19 Apr 2012

© 2012 KPIT Cummins Infosystems Limited

Agenda

Why Production Scheduling

Production Scheduling Overview

Scope and objective compared to ASCP Services to

Production Scheduling Components EXCEL
How Production Scheduling Works

Production Scheduling - Integrations

Key Setups & Process

Technical Data Flow

Benefits

QA

Appendix

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 Why Production Scheduling ?

Drawbacks of Traditional Approach

Poor visibility to demand and production plan, many disparate spreadsheets, rush everything

Long cycle times

Large amounts of work in process inventory

Unpredictable manufacturing throughput times

Constant expediting

Poor shop floor performance and poor delivery performance

No visibility to future planned requirements

Vulnerable to unplanned downtime

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Production Scheduling Overview

Production Scheduling uses a constraint-based approach to

automated scheduling

Production Scheduling is a finite scheduling product that addresses

discrete batch processing with floating multistage problems

Production
Production Scheduling can process an almost limitless number of
Scheduling variables and constraints

Oracle Production Scheduling enables us to take control of our production

scheduling problem, and helps us to maximize shop floor throughput

Out-of-the-box integration with the Oracle E-Business Suite, ASCP

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PS Scope and Objective Compared to ASCP

PS SCOPE

Plant 1 Customer X
Supplier A

DC1

Customer Y
Supplier B Plant 2

DC2

Supplier C Plant 3
Customer Z

ASCP SCOPE

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PS Scope and objective compared to ASCP

ASCP PS
Create New Supply Orders Schedule the already created supply
orders

Plan for a network of plants, Create a production schedule for a

warehouses, suppliers and single manufacturing facility
customers in the supply chain

Plan a mid to long term horizon Schedule the short term horizon
E.g. 6 months to 1 year E.g. 2 – 8 Weeks

Model aggregate level production Model very detailed production

constraints constraints

Make decision on procurement - Consider existing purchase orders as

Create new purchase orders a source of supply. No new
purchasing decisions taken

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 Production Scheduling Components
Model Workplace: The model workspace contains a tree structure, which contains all the
scenarios that make up your model, and the operations, resources, and schedule views that make
up each scenario. The model workspace contains one or more scenario folders for your model.
Each scenario folder contains all of the individual scenarios and schedules that you have created
for the current model. In model workplace, following subfolders are created to organize the
information

All Alerts
All Resources
All Resource Groups
All Visits
All Operations
All Routings

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 Production Scheduling Components
Solver: Production Scheduling provides the ability to detect resource bottlenecks automatically, even when
they dynamically float, or move, within a given schedule. Using knowledge about resource bottlenecks, the
Production Scheduling solver employs a scheduling strategy that exploits each type of bottleneck and
maximizes manufacturing throughput.

Solver sequence staging allows users to dictate to the

solver which resource or group of resources should be
focused on and in what order they should be considered
Different solve parameters can be specified for each solve
stage

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 Production Scheduling Components

Key Performance Indicator: Using KPIs, you can evaluate different schedules against each other
to determine which version of the schedule is the most cost-efficient or best fulfills customer
orders. The KPI view can be demand centric or work order centric. The KPIs are categorized into
the following groups

 Customer service
 Costs
 Manufacturing
 Materials

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 Production Scheduling Components

Advanced Analytical Decision Support: Following are the major analytical views that are
supported by production scheduling.

 Production Pegging view

 Resource Gantt and Resource Utilization combined view
 Resource Gantt and Operation Gantt combined view
 Resource Gantt, Operation Gantt, and Item Graph combined view

These views provides many ways for planners to analyze their schedules.

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 Production Scheduling Components
Advanced Analytical Decision Support – Key View /Features

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 How Production Scheduling works?

Non interactive events

1. Enterprise data is automatically extracted from an ERP system
2. Enterprise data is translated into an acceptable format for Production Scheduling
3. Data is loaded into Production Scheduling
4. The initial production schedule is produced and awaits review

Interactive events
1. Review the production schedule.
2. Decide if it is acceptable or not acceptable
3. Perform manual scheduling and simulations that enable you to evaluate different
scenarios (for unacceptable initial schedules)
4. Run a repair solve to incorporate the manual scheduling changes (for unacceptable
initial schedules)
5. Perform simulations that represent the introduction of priority orders or extra
production capacity into the schedule
6. Publish the production schedule to the shop floor using the web dispatch list
7. Publish the schedule to an ERP system

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 How Production Scheduling works?

Create or import model:

The model represents the production capacity of your enterprise. It consists of
the resources, operations, and routings that combine to form a representation of
your production process.

Solving a Model
Solving the model produces a production schedule. You can make changes to the
model and solve the model until a schedule that meets your requirements is
produced. You can resolve scheduling problems by making changes to the data
model including changing order priorities, increasing capacity, or by making
manual changes to operations using what-if scenarios.

