Why ERP Schedulers Aren’t Enough for Manufacturing
Planners and Line Supervisors are still using whiteboards for day-to-day Scheduling
Schedule Adherence can’t be managed as a real-time metric
The integration between Shop Floor production and the ERP Schedule is non existent and takes a lot of manual effort to measure expected vs. actual values
Request A Demo A better way.. The Epicor/Informance Scheduler Module Informance schedules the line and uses the current ERP planning rates
Each line has two color-coded rows, the top row for activities on the line, the bottom row for line availability
Three types of events can be created, Production Orders, Line Activities, and Down Periods for the line
As users modify the schedule, the projected inventory levels are updated
Scheduling the Production Orders Production Order execution & tracking Informance tracks the performance of the run, OEE, downtime, output, etc.
Actual cases produced are tracking in real-time
Planned to actual output variance is calculated
Statistics such as Time to Complete Order, OTIF and Schedule Adherence are provided in real-time Example Data Fields Example Values Actual Cases 1382 Planned to actual Case variance -118 Production order Status in process, complete, not started Actual cases 1216 Planned to actual variance 104 In full Yes / no Time left to complete order 2:20 minutes estimated On time Yes / no OTIF Yes / no Schedule Adherence %
Real-time production order status can then be propagated to stakeholders On Desktops in the office
Real-time order status
Current / Prev shift orders
Sch Adh stats
On the Operator terminals
Order to actual
Time remaining
On the Scorecard views
Current / Prev shift orders
That’s great… but how about closing the loop with ERP The Epicor/Informance planning rate module analyzes historical run data.
Data sufficiency tests are conducted to determine whether SKUs qualify for analysis.
The application brings in the RIGHT amount of data for analysis.
Implications if planning rates are wrong… Too LOW…
Underestimating capacity
Production runs take less time to complete than planned
Creates the potential for “waiting on product” from upstream areas
Significant for capacity-constrained operations Too HIGH…
Overestimating capacity
Production runs take longer to complete than planned
Creates the potential for missed promised dates and lower customer service levels, overtime to recover, etc.
A better way to review and adjust planning rates How are rates established?
With new equipment: based on machine capability
With older equipment:
Reviewed annually at best
Without rigorous analysis
The 13 week analysis rule of thumb…this is flawed
The Epicor / Informance planning rate module applies statistical rigor….
Parameters for analysis:
A minimum number of runs
A minimum number of run hours
Self adjusting date ranges based on data sufficiency thresholds
Running the Planning Rate Module is a 3 step process… Closing the loop What happens when the planning and execution loop is closed…dramatic improvement.
Production orders are fed from ERP
The orders are tracked for performance, OEE, downtime, output, etc.
Planning rates are analyzed for more accurate rates
Schedule attainment is improved [gravityform id="7" title="false" description="false" ajax="true"]
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