655 N Ready 32 130 23000 15543.66667 100CCPET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 5.25 02/01/2017 14:10 69 Cycle 242820 01/30/2017 18:30
hh655 Product Description hh655 N Ready 33 130 15000 15543.66667 100CCPET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 3.42 02/01/2017 19:25 69 Cycle 242820 01/30/2017 18:30
bb333 Product Description BB333 N Schedule 127 0 11512 05/27/2016 0 9416 100CCPET Free 50402 STD AMBER WHITE SG L04-Black 102 2.99 02/01/2017 22:50 74 Cycle 242825 01/31/2017 04:12
dd987 Product Description dd987 N Schedule 128 0 3666 05/27/2016 0 8627.666667 100CCPET Free 7961 STD AMBER WHITE T L04-Black 74 1.31 02/02/2017 01:50 75 Cycle 242826 01/31/2017 06:36
ee999 Product Description ee999 N Ready 34 0 7011 05/19/2016 0 45574 100CCPET Free 19939 STD GREEN WMLTYELLOW SG L08-Pink 92 2.02 02/02/2017 03:08
Production Schedule Prim.: L04-Black-CWheel
Item DescriptionSelected
Line Status WO#
D.A
.
Prod.
QTYIssue Date
Slat
#Forecast
Bott
le
Size
Bottle
TypeAllergen
Dusty
,
Sticky
BulkCap
Type
Bottle
ColorCap Color
Bulk
Type
Proposed
Line
Run
Rate
Anticipated
Run length
Anticipated start
dateOffset Cycle
Wheel
SeqIdeal Date
aa333 Product description aa333 N Running 1 0 35400 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 9.00 01/12/2017 00:00 44 Cycle 142795 01/24/2017 22:36
aa333 Product description aa333 N Printed 2 0 23142 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 5.89 01/12/2017 09:00 44 Cycle 142795 01/24/2017 22:36
hh111 Product Description hh111 N Printed 3 0 35000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 9.26 01/12/2017 14:53 0 Cycle 142751 01/12/2017 13:54
hh111 Product Description hh111 N Ready 4 0 28000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.41 01/13/2017 00:09 0 Cycle 142751 01/12/2017 13:54
hh111 Product Description hh111 N Ready 5 0 19705 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 5.21 01/13/2017 07:33 0 Cycle 142751 01/12/2017 13:54
hh111 Product Description hh111 N Ready 6 0 30171 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.98 01/13/2017 12:46 0 Cycle 142751 01/12/2017 13:54
hh333 Product Description hh333 N Schedule 101 0 2709 06/01/2016 0 29201 100CCPET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 0.67 01/13/2017 20:45 3 Cycle 142754 01/13/2017 15:12
hh333 Product Description hh333 N Schedule 102 0 11600 06/01/2016 0 29201 100CCPET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 2.87 01/13/2017 21:25 3 Cycle 142754 01/13/2017 15:12
dd765 Product Description dd765 N Schedule 103 0 96061 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 23.31 01/16/2017 00:17 8 Cycle 142759 01/16/2017 08:36
dd765 Product Description dd765 N Schedule 104 0 3441 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 0.84 01/16/2017 23:36 8 Cycle 142759 01/16/2017 08:36
dd765 Product Description dd765 N Schedule 105 0 50000 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 12.14 01/17/2017 00:26 8 Cycle 142759 01/16/2017 08:36
gg544 Product Description gg544 N Ready 7 0 24258 05/10/2016 0 64285 100CCPET Free 7892 STD GREEN WMLTYELLOW SG L04-Black 94 6.83 01/17/2017 12:34 9 Cycle 142760 01/16/2017 23:42
gg766 Product descritpion gg766 N Schedule 106 0 17788 06/03/2016 0 49077 100CCPET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 5.12 01/17/2017 19:24 11 Cycle 142762 01/17/2017 12:24
gg766 Product descritpion gg766 N Schedule 107 0 23926 06/03/2016 0 49077 100CCPET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.88 01/18/2017 00:31 11 Cycle 142762 01/17/2017 12:24
