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Industry Solution for Automobile Industry

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Four problems of Automobile and Auto-parts industry …

Four problems of Automobile and Auto-parts industry
① Quality control … Operations which are not yet standardized sometimes cause defects
② Cost and Profits … Cost and profit per product should be visualized
③ Due dates … The gaps between forecasted orders and fixed orders are hard to
be adjusted. Emergency orders and order changes are causes of
anxiety.
④ Globalization … Close coordination with foreign factories is hard to maintain
Strict quality control, schedule management, and cost control are especially required in this
industry.

Published in Automotive , Technology , Business
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  • 1. AsprovaCatalogue with case study reports and samplesIndustry SolutionNetwork Adaptive Production SchedulerAutomobile and Auto parts industryAsprova Corporationhttp://www.asprova.com/
  • 2. Industry Solution Automobile and auto-parts industry① Quality control … Operations which are not yet standardized sometimes causedefects② Cost and Profits … Cost and profit per product should be visualized③ Due dates … The gaps between forecasted orders and fixed orders are hard tobe adjusted. Emergency orders and order changes are causes ofanxiety.④ Globalization … Close coordination with foreign factories is hard to maintainStrict quality control, schedule management, and cost control are especially required in thisindustry.Asprova’s high speed production schedulerswhich enable “visualization” of schedules haveserved our clients’ needs. The following is theintroduction of Asprova’s solution.Schedulers with finite capacity make production plans which can be directly used as work instructions.Schedulers can manage urgent orders and due date changes, allocating inventories.◆ Order Gantt Chart: enables checking of overdue orders, wait times of each process, inventory allocation. TheOrder Gantt Chart’s standard feature includes a Resource Gantt Chart, an Instruction Gantt Chart, an item GanttChart, overdue flags. The Order Gantt Chart is easily operated with the mouse.Finding the due date by finite capacity schedulingFour problems of Automobile and Auto-parts industryPegged to inventoriesLeading time Due dateStart and the end of each processOperating resource at each process
  • 3. Industry Solution Automobile and auto-parts industryAsprova is capable of efficient load allocation to multiple production lines. Asprova also manages to take intoaccount facility investment simulations and manpower employment planning. Shift changes per facility orworker are easily operated with the mouse.◆ Load graph: current load status is recognizable in one view. Displayed periods, displayed resources, and textdisplay are customizable at your will. In addition, inventory graphs and leading time graphs are included as astandard feature.The “Skill map”, a table to set up process skill of employees, is provided as a standard feature. It enablesmanaging of employees’ capacity, ability/inability and processing speed, separate to integrated master tablessuch as the BOM (Bill of Materials) and resource capacities.◆ Up to 999 skill types can be added. Displays and input means are also easily customized.Skill map to manage workers capacityEfficient load adjustmentResource load status per day(per hour setting is also available)Load percentageaverage
  • 4. Industry Solution Automobile and auto-parts industryRegistering orders not only per production unit/lot but also per sales order unit/lot is possible. Productionschedules can be made to eliminate unnecessary inventory, while taking into account safety inventories.◆ Sales plan table: The information on orders for a certainperiod can be registered with the accuracy of companyforecast, sales forecast, customer forecast, and confirmedorders.*Sales order option is required.◆ Inventory graph: inventory changes andmaterial requirement can be calculated at oneview. In addition, production graphs andconsumption graphs are available. Calculationfunctionality for each term is also included.Key Performance Index (“KPI”) including sales, profit, profit ratio and material cost can be calculated by cost peritem and working cost per resource. Calculation formulae can be freely customized. Also, a standard costbreakdown can be calculated. It can be used to verify the result of facility investment simulations as well.* KPI option is required◆ KPI (Key Performance Index): KPI can evaluate the schedule result and keep records.◆ KPI radar chart: KPI radar chart enablescomparison of the simulation result by radarchart. (with HTML View)Evaluation of the result of scheduling and simulation by KPIProduction Scheduling pegged toinventories and order information
