CP-49:Streamlining your Production Floor with … Streamlining Your Manufacturing Floor... · CP-49:Streamlining your Production Floor with Dynafact and ... Rough Cut Capacity Planning

CP-49:Streamlining your Production Floor with Dynafact and Costpoint

Pete Cox – DynafactPaul Whiteman – Lexell Blue

Agenda

Introductions Manufacturing Maturity Costpoint Basic Manufacturing Costpoint Advanced Manufacturing Dynafact Advanced Planning & Scheduling How Costpoint and Dynafact work together Summary & Questions

Confidential Deltek 2015

Introductions – Dynafact


Dynafact is a software development and services company Founders over 50 years of experience in the design and application of manufacturing

scheduling technology David Cox (CEO) credited with the first PC based Finite Capacity Scheduling System Dynafact brings value to its customers by providing them with tools they need to reduce

waste and improve throughput Focus on one product with a philosophy of continuous improvement Chosen top APS Company and best fit by Deltek in 2008 after an in-depth evaluation of

several companies and technologies

Introductions – Lexell Blue


Lexell Blue, LLC headquartered in Northern Virginia Comprised of four partners and a team of consultants with extensive experience with the

Deltek GovCon suite of products Costpoint consulting services Costpoint / TE Implementations Costpoint Project Manufacturing / Materials Management Data Migration, Merges, Restructures, and Splits Extensibility Interfaces Reporting Product Installations Product usage assessments

Manufacturing Maturity

Costpoint Basic Manufacturing

Costpoint Advanced Manufacturing

Dynafact

FiniteCapacitySchedule

InfiniteCapacitySchedule

Tool Sophistication

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Dynafact



Tool Sophistication

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Confidential Deltek 2015Confidential Deltek 2015

Basic Manufacturing ModulesBasic features most utilized: Define indented Bills of Material Procure and inventory materials by project Manage picking and material shortages via Manufacturing Orders Track assembly costs via Manufacturing Orders (material, labor, OSP, burden)

Features also utilized: Manage customer deliverables via Sales Orders Generate material requirements (Buy and Make) supply orders via CMR (PMR) Define Routing operations, time standards, assembly travelers


Part Planning Data Make / Buy Planning Types MRP MPS Reorder

Order Policies Discrete Lot Size Min/Mult Lot Size Period Order To Point Reorder Point

Standard Lead Times


Materials Requirements Compute Materials Requirements (aka CMR, PMR, MRP-Lite)

Create Requisitions from Sales Orders

Generate Purchase Requisitions from Sales Order line demand Explode Bill of Material Order schedule based on Part Lead Times

Inventory Reorder Report

Monitor inventory levels against reorder points Generate replenishment Purchase Requisitions


Compute Materials Requirements Good for automating initial material order creation based on specified end-part(s) Specify end-part demand quantity/date or use existing demand (Sales Order, Reservation) Explodes BOM, identifies requirements based on Net Available Inventory and Project

planning rules Buy and Make list reports Indented BOM requirements report

Generates Purchase Requisitions and Manufacturing Orders Orders scheduled based on Part lead times and infinite capacity Limited in monitoring changes in master data, demand or supply chain


Compute Materials Requirements





Dynafact



Tool Sophistication

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Materials Requirements Planning Sophisticated project based materials requirements planning tool

Monitors all demand sources (Sales Orders, Forecasts, Safety Stock, MO, Reservation)

Explodes BOM, Planned Orders based on Inventory, Orders and Project planning rules

Provides Planners effective tools to verify Planned Orders

Generates Purchase Requisitions, Manufacturing Orders and Transfer Reservations


Materials Requirements Planning Orders scheduled based on Part lead times and infinite capacity. Lead time scheduled

dates independent of quantity ordered

Effective monitoring of changes to master data, demand and supply chain: Cancel Order, Decrease Qty Action Messages, Reschedule Order

Multi-Plant supply chain planning

Substitute part planning, Transfer Reservations and Shelf Life Expiration (new in 7.1)

Inventory Abbrev Pegging


Materials Requirements Planning


Project Planning Options Project - No Common Stock Project - Common Stock Top-Level Project – No Common Stock Top-Level Project – Common Stock Netting Group – Common Stock Netting Group – No Common Stock All Projects No MRP Planning


MRP – Respond to Action Messages


Multi-Plant Supply Planning Utilize Inventory Abbrev Peggings and Netting Groups to consolidate multiple plant Supply

and Demand Inter-Warehouse-Abbrev Transfer Reservations connect Supply and Demand


End Item Assembly- VA Warehouse- Project 123

Sub Assembly A- VA Warehouse- Project 123

Sub Assembly B- VA Warehouse- Project 123

Sub Assembly C- GA Warehouse- Project 456

Production Capacity Work Center – define resource capacity Routing Operations – define setup, queue and unit run time standards


Production Capacity Resource loading Based on Work Center capacity, routing operation time standards and MO dates

possible to create a time-phased resource load Dependent on custom reporting (Cognos or other tools) to calculate and report

Production Scheduling Manufacturing Order dates scheduled manually


Master Production Schedule


Two business use cases to manage via Costpoint MPS:

1. Used as a Forecasting tool only:a) Maintain End-Item Production Demand Forecastsb) Allow MRP to plan all end item and lower level requirementsc) Sales Order consumes Forecasts

2. Used as Master Production Scheduling:a) Maintain End-Item Production Demand Forecastsb) Rough Cut Capacity Planning (RCCP) analysis of Key Resource capacityc) Manual maintenance of Firm Planned Manufacturing Order scheduled) Allow MRP to plan lower level requirementse) Sales Order consumes Forecastsf) Limited use within Costpoint client base

Master Production Schedule


Non-Production MRP plans for What-If MRP runs




Dynafact

FiniteCapacity

InfiniteCapacity

Tool Sophistication

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What is Dynafact’s DMS Application?