gg766 Product descritpion gg766 N Schedule 108 0 23765 06/03/2016 0 49077 100CCPET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.83 01/18/2017 07:23 11 Cycle 142762 01/17/2017 12:24
gg655 Product Description gg655 N Ready 8 0 29980 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 14:13 12 Cycle 142763 01/17/2017 19:30
gg655 Product Description gg655 N Ready 9 0 29999 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 22:56 12 Cycle 142763 01/17/2017 19:30
gg655 Product Description gg655 N Ready 10 0 29709 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.64 01/19/2017 07:40 12 Cycle 142763 01/17/2017 19:30
gg655 Product Description gg655 N Ready 11 0 4569 95001 100CCPET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 1.33 01/19/2017 16:18 12 Cycle 142763 01/17/2017 19:30
dd876 Product Description dd876 N Schedule 109 62 48070 05/27/2016 0 20266.66667 100CCPET Free Dusty 12610 STD AMBER YELLOW T L04-Black 112 11.35 01/19/2017 17:38 13 Cycle 142764 01/18/2017 09:18
ff234 Product Description ff234 N Ready 12 73 20000 6581 100CCPET Free 90 STD AMBER YELLOW C L04-Black 105 5.04 01/20/2017 04:59 15 Cycle 142766 01/18/2017 14:30
ee444 Product Description ee444 N Ready 13 118 2973 16421 100CCPET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.79 01/20/2017 10:01 19 Cycle 142770 01/19/2017 00:00
ee444 Product Description ee444 N Ready 14 118 2298 16421 100CCPET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.61 01/20/2017 10:48 19 Cycle 142770 01/19/2017 00:00
ee888 Product Description ee888 N Ready 15 42 23000 12077 100CCPET Free 29172 STD AMBER YELLOW SG L04-Black 71 8.57 01/20/2017 11:25 20 Cycle 142771 01/19/2017 04:18
ff456 Product Description ff456 N Schedule 110 26 17333 05/27/2016 300 6273 100CCPET Free 50402 STD AMBER YELLOW SG L04-Black 105 4.37 01/20/2017 19:59 21 Cycle 142772 01/19/2017 08:48
aa111 Product Descr aa111 N Schedule 111 71 22200 05/27/2016 9900 9296.666667 100CCPET Free 52714 STD AMBER YELLOW T L04-Black 109 5.39 01/23/2017 00:21 24 Cycle 142775 01/19/2017 16:00
bb111 Product Description bb111 N Schedule 112 93 7824 06/07/2016 0 9434.666667 100CCPET Free 16875 STD AMBER YELLOW T L04-Black 106 1.95 01/23/2017 05:44 25 Cycle 142776 01/19/2017 18:18
bb111 Product Description bb111 N Schedule 113 93 6886 06/07/2016 0 9434.666667 100CCPET Free 16875 STD AMBER YELLOW T L04-Black 106 1.72 01/23/2017 07:41 25 Cycle 142776 01/19/2017 18:18
ff123 Product Description ff123 N Ready 16 77 36000 12325.66667 100CCPET Free 447 STD AMBER YELLOW T L04-Black 109 8.74 01/23/2017 09:25 26 Cycle 142777 01/19/2017 20:42
cc456 Product Description CC456 N Schedule 114 109 29070 06/07/2016 300 18488.66667 100CCPET Free 3860 STD AMBER YELLOW T L04-Black 120 6.41 01/23/2017 18:09 28 Cycle 142779 01/20/2017 03:00
ff677 Product description ff677 N Schedule 115 0 10016 06/03/2016 0 16874 100CCPET Free 50126 STD AMBER YELLOW T L04-Black 109 2.43 01/24/2017 00:33 29 Cycle 142780 01/20/2017 07:06
hh444 Product Description hh444 N Ready 17 0 43816 05/18/2016 0 24581 100CCPET Free 52385 STD GREEN WMLTYELLOW C L04-Black 120 9.66 01/24/2017 02:59 34 Cycle 142785 01/20/2017 20:54
ff789 Product Description ff789 N Ready 18 0 31392 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 6.75 01/24/2017 12:39 35 Cycle 142786 01/20/2017 23:36
ff789 Product Description ff789 N Ready 19 0 9022 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 1.94 01/24/2017 19:24 35 Cycle 142786 01/20/2017 23:36
ff789 Product Description ff789 N Ready 20 0 25444 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 5.47 01/24/2017 21:20 35 Cycle 142786 01/20/2017 23:36
