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Source: Sheet Metal & Production Magazine Issue 7, 2023 / Full text 4243 words, 8 minutes to read
Text/Guangdong Yilin Enterprise Management Consulting Co., Ltd
The ancients said: "All things are foreseen, and those who are not prepared are wasted." The "pre" here is the plan, which shows that the ancients were also very aware of the importance of planning.
As the saying goes: "Before the soldiers and horses move, the grain and grass go first". Strictly speaking, strategic planning comes first. If you win an enemy with equal or superior combat strength, you generally need to plan more than ten years, decades, or even generations or more in advance, and continue to improve the country's comprehensive strength and pre-war mobilization capability from all dimensions. In addition, a detailed battle plan, even if some of the items are only a little out of order and a little delay in progress (time buffer for key matters), will lead to the defeat of the war.
The importance of program management
The same is true for the improvement of plant operations management. In the plan management, the plan achievement rate index based on the standard working hour quota is related to the improvement of operation efficiency, the inventory turnover rate is related to the capital utilization rate and the material sluggishness rate, and the supplier bargaining selection in the procurement plan is related to the cost of obtaining materials. All costing and quotations are based on the planned budget, and any planned over-budget, abnormal program management controls, etc., will lead to the consequences shown in Figure 1.
Figure 1 Consequences of a runaway plan
The uncontrollable cost will eventually make the enterprise management go to a vicious circle, weaken the competitiveness of the enterprise, lead to customer dissatisfaction, make the enterprise gradually go down, if it is serious, it will make the enterprise die quickly.
At present, most traditional industries basically belong to the buyer's market with oversupply, and in such industries, in addition to the head brand can be appropriately premium, the essence of competition between enterprises is the competition between enterprises and customers for cost and profit. Therefore, the excellent level of planning control determines the cost of the entire supply chain, determines the cost of products, determines the amount of value that can benefit customers, determines the amount of profit and loss, and determines the continued existence of the enterprise.
Common pain points for plan control
Let's briefly outline the common difficulties in controlling sheet metal stamping assembly plans in the 6C industry.
First, customer demand is variety, small batch, frequent adjustment is the trend of the current demand plan, we must meet customer needs. Many enterprise order needs are updated weekly by different customers, and some will adjust and update the bi-weekly shipping plan every day. The advance or delay of the forecasted demand plan will re-disrupt the main production plan, and it is necessary to quickly identify the variances, and secondly, initiate a review of the feasibility of the variances to feedback consensus to ensure the feasibility and stability of the plan. Most of the time, we don't do enough about these points, and we don't do enough.
Second, the adjustment of the order demand plan needs to synchronize the operation plans at all levels of the main production plan, and only in this way can the time plan of the lower level of the operation task associated with the order be the demand plan of the latest production capacity, so as to ensure the feasibility and stability of the master production plan. In most cases, we have adjusted the order that needs to be planned in advance, but the plan needs to be delayed, or the plan that should be delayed due to limited capacity has not been re-reviewed and adjusted, which will consume our already tight capacity resources or external supply resources, thus limiting the overall output and efficiency. In addition, many self-made parts of the upper and lower levels of the plan out of joint, not synchronized and not matching, often there will be the mother part has been scheduled to start the plan and the sub material is not scheduled, or the child part completion plan is later than the mother part of the start plan, resulting in poor supporting of the plan, affecting efficiency and output, resulting in delayed delivery and increased costs.
Thirdly, many scheduling plans lack detailed operation task decomposition, lack of accurate standard operation hours, standard conversion hours, lack of optimal resource allocation (all based on experience), lack of automatic identification of similar processes to reduce the number of production changes and production conversion actions, lack of work orders or relatively accurate planned start and planned completion dates of work tasks or work tasks, it is difficult to measure the rationality of plan achievement and efficiency achievement, and it is difficult to promote output improvement.
Fourth, most enterprise ERP systems run material requirements planning based on the order plan at the time of receiving orders, many order requirements have been adjusted, but most of the material plans have not been adjusted synchronously. The out-of-stock plan and delivery plan are also not synchronized with the latest work order plan. Some non-urgent material requirements occupy bottleneck capacity or external supply bottleneck resources, resulting in high material inventories and frequent material shortages, resulting in shutdowns or changeovers. A unstable material requirements plan, suppliers will not take it seriously, because doing it can only occupy their positions and funds. It can only be that he will do whatever you are in a hurry to chase, and at the same time, the plan he promised before could not be delivered on time because of our urgent order demand, so the condition of the complete set of materials became worse.