Dynafact is an Advanced Planning and Scheduling Technology It takes the demand from Costpoint in the form of Manufacturing Orders and Planned MRP

Orders, arranges them into BOMs and Schedules them against available capacity It has simulation tools that allow you to perform quick “what if” scenarios. It is fully integrated to Costpoint and the interface is easily configurable DMS can be used from a high level Capacity Planning tool to a Detailed Shop Floor

scheduler. Scaling the system allows for a quick ROI! It can generate both Infinite and Finite schedules


Infinite Vs Finite Logicscheduling

02468

10121416

Mon Wed Fri

CapacityJobs

012345678

Mon Wed Fri

CapacityJobs


How Dynafact Drives Value!Dynafact Focuses on the Drivers of your orb removing the manufacturing impediments to success.

ImproveProfitability

Improve Competitiveness

DecreaseOperational

Costs

Increase Revenue

Value Creation

ImproveCustomer

Satisfaction

Increase On-Time Delivery

Decrease Lead Time

Decrease Expediting Costs

Decrease Cost of Overtime

Reduce Inventory

Manufacturing Value Drivers

Impediments to greater achievement •Customer commitments based on “Standard Lead Times” and not reality

•Failing to recover from Rework and emergency work interruptions

•No visibility to the impact of changes to the schedule

•Difficulty to accurately predict ETC

•Unexpected bottlenecks (skill sets and special equipment)

•Unplanned Overtime

•Limited ‘timely’ visibility to EVM (Project statuses)

•Not prioritizing work with the “big picture” in mind

•Initiating assembly parts before ready

•Keeping just in case inventory

•Depending on spreadsheets for capacity planning


Who is it for? Dynafact’s DMS technology is an excellent tool for both Tactical Planning AND Operational Planning. Particularly important in Dynamic “Engineer to Order” environments where only partial information is known up front. It is these environments that can benefit the most. Plan your work and work your plan with situational awareness, all known information at your fingertips is critical for success. Learn to act quickly to unplanned events.

Kaizen: Plan-Do-Check-Act“It is not the strongest of the species that survive, not the most intelligent, but the one most responsive to change.” Charles Darwin


Deltek Project Manufacturing CapabilitiesConfig Mgmt &

EngineeringB&P Supply

ChainProduction Sales Order

Product Definition

BOM

Routings / Work Plans

Procurement Planning

Purchasing

Bar Code Integration

Receiving

Production Control

MES

Order Entry

MRP

MPSMaterials

Estimating

APS Shop Floor Time

ECNInventory

Shipping

Invoicing

= Existing Deltek Capabilities = Existing Partner Capabilities

Planning Quality

Incoming Inspection

WIP Quality

Non-Conformance

CAPA

Tool & Gauge

MRO

As-Proposed

As-Designed As-Planned As-Built As-Maintained


Project Manufacturing IntegrationParts

Bills of Material

ECN

Drawings

Models

PLM


ResourcesThere are a variety of ways to set up resources based on the dynamics

of the shop and requirements

A resource can be like a noun: A person, place or thing. It can also be multiple or single.


1 Resource

1 Resource5 People

If resources are unique and have varying skills you can individualize them and they can belong to multiple pools


Pools are used to gather resources that need to be segregated based on capability.

Rules: Resources can belong to multiple poolsThey can be level loaded or follow a picking sequence

Welder Skill A

Welder Skill B

Welder Skill C

Skill A Pool

Skill B Pool

Skill C Pool


They are personalized and typically can only be maintained by their authors. They can easily be manipulated to present unrealistic information. Since Spreadsheets are static they only get updated when a request from

management is made to get detailed shop performance information but are out of date most of the time (until intense administration is required to bring them up to date).

Capacity loads and production schedules are not integrated so calculating the result of a changes and accounting for in process production is an administratively difficult task that is largely dependent on guess work.

Spreadsheets always leave you wanting more. As a result, people try to expand the use and more and more spreadsheets are created to capture more required information. Expanding a flawed process just leads to “Spreadsheet Chaos” and compounds the problem.


Trying to run your shop with spreadsheets?

1. Can we take on new work and meet the delivery requirements?

2. Do we have overall shop capacity, people, machines and space?

3. Do we have the capacity in our special skill sets that are required in order to deliver on time?

4. What is the best recovery plan for a machine breakdown, emergency work interruption, reprioritizing projects?

5. What recovery plan is at the minimal cost to our company? 6. What are the Job statuses and % completes in the shop?


Questions that need answers:



Dynafact Shop Analytics

Multiple Calendars and Head Count Requirements



Visually see your schedule Configure the View

Know where you stand!


Line of Balance (Waterfall or Where your parts are and where they need to be)


Questions & Contacts

Paul Whiteman Peter J. Cox [email protected] [email protected] 571.214.9613 705.732.4241www.LexellBlue.com www.dynafact.com

Documents

CP-49:Streamlining your Production Floor with … Streamlining Your Manufacturing Floor... · CP-49:Streamlining your Production Floor with Dynafact and ... Rough Cut Capacity Planning