bb777 Product Description BB777 N Schedule 116 0 23600 05/27/2016 0 25241 100CCPET Soy 2090 STD GREEN WMLTYELLOW SG L04-Black 120 5.20 01/25/2017 02:49 37 Cycle 142788 01/23/2017 04:54
gg433 Product Description gg433 N Ready 21 0 7473 05/18/2016 0 36986 100CCPET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 1.62 01/25/2017 08:01 38 Cycle 142789 01/23/2017 07:42
gg433 Product Description gg433 N Ready 22 0 16640 05/18/2016 0 36986 100CCPET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 3.61 01/25/2017 09:38 38 Cycle 142789 01/23/2017 07:42
cc234 Product Description cc234 N Schedule 117 0 75535 06/01/2016 0 30754 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 16.65 01/25/2017 13:15 40 Cycle 142791 01/23/2017 15:36
CC123 Product Description CC123 N Ready 23 0 6000 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 1.51 01/26/2017 05:54 41 Cycle 142792 01/23/2017 19:00
CC123 Product Description CC123 N Ready 24 0 25000 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.30 01/26/2017 07:24 41 Cycle 142792 01/23/2017 19:00
CC123 Product Description CC123 N Ready 25 0 24666 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.21 01/26/2017 13:42 41 Cycle 142792 01/23/2017 19:00
CC123 Product Description CC123 N Ready 26 0 8766 34934.33333 100CCPET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 2.21 01/26/2017 19:55 41 Cycle 142792 01/23/2017 19:00
aa222 Product Descr aa222 N Ready 27 0 28960 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 6.96 01/26/2017 22:08 42 Cycle 142793 01/23/2017 23:24
aa222 Product Descr aa222 N Ready 28 0 24000 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 5.77 01/27/2017 05:06 42 Cycle 142793 01/23/2017 23:24
hh222 Product Description hh222 N Ready 29 0 39060 05/18/2016 0 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 9.94 01/27/2017 10:52 43 Cycle 142794 01/24/2017 08:42
hh222 Product Description hh222 N Ready 30 0 49163 05/18/2016 0 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 12.51 01/27/2017 20:48 43 Cycle 142794 01/24/2017 08:42
ff567 Product Description ff567 N Schedule 118 0 14409 05/26/2016 0 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 3.34 01/30/2017 09:18 45 Cycle 142796 01/25/2017 05:18
ff567 Product Description ff567 N Schedule 119 0 65232 05/26/2016 0 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 15.14 01/30/2017 12:39 45 Cycle 142796 01/25/2017 05:18
ff567 Product Description ff567 N Schedule 120 0 44382 05/26/2016 0 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 10.30 01/31/2017 03:47 45 Cycle 142796 01/25/2017 05:18
ff345 Product Description ff3454 N Schedule 121 0 18318 06/07/2016 0 15950.66667 100CCHDPE Free Dusty 1380 STD LIMEGRNGREEN T L04-Black 110 4.41 01/31/2017 14:05 48 Cycle 242799 01/25/2017 18:06
ff345 Product Description ff3454 N Schedule 122 0 10200 06/07/2016 0 15950.66667 100CCHDPE Free Dusty 1380 STD LIMEGRNGREEN T L04-Black 110 2.45 01/31/2017 18:30 48 Cycle 242799 01/25/2017 18:06
gg988 Product Description gg988 N Schedule 123 0 3232 06/01/2016 0 16121 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 0.71 01/31/2017 20:57 56 Cycle 242807 01/26/2017 18:18
gg988 Product Description gg988 N Schedule 124 0 39376 06/01/2016 0 16121 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 8.68 01/31/2017 21:40 56 Cycle 242807 01/26/2017 18:18
gg877 Product description gg877 N Schedule 125 0 5000 06/03/2016 0 1534 100CCPET Free Dusty 54801 STD AMBER WHITE T L04-Black 104 1.27 02/01/2017 06:20 63 Cycle 242814 01/30/2017 06:06
ee333 Product Description ee333 N Schedule 126 72 18000 06/01/2016 300 6808 100CCPET Free Dusty 1660 STD AMBER YELLOW C L04-Black 105 4.54 02/01/2017 07:37 64 Cycle 242815 01/30/2017 07:18