  • 5. Industry Solution Automobile and auto-parts industryAsprova is available in Japanese, English, Chinese (Simplified Chinese and Traditional Chinese), Korean, German,Spanish, Portuguese, and Thai. Using the same package enables very close co-operation and understandingbetween different plants.◆ Adaptable to Multi-languages: Displayed languages can be changed during running.◆ Adaptable to Network: production scheduling is shared through the network.JapaneseChinese(Traditional)DeutschlandEnglishKoreanThaiChinese(Simplified)Adaptable to global networks
  • 6. Industry Solution Automobile and auto-parts industryIntroduction to the case studiesTo read our latest case study, please go tohttp://www.asprova.com/em/case/index.html
  • 7. Case Study 1Kihara Manufacturing Company, Ltd.Pipe Manufacturer Chooses Asprova for Scheduling SpeedAchieves Load Leveling and Major Inventory ReductionThe Ibaraki factory of Kihara Manufacturing Company specializes inproduction of piping and tubing, including truck exhaust pipes, engine pipes,and hydraulic pipes for construction equipment. Production scheduling isperformed twice each morning, first for products and then again for parts.Weighed down by the complexity of handling a large number of customersand product varieties and the resulting large number of order changes, theywere drawn to Asprovas ability to maintain fast scheduling speed in the faceof overwhelming data size. Due to the flexibility of the Asprova program, theywere able to deal with the large number of customers and products whilekeeping customization to a minimum.Problems Prior to Introduction● MOUNTAINS of paperwork due to complicatedscheduling procedures● CONFUSION on assembly line due tocontradictory instructions from different processmanagers● PROCESS managers hoarding inventory to avoidmissed deadlinesReason for Introducing Asprova● ASPROVAs scheduling speed● MINIMAL need for customization● QUALITY of response from Scheduling SystemLaboratoryBenefits of Introduction● ASPROVAs load calculations enabled schedulingto be performed centrally every morning withoutexchange of paperwork.● CONTROL of factory floor through reliableschedules led to inventory reduction of more than200 million yen.● CLARITY of priorities and accuracy of loadcalculations in Asprovas manufacturinginstructions eliminated need for corrections byprocess managers.Data VolumeFinished products 3,400Total items 10,000Resources 100Processes 3Scheduling period 58 daysScheduling cycle once / dayLots in scheduling period 6,000Jobs in scheduling period 15,000Production Scheduling in State ofConfusionUp till now in the Ibaraki factory of KiharaManufacturing Company, process managers for eachcustomer carried out instruction-based production whichdepended on the exchange of considerable paperwork inthe form of production plans, work charts, missing itemlists, and instruction supplements. Since it was notfeasible for detailed factory-wide production schedules tobe drawn up centrally on a daily basis, much of the burdenof scheduling was placed on the shoulders of the processmanagers themselves, who were often unable to setappropriate priorities to the requests for needed partscoming in simultaneously from numerous other managers.As the factory floor and production management officebecame increasingly swamped in paperwork, the problemwas worsened by managers making unnecessarily largerequest for parts or hiding inventory stock for fear ofmissing deadlines. Although a production managementsystem had been installed on the factory mainframe formore than 20 years, the reality of the factorys productionscheduling was that it was in a state of confusion."For more than 10 years," explains Masami Satoh,Chief of Production Management, "we had been lookinginto introducing a scheduling management system, and infact we tried several different ones, but none of themreached the stage of actual installation." The main reason,he says, was that most of the systems were unable tohandle the large number of customers and productvarieties. They decided on Asprova because of the highspeed of its scheduling computation, and because theyvalued Scheduling System Laboratorys quick response toall of their needs. Concerning the speed of computation,Satoh says, "We saw the demo and were amazed."Kihara Manufacturing Company, Ltd.Main office: 6-14-9 Soto-kanda, Chiyoda-ku, Tokyo 101-0021 JapanIbaraki factory: 5166 Uchimoriya-cho, Mizukaido-shi, Ibaraki-ken303-0042 JapanCompany established: February 1943, Factory established: July 1954Representative director: President Tsuneo KiharaCapital: 107 million yen, Employees: 270 (as of June 1998)Annual sales: 5 billion yen (in 1997)Since its establishment, Kihara Manufacturing Company hasspecialized in producing a diverse range of low-pressure to high-pressurepipes for use in motors, industrial machinery, ships, and other machinery.
