Jeremy Wiegman
It was recently brought to my attention how interconnected lean manufacturing principles are with planning and scheduling. In the ideal world of lean manufacturing, one piece flow would be integrated into the production systems as much as possible.
I have observed demonstrations where two test groups were given the same manufacturing task. Group A was to process their tasks in batches. Product from one operation couldn’t move to the next operation until the entire quantity of the previous operation was completed. Group B was given the exact same task, but with different “rules to play by”. Rather than process the operations in batches, Group B was directed to process the task using single piece flow, meaning as soon as one part was completed in one operation, it could move to the next operation. An observer timed both groups as the assigned tasks were completed. Group B, using single piece flow was able to complete the task before Group A, who was processing in batches.
While recognizing that single piece flow isn’t an option for many facilities, it is however, important to reduce the batch size quantity in order to improve the flow of product through the manufacturing process. This dynamic becomes very apparent when using an APS system. Typically, an APS system generates a gantt chart to visualize sequencing and timing of orders and operations in a facility. Within the gantt chart are boxes of time indicating how long an order or operation will take. These boxes line up to also how long each operation will take in conjunction with other operations from other orders. As you can see from the graphic below, the overall amount of time it takes to move product through a facility is less if the batches sizes are smaller, creating more flow.
There are several ways to increase the flow in a facility. One method is to decrease quantities per order at the beginning of the process. Another is to use Planet Together, an Advanced Planning and Scheduling Software. Planet Together offers several functions that address this situation.
One method is to employ a feature called transfer quantity. This feature allows the user to determine when a subsequent operation can start. It allows a subsequent operation to start when the previous operation is complete, or when a certain percentage or quantity of the previous op is complete.
The second feature that Planet Together offers is called Splitting Operations. This feature allows an operation or order to be split into mini operations or orders based on quantity, percentage, time etc. Both of these features allows the user to increase the flow of product as well as decrease possible downtime due to waiting for operations to complete.
For a demonstration and to learn more how PlanetTogether can help you improve flow in your schedule please contact Scheduling Solutions!
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Most manufacturers recognize that, in order to compete in today’s fast changing world, they need an APS solution that addresses their unique needs. They also recognize that most APS solutions on the market do not work, cannot work, and will never work.
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