hh655 Product Description hh655 N Ready 31 130 8888 15543.66667 100CCPET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 2.03 02/01/2017 12:09 69 Cycle 242820 01/30/2017 18:30
hh655 Product Description hh655 N Ready 32 130 23000 15543.66667 100CCPET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 5.25 02/01/2017 14:10 69 Cycle 242820 01/30/2017 18:30
hh655 Product Description hh655 N Ready 33 130 15000 15543.66667 100CCPET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 3.42 02/01/2017 19:25 69 Cycle 242820 01/30/2017 18:30
bb333 Product Description BB333 N Schedule 127 0 11512 05/27/2016 0 9416 100CCPET Free 50402 STD AMBER WHITE SG L04-Black 102 2.99 02/01/2017 22:50 74 Cycle 242825 01/31/2017 04:12
dd987 Product Description dd987 N Schedule 128 0 3666 05/27/2016 0 8627.666667 100CCPET Free 7961 STD AMBER WHITE T L04-Black 74 1.31 02/02/2017 01:50 75 Cycle 242826 01/31/2017 06:36
ee999 Product Description ee999 N Ready 34 0 7011 05/19/2016 0 45574 100CCPET Free 19939 STD GREEN WMLTYELLOW SG L08-Pink 92 2.02 02/02/2017 03:08
WO#
New
Prod Action Description Prod.Qty For release Firm Order Type Issue date Sugg Due Date
101 aa111 Release Product Descr aa111 29584 Planned order 8/23/2016 8/30/2016
102 aa111 Release Product Descr aa111 21979 Planned order 11/11/2016 11/18/2016
103 bb111 Release Product Description bb111 22946 Planned order 8/25/2016 9/5/2016
104 cc456 Release Product Description CC456 37541 Planned order 9/7/2016 9/16/2016
105 dd876 Release Product Description dd876 58336 Planned order 9/28/2016 10/7/2016
106 ee444 Release Product Description ee444 48032 Planned order 8/31/2016 9/9/2016
107 ee888 Release Product Description ee888 50295 Planned order 8/23/2016 8/30/2016
108 ee888 Release Product Description ee888 31134 Planned order 11/11/2016 11/18/2016
109 ee333 Release Product Description ee333 14645 Planned order 10/5/2016 10/14/2016
110 ff123 Release Product Description ff123 41176 Planned order 9/20/2016 9/29/2016
111 ff234 Release Product Description ff234 15113 Planned order 10/5/2016 10/14/2016
112 ff456 Release Product Description ff456 16970 Planned order 9/21/2016 9/30/2016
113 hh655 Release Product Description hh655 51641 Planned order 8/31/2016 9/9/2016
114 bb333 Release Product Description BB333 26397 Planned order 8/25/2016 9/5/2016
115 dd987 Release Product Description dd987 22751 Planned order 9/12/2016 9/21/2016
116 ff345 Release Product Description ff3454 44741 Planned order 8/24/2016 9/2/2016
117 ff345 Release Product Description ff3454 38466 Planned order 11/11/2016 11/18/2016
118 ff677 Release Product description ff677 63295 Planned order 9/22/2016 10/3/2016
119 gg766 Release Product descritpion gg766 71801 Planned order 8/23/2016 8/30/2016
120 gg766 Release Product descritpion gg766 45931 Planned order 9/12/2016 9/21/2016
121 gg766 Release Product descritpion gg766 36711 Planned order 10/12/2016 10/21/2016
122 gg766 Release Product descritpion gg766 55266 Planned order 11/11/2016 11/18/2016
123 aa222 Release Product Descr aa222 91008 Planned order 9/5/2016 9/14/2016
124 aa222 Release Product Descr aa222 67762 Planned order 10/3/2016 10/12/2016
125 aa222 Release Product Descr aa222 99931 Planned order 11/4/2016 11/11/2016
126 aa333 Release Product description aa333 240073 Planned order 8/23/2016 8/30/2016
127 aa333 Release Product description aa333 130588 Planned order 11/11/2016 11/18/2016
128 bb777 Release Product Description BB777 64172 Planned order 9/13/2016 9/22/2016
129 cc234 Release Product Description cc234 85886 Planned order 8/23/2016 8/30/2016
