Package systems are developed for assembly-type manufacturing processes because standardization of operations is easier. On the other hand, process-type manufacturing uses continuous lines where operations are carried out consecutively, preventing idle time and interruptions by other orders.
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Production Scheduler in Indonesia
Production planning and load planning are closely related and require verification based on quantities. It is important to compare production quantities,…
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What this article covers
- Assembly-type manufacturing processes are easier to standardize and suitable for package systems.
- Process-type manufacturing uses continuous lines designed to prevent idle time.
- In Asprova, setting the overlap MAX to 0 prevents interruptions by other orders.
- Utilizing resource lock reduces waiting time between processes and improves production efficiency.
- In 24-hour operations, setting the shift table to 0:00-23:59 prevents crossing over days.
Assembly and Process Types in Manufacturing Processes
When introducing a production management package system, it is generally assumed that the customer's operations will align with standard business flows. However, many package systems are developed for assembly-type manufacturing processes because they are easier to standardize compared to process types, which often require customization due to the difficulty in standardizing operations.
In process-type manufacturing, continuous lines are used, allowing operations to proceed without idle time or interruptions by other orders. Additionally, tanks are often used, and there is a constraint that prevents assigning other orders to the tank until the preparation work in the current process is completed and the next process is finished.
- Maximum time gap between current and next process
- The next process must start within an hour after the current process to prevent fermentation or quality degradation.
- No other orders should be assigned between processes (no idle time between processes).
- No other orders assigned for a certain time after the current process
- The tank is occupied for 3 hours after the work is completed.
- The tank is occupied for 60 minutes after the next process starts.
- The tank is occupied until the next process is completed.
- Avoid crossing over days in operations
Avoid Assigning Other Orders Between Current and Next Process
With the Asprova production scheduler, it is possible to plan production that maximizes operating rates by assigning other orders during idle times. However, it is also possible to prevent other orders from interrupting between operations in a continuous line, maintaining process efficiency and consistency in planning.
- Enable the overlap MAX setting in the plan settings.
- Set the overlap method in the manufacturing BOM to ES (End Start).
- Set the overlap MAX in the manufacturing BOM to 0.
No Other Orders Assigned for a Certain Time After Current Process
Using the Asprova production scheduler, it is possible to plan production so that no other orders are assigned after the current process until the start or end time of the next process. This ensures smooth transitions between processes and efficient production.
- Enable resource lock in the plan settings.
- Set "PE (Parent End until the end of the subsequent process)" in the resource lock of the resource table.
Case: In one production line, utilizing resource lock reduced setup time and improved overall production efficiency.
Takeaway: Properly setting resource locks can reduce unnecessary waiting times between processes and enhance production efficiency.
Avoid Crossing Over Days in Operations
When manufacturing from liquid preparation to filling in a continuous line, it is important to plan production so that operations do not cross over days. This prevents interruptions in manufacturing time and enables efficient production. Particularly in 24-hour operations, setting the shift table to 0:00-23:59 with a 1-minute interruption prevents crossing over days. Additionally, setting the maximum manufacturing interruption time in the resource table to -1M allows operations to proceed as planned.
- For 24-hour operations, set the shift table to 0:00-23:59 with a 1-minute interruption.
- Set the maximum manufacturing interruption time in the resource table to -1M.
Case: A pharmaceutical company successfully minimized day-crossing interruptions in a 24-hour production line using Asprova.
Takeaway: Shift and resource settings are crucial to prevent crossing over days.
Frequently Asked Questions | Efficiency Improvement and Constraint Management in Manufacturing Processes
We summarize frequently asked questions based on the content of this article.
What are the characteristics of process-type manufacturing processes?
Process-type manufacturing processes use continuous lines where operations are carried out consecutively, preventing idle time and interruptions by other orders. Tanks are often used, leading to specific constraints.
What are the advantages of using Asprova for production planning?
Using Asprova allows for production planning that maximizes operating rates by assigning other orders during idle times. It also prevents interruptions by other orders between operations in a continuous line.
How to prevent crossing over days in operations?
For 24-hour operations, setting the shift table to 0:00-23:59 with a 1-minute interruption prevents crossing over days. Additionally, setting the maximum manufacturing interruption time in the resource table to -1M allows operations to proceed as planned.