  • 8. Case Study 1Figure 1: System structureData is transferred with the office mainframetwice daily in order to carry out scheduling, firstfor the customer-side plans, and then for thefactorys internal requirements. The mainframeexplodes requirements for parts, determinesdue dates, and outputs manufacturinginstructions.Figure 2: Gantt chart showing results of scheduling with Asprova.Figure 3: Main menu from Asprova peripheral utility, developed byKihara Manufacturing Company in response to various needs fromthe customer relations department.Satoh says their appreciation was further increasedupon finding that Asprovas standard version was ableto deal with the continual thorn in their side -- the hugenumber of product varieties -- with a minimum ofcustomization.Cant Operate Without AsprovaNow scheduling is performed twice a day, first toschedule the final products, and then again to schedulethe component parts based on those results. Althoughperforming daily scheduling on a scale as large as theIbaraki factorys means some daunting demands on thescheduler for computational speed, Asprova easily metthe challenge by generating a schedule in only 10minutes.At the same factory, during the investigatorystages of the scheduler introduction, managers haddescribed their hopes for the role of the scheduler in alist including such tasks as integratingcustomer-specific manufacturing instructions,generating reasonable instructions based on resourceload planning, guaranteeing that following the schedulewill finish lots on time, producing only the requireditems, facilitating frequent re-scheduling, and ensuringtimely completion of job preparations. Asprova, theysay, has fulfilled nearly 100 percent of their hopes.Not only that, but Asprova has also allowed themto effect a drastic reduction in inventory. "Up till now,"explains Satoh, "process managers were onlymanaging to stay on top of demand by producinghundreds of pipes at a time. Now that we havescheduling under control, weve started producingsmaller lots to cut down on inventory." On a price base,he says, this inventory reduction has totaled about 30percent.With this growing list of achievements, Asprova israpidly becoming an indispensable element of theIbaraki factory. As Sumio Sakamaki, Chief of SystemsDevelopment in the Production Division, says, "Asprovahas become so much of part of our productionmanagement system, I dont think work in this factorycould even go on without it."Asprova CorporationGotanda Mikado Bulding 8F, 2-5-8 Hiratsuka, Shinagawa-ku, Tokyo 142-0051, JapanPhone: +81-3-5498-7071 Website: www.asprova.com e-mail: universal@asprova.com
  • 9. Case Study 4F-tech, Inc.Auto Parts Manufacturer Chooses Asprova For Scheduling SpeedReduces Setup Time and Inventory in Two MonthsF-Tech Inc. primarily manufactures suspensions and rear axle beams forautomobiles. Before introducing Asprova, they made schedules relying ontheir intuition and experience based on required quantities calculated by themainframe computer. Frequent changes in orders, however, put a heavy loadon scheduling managers and caused inconsistency between material orderingand scheduling. To resolve this situation, they have introduced Asprova, apopular high-speed scheduling system, and DISP, a production managementmodule. The introduction of these systems has reduced not only the load onscheduling managers but also inventory in a short period of two months afteractual operation began.Problems Prior to Introduction● HEAVY workload for scheduling managerstrying to keep up with frequent order changesthrough manual scheduling methods● EXCESSIVE inventory hoarded to avoid latedelivery and confused production in the face offrequent schedule changes● EXCESSIVE raw material inventory andhand-writing of material orders due toinconsistency between material ordering andschedulingReason for Introducing Asprova● ASPROVA’s diverse standard features● ASPROVA’s fast scheduling speedBenefits of Introduction● CUT time required to make a schedule down toa couple of hours, reducing the workload of thescheduling managers.● IMPROVED accuracy of scheduling, reducingsetup time, lead time, and inventory.● ENABLED source data for material orders tobe sent automatically to the mainframecomputer, preventing material shortages.Heavy Load on Scheduling ManagersThe mainframe computer in F-Tech receives orderdata once a month covering a period of three monthsand receives data on order changes daily. Beforeintroducing Asprova, however, material requirementswere generated only once a week on the mainframebecause it took too much time and they had no way totake into account the load on the line. As a result,scheduling managers had to make daily schedulesbased on their own intuition and experience, manuallytranscribing order changes and taking into account theinventory and load on the line. Despite their effort, itwas very difficult to handle the great number of orderchanges, and careless mistakes would inevitably occur.Since accurate scheduling was quite difficult, they wereforced to change schedules frequently, taking on anexcessive workload. As Katsumi Arima of theProduction Management Department of the ProductionDivision says, “The whole day would be taken up justadjusting the schedule.” These frequent changes in theschedule would in turn force the factory floor to keepextra inventory of intermediate parts to prevent latedelivery and confusion in production. Also, themanually-drafted production plans and material ordersdid not match because materials were ordered based onthe data in the mainframe, which did not reflect themanual changes. Again, they were forced to ordermaterials manually to keep extra inventory so that theproduction line could go on running.“The first thing we needed," said Toru Okutomi,Manager of the Production Management Department,Production Division, "was to reduce the man-hoursrequired for scheduling.”Data VolumeFinished products 600Total items 5,150Resources 58Processes 5Scheduling period 3 monthsScheduling cycle ConstantlyLots in scheduling period about 45,000Jobs in scheduling period about 150,000F-Tech Inc.Main office (Kuki office): 19 Showa-numa, Shobu-cho,Minamisaitama-gun, Saitama-ken 346-0194, JapanCompany established: July 1947Representative director: Akihide FukudaCapital: 1778.9 million yenEmployees: 980Since its establishment, F-Tech Inc. has manufactured auto partssuch as suspension assemblies, sub frame comp., and rear axle beams.The company has numerous patents and utility model rights regardingauto parts such as a pedal leg-power reducer and a foot-operatedparking brake.