130 cc234 Release Product Description cc234 58744 Planned order 11/11/2016 11/18/2016
131 gg988 Release Product Description gg988 27647 Planned order 9/16/2016 9/27/2016
132 dd765 Release Product Description dd765 40254 Planned order 8/23/2016 9/1/2016
133 dd765 Release Product Description dd765 54468 Planned order 9/6/2016 9/15/2016
Status WO# Product Size Description DA Prod.Qty Line
Running 1 aa333 250 Product description aa333 16 35400 L04-Black
Printed 2 aa333 250 Product description aa333 16 23142 L04-Black
Printed 3 hh111 120 Product Description hh111 6 35000 L04-Black
Ready 4 hh111 120 Product Description hh111 6 28000 L04-Black
Ready 5 hh111 120 Product Description hh111 6 19705 L04-Black
Ready 6 hh111 120 Product Description hh111 6 30171 L04-Black
Ready 7 ff789 90 Product Description ff789 9 31392 L04-Black
Ready 8 ff789 90 Product Description ff789 9 9022 L04-Black
Ready 9 ff789 90 Product Description ff789 9 25444 L04-Black
Ready 10 hh222 150 Product Description hh222 13 39060 L04-Black
Ready 11 hh222 150 Product Description hh222 13 49163 L04-Black
Ready 12 aa222 100 Product Descr aa222 17 28960 L04-Black
Ready 13 aa222 100 Product Descr aa222 17 24000 L04-Black
Ready 14 hh444 30 Product Description hh444 13 43816 L04-Black
Ready 15 gg433 50 Product Description gg433 14 7473 L04-Black
Ready 16 gg433 50 Product Description gg433 14 16640 L04-Black
Ready 17 gg544 200 Product Description gg544 17 24258 L04-Black
Ready 18 gg655 200 Product Description gg655 23 29980 L04-Black
Ready 19 ee999 200 Product Description ee999 35 7011 L04-Black
Line Allocation Wheel Sequences
Scheduling by Line
Navigation
47 #APICS2017
PRODUCT WHEEL ACCELERATOR CONCEPT
The upper section shows orders currently scheduled on the line
The lower section new orders that need to be scheduled.
Information about each order is readily visible, e.g. size of order, product days available,
key product characteristics (light green) that drove wheel scheduling, other product
characteristics, and how long the order should run (based on latest rates and OEE by line.)
Data shown is for illustration only and is not actual
48 #APICS2017
SCHEDULING PRIOR TO WHEELS
Individual order by order decisions
Live production system for line state and
order information
Order placement is "live" in the
production system
Massive mental library required
SCHEDULING WITH THE PRODUCT WHEEL
ACCELERATOR
Weekly load of line state and orders
Tool proposes line for orders and then
proposes sequence on each line
Scheduler reviews / adjusts line by line
Safe place to get schedule right
Export for production system update
PRODUCT WHEEL ACCELERATOR CONCEPT
49 #APICS2017
WHEEL ACCELERATOR INTERFACE FOR SCHEDULER
49
Monthly update of
Characteristics – Place
New copy over old
After PWR or Other
Updates – Rebuild line
Allocation and Wheels
To Schedule – 1) place
Open, Production and/or
Hold order extract in
Folder and 2) select
Any Time - To View
(and use) Select
Appropriate line
(or Overall)
To Schedule –
3) Update
“Actual” in
CWheels
To Schedule – 4) Use
Functions in dashboard,
or by hand to sequence
Production & Open Orders
PRODUCT WHEEL ACCELERATOR
Current Month PWR
Master Line - Mline
Master Wheels for Line
Current Wheels for Line
Update MLine
Load Mwheels
Load CWheels
Load Production & Open Orders
Go to Current Month PWR template
Go to Mline
?
50 #APICS2017
PRODUCT WHEEL ACCELERATOR – Selected Functions
Data shown is for illustration only and is not actual
• Advance Wheel
• Freeze zone
• Sequence all
• Sequence a
selected set
• Move to another
line
• Export Schedule
• Show Key
statistics
• Reason for Break
• Spokes skipped
• Reset
• Etc.