Fifth, the material feasibility review of the order delivery review is extensive, the BOM is still rough during the order review, and the material feasibility assessment is basically based on the general product material cycle estimate of the complete set of plans, in fact, each product has different cycle materials, it is difficult to ensure the reliability of the material cycle and the material pre-complete set of plans. In addition, the capacity feasibility assessment is extensive, the processing technology of many processes is still not clear during the order review, the outgoing self-production is not determined, the order-related operation tasks are not subdivided, the relevant resource standard production capacity is not associated, and the capacity demand during the period is not subdivided into the daily contractable amount, resulting in the planned excess capacity supply and insufficient planned delay, or the planned amount during the period is insufficient, resulting in the waste of shutdown and waiting.
Sixth, the material loss setting did not carry out PQ consumption analysis, did not set a reasonable loss rate according to the specific process of the specific product, and did not set the reasonable loss rate according to different batches. The loss rate of some materials is too low, which often causes the second or third supplementary feeding, resulting in an increase in the cost of production conversion, and the high loss rate of some materials causes the material backlog to be sluggish and dead.
Seventh, the data update such as order insertion adjustment and return is not timely, and a number of orders demand the same product at the same time, which needs to be manually assigned and judged, and the workload is large, which can easily cause the error and omission of the list of orders out of stock, and produce the wrong order of stock-out priority and information, resulting in the urgent order is not arranged, and the order is not urgent, but has been arranged, which disrupts the order of demand planning and out-of-stock planning.
The main reason for the difficulty of planning control
So what are the main reasons for the difficulty of planning control, see Figure 2 for details.
Figure 2 The main reasons for the difficulties in planning control
The overall capacity of key program managers is weak, and many tasks are not done well enough and are not in place. But on the surface, it is due to the excessive workload, which cannot be done, the frequency of doing it is not enough (mutation adjustment), and the depth of doing is not enough. And the enterprise configuration can not add people at will, so the management executor even began to sacrifice some basic principles, today can not do today seems to be reasonable, after all, every night overtime, can do as much as you want. I don't know what I haven't done or haven't done well today, but the things that the leader or boss has explained have been actively completed, but the result is not good. In this way, the entire management data chain is inaccurate, and it is difficult to make analytical decisions and plan adjustments based on data.
If the comprehensive competence of key program management personnel is high, the capacity of the entire program management team can be gradually improved, including the ability of the supporting systems to support the operation of the organization, which is the basis for improving the overall program management level.
However, professional and systematic program managers are basically experts in the industry, and many times they are not available, but if they are used for a long time, the cost is also very high. Therefore, small and medium-sized enterprises need to learn their management thinking, methodology, and learn from their advantages and tools.
Plan job cases intelligently and efficiently
The following is a simple illustration to share some intelligent and efficient planning operation cases for reference, see Figure 3 ~ Figure 9. The following supply chain operation automation cases are customized and developed by Guangdong Yilin Enterprise Management Consulting Co., Ltd.
Figure 3 An example of intelligent and efficient order demand variation analysis
(1) An example of intelligent and efficient order demand variation analysis (Figure 3). Advantages: Batch analysis of customer order demand variation, efficient, fast and accurate identification of variation, timely communication and confirmation of consensus order demand variation, improve the stability of order demand, timely and effective review of order demand variation, analysis of demand variation, rapid response to customer expectations, quickly meet customer needs, effective analysis and review of demand rule quotas, identify the compliance of addition and subtraction orders, timely adjustment of plan synchronization demand, reduce inventory backlog and sluggishness, timely synchronization of demand variation, timely synchronization of task lists, and adjustment of resource planning layout.
(2) Order planning work order planning synchronization case (Figure 4). The out-of-stock plan is automatically adjusted and updated after the order demand is adjusted, the out-of-stock plan is re-adjusted after the inventory allocation emergency order, and the work order production plan can be adjusted according to the latest out-of-stock plan.
Figure 4 Order planning and work order synchronization case
(3) Advanced planning and scheduling - intelligent automatic scheduling case (Figure 5). Adjust the scheduling plan based on the latest customer needs: the system automatically loads the scheduling tasks, automatically identifies the optimal processing resources, adjusts the scheduling sequence with one click, automatically adjusts based on the scheduling constraints, and clearly changes the production and production time plan. Plan material delivery according to the latest production plan: forward-looking production output time plan, automatic decomposition of processing and production conversion time, to achieve balanced quantitative beat production, based on standard working hours quota scheduling, and one-click generation of plan parameter adjustment.