Publishing a Production Schedule

Once production schedule is solved, user can publish it for use on the
shop floor. Once the schedule has been committed and published, Production
Scheduling enables user to export operation schedules and reports to external
systems.

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 Production Scheduling Integration - With EBS

The process for using Production Scheduling with the Oracle E-Business Suite in
standalone mode is as follows:

Schedule is run from the Oracle Workbench, extract data from the E-Business Suite

In PS, various scenarios are run until the best schedule is achieved

Approved and published back to the planning server, work orders are released
automatically to the E-Business Suite

When integrated with EBS without ASCP, the data extracted to PS is based on the
category codes created in Oracle Inventory and mentioned in the PS plan options

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 Production Scheduling Integration - With EBS

When configured in standalone mode, Production Scheduling only schedules the work
orders that it receives from Oracle ERP. And does not schedule any planned orders.

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 Production Scheduling Integration - With ASCP

The process for using Production Scheduling with the ASCP is as follows:

Run the ASCP plan.

Release new orders from the ASCP plan

Run Production Scheduling. This extracts the latest data from the EBS and ASCP:

•The work orders within the planning time fence.

•The new work orders released from ASCP.
•Planned orders from ASCP that exist within the scheduling horizon specified
for the Production Scheduling schedule

Run various scenarios in Production Scheduling until the best schedule is achieved.

Approve and publish the preferred schedule to release any work order reschedules

When integrated with ASCP, the data extracted to PS is based on the ASCP Plan name
that is mentioned in the PS plan options.

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Production Scheduling Integration - With ASCP

ODS/PDS

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Plan Cycle – Running PS & ASCP Plans
Typical Cycle flow when running with ASCP

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Integration Comparison- PS Standalone Vs PS with ASCP

Running PS “Standalone” Running PS with ASCP Plan

Schedule work orders only Schedule work orders and planned orders

Forecast demands specified via Demand Forecast demands come in via the
schedules referenced ASCP plan

Inter-org demands included only via Inter-org demands also include planned
internal sales orders order demands from the ASCP plan

Items to be included in PS specified via Items to be included in PS derived from the

specification of category sets / categories items in the ASCP plan

Forecast consumption performed in ASCP is

No Forecast consumption
retained within PS

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 Production Scheduling - Key Setups & Process
Setup Data In E-Business Suite
ITEM
BILL OF MATERILS
ROUTINGS
RESOURCES
Setup key Profile options
Profile Option
MSC: PS/SNO Client Install
Path
MSC: PS Currency Symbol
MSO: Enforce Resource
Sequence Contiguity
MSC: PS Consistent Resource
Assignment
Scheduling Model
Valid Values Description
The path where the Supply Chain Planning Production
Text (Default: C:\) Scheduling (PS) is installed. PS is installed automatically
the first time it is accessed by the E-Business Suite.
The currency symbol used by PS for measurement of
Text (Default: $)
costs and calculation of key performance indicators.
If Yes, then activities within EBS operations are modeled
Yes, No (Default: Yes) as PS operations with S@E (Starts at End) constraints. If
No, the S>E (Starts After End) constraints are used
Yes – If multiple operations within a routing have
alternate resources defined, PS will keep the choice of
alternate resource consistent between operations in a
routing when making offloading decisions
Yes, No (Default: No)
No – PS will not attempt to keep the choice of alternate
resource consistent across operations in a routing
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 Production Scheduling - Key Setups & Process
Setup Production Schedule Name & Options

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 Production Scheduling - Key Setups & Process
Setup – Run Data Collection

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 Production Scheduling - Key Setups & Process
 Run ASCP Plan & Release Planned orders

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 Production Scheduling - Key Setups & Process
Launch Schedule / Open PS Workbench

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 Production Scheduling - Key Setups & Process
Run Solver
Review Schedule Results, Make Changes

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 Production Scheduling - Key Setups & Process
 Approve & Publish the Schedule

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Benefits of Production Scheduling

Maximize throughput and increase resource

utilization

Improve shop floor performance

Decrease WIP inventory value

Determine the best schedule through interactive

simulation

Comprehensively plan and schedule production

integrated with Oracle Ebusiness Suite

Incremental deployment –get benefits quickly

without the loss of integration

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PS -Technical data Flow

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PS -Technical data Flow

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Q&A

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Appendix

Acronym Meaning
PS Production Scheduling

ASCP Advanced Supply chain planning

ADS Oracle Applications Data Store

ODS Operational Data Store

PDS Planning Data Store

APS Oracle Advanced Planning Suit (now AKA “ VCP -

Value Chain Planning” )

XML Extensible Markup language

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 Thank You

Presenter
Ravindra Padghan
Narendra Fadnavis

Email -
ravindra.padghan@kpitcummins.com
narendra.fadnavis@kpitcummins.com