Process synchronization = One Talk-Giver
Automatic Synchronization of All Production Processes With the Orchestrating End-to-End Planning System From APS.
Most providers of planning software for industrial manufacturing offer a fragmented system, that is, one that contains functionally independent application modules. These often do not interoperate seamlessly with each other, and thus do not enable flow production.
It is imperative for Industry 4.0 to employ a full-auto APS, SCP system which is capable of orchestrating production so that complicatedly intertwined processes become lined up seamlessly.
Full process synchronization is based on accurate planning, which entails assigning manufacturing orders in correct order to be processed on the correct resources. This is only possible with the help of a robust APS software, whereby:
- There is only one production tact time for every team all production resources.
- The orchestrator observes, controls and plans the factory from a bird’s eye perspective.
- One production tact = tact time production = the bottleneck process established the production tact for all other processes.
Ideally, final assembly should be able to handle a total mix of products according to the delivery sequence!
All related and parallel processes e.g., subassemblies and the mechanical production line should handle products sequentially, according to final assembly tact, and in its sequence.
This is the basis of a well-synchronized production process, just-in-time-production with minimal lead time, and minimal inventory.
Lot sizes should be as small as possible. Together, machine setup time and production lot sizes reveal the grade of your just-in-time standard.
Just a small degree of inaccuracy becomes, with time, magnified exponentially.
This makes it necessary to perform constant downstream adjustments to the plan, as, say, a change made to a customer order is going to affect all downstream processes as well as parallel processes.
Without an APS planning system, one has to resort back to manual planning with Excel.
There is only one way – completely correct planning. Every other way leads to exponentially growing inaccuracy.
The planning department acts as a conductor in directing all processes to achieve and maintain a great degree of process synchronization.
The factory, hereby, is observed and controlled from a bird’s-eye perspective. This allows the planner to issue manufacturing orders to each resource according to an optimized sequence, calculated by an APS tool.
Making use of an advanced planning and scheduling system is the best method to greatly improve total efficiency.
Further advantages are that planning efforts are reduced to a fraction, and implementation only takes a few months!