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ADVANCED
PLANNING SYSTEM

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MSF Advanced Planning System (APS) consists of three functions: Real Time Production Monitoring, Production Auto Schedule and Labor Auto Schedule Functions.

Production environment on shop floor, it can be observed production changes in real time like machine status and material details. MSF real time monitoring shows all production that can be monitored by way of dynamic real-time systems that collect and process the complete range of production-related data such as quantities, process parameters, and plant and machine status.

MSF auto schedule functions in case of unacceptable deviations or discrepancies, corrective steps which may include MSF input, are automatically executed. Depending on the degree of automation, data can be directly transferred to subordinate systems. The following gives detail how to works them.

MSF APS has fully autonomous system. When stocks are available, related status are changed. But MFS APS is working differently. Customer quotation is opened at the beginning. This goes to technical department, if it is not produced before. If it is procured before, quotation cost is in the system so it is coming automatically.

Then it goes to “sales order”. If it is not, it is opened a request to technical department. After technical working on the request, technical department creates a material master. Then it goes to production department in order to make an estimated production process and creates “rooting” and “bill of material (BOM)”.

Lastly it is made a cost and used on customer quotation offer. After confirmation of the quotation of offer by the customer, “sales order” is creating automatically. On the sales order, it has to be set necessary parameters. Then for production order created automatically, without going to production department, the order is taking step to “material resource plan (MRP)”.

What does MRP have? This, if the material is to buy or not. Does it have to procure in the factory or outsource? The step is made a decision for MRP. If it is outsourced, it is created an “purchase order” for it automatically. For raw material, it is created an purchase order automatically also. Or if it is procured in the factory, automatically it is created a production order.

For outsource, it is purchased an operation. This purchase order status become relevant for the outsource is made by selecting “outsource”. Then it is assigned a status for all production orders. Under production order it is created job orders. Stocks is checked, how much is it in stock, how much can it be used, system decides automatically instead of any human touch manually in any steps. Then after assigning status like purchase order and production.

Then afterwards production orders are waiting for action of purchase order and production.  This waiting step is on “reservation” function. System has “reservation” which ties four function together “sales order”, “purchase order”, “production order” and “job order”. After then there is “goods movement” function which is created automatically on the back side that is making decision with smart algorithms.

How it is work? Already purchase order confirmed and then system opens a goods movement document on which day will be received related purchase. When the goods reach to factory, it is matched with purchase order via just warehouse confirmation. This goods movement is associated directly with reservation on the back side. At this moment, when the reservation is get the knowledge about confirming of the goods movement, it will check all related department and job order, then say them the reservation is ready to involve planning. Job order inform back to reservation there are another job orders waiting it. Then all job orders check theirs and if they are ready, let them go to scheduling together. And it is changed their status be ready. Then the reservation inform the purchasing to be out and cut their relation afterwards. Purchase order is closed automatically.

Then after it is not needed to be taken action by the purchasing department. All this data is retrieving from the system and updating in the system. There is no any Manuel inputs with human touch. As an example, if 100 pcs are purchasing and 50pcs are received, 50pcs are ready though rest 50pcs not received yet. Continue to used for production what are in hand. This time it is partially closed the purchasing till all material are received and assigned to job orders.

An another case, company can decide to purchase not partially, but bulk and one time purchase, system can understand this also. Waiting job orders from beforehand to end, deliver them to their reservations and is finished this step.

On the other hand, if there is outsource purchasing, this also same steps have, goods movement are finished, it means that this job is directly completed. On this type of job order, purchasing start/finish dates are defined. Example, delivers starts from Monday and finish’s to Friday, in fact this period of time is defined as job start and finish date. It is called “long term processing”. Purchasing for this is open but, it will process between on these days. When is received this outsource purchasing to warehouse, it is closed the purchase automatically. Afterwards this material is called as “in process material” that other jobs are waiting this material.

On the scheduling function, this material has starting and finishing time, so it is planned just to start and finish, not between the dates. It is known that between start and finish time fixed because it is contractual under warranty. At the based on these time, it is planned before this starting time and after finishing  time. After outsource is completed, again saying to scheduling, it can be scheduled after jobs. The story is not over with this.

APS has another part, MES. Without MES, APS is not be an advanced planning capability its own. The fact that if it is retrieving real time answer from job orders, it can be said it has APS. Without APS, there are some application but it is not real APS, they need to be used Manuel inputs, they don’t have process tracing. It is not meaning they have APS. In fact there are not much solution that have real APS capability. Manuel inputs have so risky and potentially they can have high probability faulty or error. Only just one error can make disrupt all scheduling.

Why MES is important? Because if you want to trace production in real time, you have to know unplanned stops, like failure or maintenance that can be above on your plan. If MES and scheduling are working together, it can be get real efficiency. Based on the constraints and parameters, scheduling makes schedule what it real time data taking from jobs in order to define start/finish dates. What MSF do, MES system checks the other jobs every time and every steps that finishing the step information and ask them to be checked what are the next step. And also it is given step finished info to scheduling. Schedule trace all in real time. After finishing all jobs, production order will be finished.

Then, scheduling looks sales order that it is finished, so open delivery for goods movement notification to the warehouse. It means that last step to be sent the production to the customer. And production is finished but not be delivered. Last status for the sales order is deliver. On this point it will make them to be delivered. Then every process will be completed.

What is benefit of MSF? As it detailed explained, MSF optimizes machine utilization, provides computer-based rescheduling due in case of changes in priority or others, and clearly displays the process execution. Thus, it ensures on-time and optimized production runs.

The solution is that MSF provides managing the employee dynamically and flexibly in real-time using hidden capacity. In addition to this, it can be assigning job orders to workstations optimally and planning instant production status changing.

MSF labor auto schedule is a process the operation data which is transferred to the system and artificial intelligence algorithm decides the number of people to be assigned to the relevant operation. While the algorithm is deciding the number of employees for the related jobs, it uses before stated total capacities in the system, thus the job orders automatically plan to reach maximum capacity every hour. Also, employee abilities are considered when employee is selected for the related job.

MSF manages the production areas properly with an advanced planning system, thus provides to increase production efficiency and flexibility, saving time spent on planning, increasing the production capacity, line balancing and revealing hidden capacity. On the other hand, as employee management is kept under control with real-time labor auto scheduling, workload balancing is provided.