Figure 5 Advanced scheduling and automatic scheduling
Advantages: Improve the efficiency of scheduling plan and reduce the loss caused by human scheduling errors; improve the forward-looking stability of production scheduling, synchronize material delivery scheduling, and achieve complete set of accurate delivery and low inventory; Based on the accurate production transfer and production time plan, plan in advance to reduce the idle waste of personnel and equipment waiting; Accurate production time plan can reduce site occupation and reduce repeated and ineffective handling of materials; Accurate production time plan can be used for handicraft control and timely monitoring and counseling 4M weaknesses to improve efficiency and quality.
(4) Case of complete set analysis of work order lack of materials.
1) Analysis of the complete set of work order material shortage.
Based on the production scheduling plan, the results of the complete set of inspections are dynamically updated, the complete sets of general materials are accurately investigated, the complete sets of simulated material preparation reduce occupation, and the lack of materials at the same frequency reduces inefficient communication. Material deduction synchronization full set of investigation, physical material preparation synchronous complete set of investigation, material changes are updated in real time, arrears are synchronized with material delivery scheduling, and the complete set of responsibilities is clear and conducive to improvement.
Advantages: high efficiency, saving personnel, the same frequency of material shortage, material control plan, production, procurement, warehouse management, and material arrears investigation and reporting are all provincial; accurate, reduce losses, due to human analysis errors caused by the lack of materials, report the wrong stoppage, cut off materials, etc.; timely, the latest complete set of conditions (Figure 6), dynamic update is convenient for temporary and rapid adjustment of the plan to avoid lack of materials; synchronization, material and plan synchronization, according to the production schedule synchronous simulation update forward-looking material demand plan; efficiency, reduce waste, increase production and generate income, improve the complete set to reduce the loss of shutdown and material breaking, and reduce inventory.
Fig.6 Dynamic set-up status
2) Material requirement scheduling. Advantages: efficient, labor-saving, no matter how many suppliers and how many materials are involved, the delivery schedule is generated with one click; synchronization, according to the supply cycle and difficulty to synchronize the latest scheduling plan, material demand planning is neither early or late; forward-looking, no matter how many requirements are efficient, fast and accurate, the material delivery scheduling decomposition cycle is long enough; high set, automatic calculation of demand scheduling to avoid errors and omissions, the plan is relatively stable, and the complete set of materials is improved; low inventory, planned material control, procurement, supplier consensus, material delivery notice and warehouse control receipt voucher.
(5) Example of capacity supply analysis (Figure 7). Advantages: Once the order demand, work report and planning parameters are adjusted, one-click generation, efficient and accurate; review orders based on dynamic capacity supply and demand analysis to ensure the stability of production plan and material plan; avoid order swap or loss due to lack of capacity supply and demand analysis (missing, wrong, lagging); bottleneck resource management, plan outsourcing in advance to avoid the increase of urgent order costs and improve sales; dynamic early warning of resource bottlenecks, timely and effective mining and utilization of bottleneck resources, and improve overall output and sales.
Figure 7 Capacity supply analysis example
(6) The case of loss reservation for logistics demand planning is shown in Figure 8.
Figure 8 Loss reservation case for logistics demand planning
(7) The case of automatic update of the shipment plan of unfinished orders is shown in Figure 9 and Figure 10.
Figure 9 Shipment plan for unfinished orders
Figure 10 Out-of-stock plan for incomplete orders
Conclusion
The level of data analysis and processing ability determines whether there can be more time to release and optimize and adjust the scheduling plan and material plan in combination with the actual situation on site, which determines the quality of the scheduling plan and material plan, and affects the level of production cost.
To plan well, it is far more than staying in the conventional hard indicators of short cycle, high quasi-delivery, high set and low inventory. The core goal of the manufacturing industry is to satisfy customers, control costs, and achieve profitability, so the core of the plan must return to serving high efficiency, high effective output, low cost, and low waste. Planning demand management, which products to make, how much to do, how much to do each time, and how often to do it, these are all very important, affecting the satisfaction of customer needs (potential loss of sales), inventory backlog sluggish and wasteful, and unbalanced production planning tasks resulting in high costs. All planned operations must also focus on the best batch and the best dispatch plan, make full use of bottlenecks to improve effective output, reduce resource waste, and choose the best procurement time to reduce procurement costs.
Good control of plan management can reduce the proportion of exceptions. Anomalies and costs are twin brothers, and controlling the proportion of anomalies is to reduce waste, save costs, and create revenue.
The plan management control is good, and the new product is easy to be the first to go on the market, which is the first opportunity for the enterprise to participate in market competition, which is also the embodiment of the excellent management level of new product plan control and project plan control. It can be said that the level of overall plan management and control of an enterprise determines the core competitiveness of the enterprise and determines the future of the enterprise.
Therefore, outstanding entrepreneurs in the 21st century need to pay more and more attention to the improvement of plan management level and realize the automation and intelligence of plan management.
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