51 #APICS2017
ACCELERATOR BENEFITS
"I schedule every week using the wheels and tool - hundreds of
orders across two dozen lines. We built the best sequence,
people on the floor can see the simplification and have
confidence in the schedule the Wheel Accelerator generates”
Ivy Garcia – Planner/Scheduler – Nature’s Bounty
52 #APICS2017
ADDITIONAL PW ACCELERATOR BENEFITS
The PWA enables the inherent benefits of wheels
Simplified planning and scheduling
Fewer, simpler, faster changeovers
Improved OEE, higher throughput
Reduced inventories
Greater stability and predictability
53 #APICS2017
“Wheels provide a great report tool …….. to access
information about the products packaged, filtering
by any criteria needed”
Yenny Yataco – Nature’s Bounty – Planner/Scheduler
ADDITIONAL PW ACCELERATOR BENEFITS
It also provides a tool for better long range planning
Quantification of when difficult products will be run
Quantification of future component needs
54 #APICS2017
"I can schedule the weeks orders to the wheel on all lines in
a few hours, then work on improvements…“
Ivy Garcia – Planner/Scheduler – Nature’s Bounty
ADDITIONAL PW ACCELERATOR BENEFITS
A dramatic reduction in the time planners and schedulers
spend on routine scheduling more time for true crises
55 #APICS2017
“The product wheel is so powerful that you will notice when it’s not being followed. A
couple of months ago our throughput numbers went down. … I went to the Planning
Manager and asked her, are we following the product wheel? Her response was no,
due to a programming issue. I knew right away that the wheel was not being followed
since our change overs had been reduced by 20% when we implemented it”.
Adelino Rivera – FLA Operations Director – Nature’s Bounty
THE BUSINESS LEADERSHIP VIEW:
56 #APICS2017
Product wheels are key part of an integrated
set of Lean tools
Value Stream Mapping
Cellular Flow
Changeover reduction (SMED)
Total Productive Maintenance (TPM)
Pull replenishment systems
OBSERVATIONS
57 #APICS2017
Addressing the day to day use of the wheel
in scheduling unlocks the power of the
wheels.
Freeing time for exceptions
Cementing the wheels gains
Supporting the wheel driven rhythm
OBSERVATIONS
58 #APICS2017
Compromise is often required
But ….. No matter what compromises
are required
You will almost always end up better
off
OBSERVATIONS
59 #APICS2017
BENEFITS OF PRODUCT WHEELS
1. Levels production
2. Optimizes sequences
3. Optimizes campaign lengths
4. Enables inventory target setting
5. Reduces inventory
6. Improves delivery performance
7. Bring order to chaos – stop the insanity!
Brings order and structure to complex scheduling
decisions
8. Provides a mathematical basis to support decision making
60 #APICS2017
BENEFITS OF PRODUCT WHEELS
Are realized in stages, when
1. Product families are grouped
2. Ideal campaign lengths are set
3. Sequencing reaches the line
4. The scheduling process settles in
5. The rest of the supply chain responds to the production
rhythm
6. Analysis takes advantage of wheel informed data
61 #APICS2017
OTHER PRODUCT WHEEL USERS
BG Products
Appvion
Dow Chemical
DuPont
62 #APICS2017
A ROSE BY ANY OTHER NAME …..
Exxon Mobil
“FSVV”
(Fixed sequence variable volume)
Pharmaceutical companies
“Rhythm wheels”
63 #APICS2017
POTENTIAL APPLICATIONS
Industries that can benefit from Product Wheels
Food: ketchup, mayonnaise, cereals, snack items, etc.
Beverages: water, beer, soda, etc.
Paints and coatings
Pharma
Extruded polymers, synthetic rubbers
Sheet goods: paper, plastic
Personal care: toothpaste, shampoo, creams and lotions
Automotive fluids: power steering fluids, oils, lubricants, etc
Metal forming
64 #APICS2017
A FINAL THOUGHT
“ Using Product Wheels with our large product mix
and running them in the most optimal sequence to
create better flow , reduce our changeovers and
free up capacity ………… PRICELESS !! “
Cheryl Alker – Planning Manager – Nature’s Bounty
65 #APICS2017
WE WROTE THE BOOK ON WHEELS ……
Productivity Press
May 2009
Productivity Press April 2013
66 #APICS2017
QUESTIONS?
67 #APICS2017
APICS 2017 Session Evaluation
Visit www.apics.org/Mondayor
download the APICS2017 app
68 #APICS2017
THANK YOU