  • 10. Case Study 4Figure 1: System ConfigurationMaster order information is sentfrom the mainframe, and schedulingis performed by two Asprovas linkedwith DISP. The resulting scheduleis then used for generating workinstructions, and part of the data isreturned to the mainframe to beused for issuing material orders.Thus, among various objectives, they recognized themost important one to be the reduction in the load onscheduling managers. After comparing several modules,they were most impressed with the high-speed schedulingand the standard features of Asprova. In terms ofscheduling speed, in particular, Arima said that Asprovawas by far the fastest.Figure 2: Gantt chart created through scheduling with Asprova. Changesand additions are identified by color or by fixing the associated jobs inplace.Figure 3: One of the screens from DISP. These screens are customizedto the user’s needs.Since, however, as Okutomi explains, “weneeded capabilities that would enable peripheralconnections besides scheduling,” they decided tointroduce Asprova together with DISP, a productionmanagement module from NEC Techno-Service, anAsprova distributor.Results Within Two Months of OperationWhen it came time to install Asprova and DISP,F-Tech took charge of preparing the necessary dataand determining the system specifications, while NECTechno-Service took charge of most of the systemdevelopment. “Determining the specs was not aneasy job,” Arima said. “Also, we got a lot of errorsbecause the mainframes configuration charts didntinclude the process codes, and correcting these errorstook a lot of time.” Since he had to do regular workas well, he says, it took time to get ready for the testrun.Now, after the installation of Asprova, theschedule can be created in a couple of hours,reducing the load on the scheduling manager, whichwas the initial objective. Asprova has also enabledaccurate scheduling making full use of the precisedata prepared at installation. As a result, the factorynot only produces items as scheduled but has alsobeen able to reduce setup time, lead time, andinventory. They can now order materials by sendingsource data directly to the mainframe so that sufficientmaterials can be kept all the time. Although only twomonths have passed since they started operatingAsprova, they are already enjoying various benefits.“I think we will have further good effects as timepasses,” says Arima.In the future, F-Tech is planning to deploy PCterminals at each process to enter the results data thatis now written on daily reports, and to create a systemto confirm schedules using the Asprova SchedulingMonitor, thus more efficiently utilizing Asprova andDISP.Asprova CorporationGotanda Mikado Bulding 8F, 2-5-8 Hiratsuka, Shinagawa-ku, Tokyo 142-0051, JapanPhone: +81-3-5498-7071 Website: www.asprova.com e-mail: universal@asprova.com
  • 11. Case Study 3Shonan Unitec CorporationAuto Parts Manufacturer Reduces Inventory and Achieves ConsistencyAmong Process Plans"Asprova" a Byword For Production Planning Throughout the FactoryShonan Unitec Corporation specializes in production of auto partssuch as pedal assemblies, pulleys, press parts for cabs, as well as variousother products such as sound barriers, pedestals, etc. Before theintroduction of Asprova, schedules were prepared separately for eachprocess based on documents generated by the mainframe computer.This caused mismatches between processes and excess inventory foreach process, resulting in long overtime work. Now, after introducingAsprova, they are able to make consistent schedules by visually checkinghow much load is applied or required, enjoying various benefits such asreduction of inventory and workload. When it comes to productionplanning, everyone in the factory thinks of Asprova.Problems Prior to Introduction● INCONSISTENCY between processes andexcess inventory from having different staffmembers prepare schedules for each processbased on documents generated by themainframe computer● LONG overtime work required to completeitems by their due dates, putting heavy load onthe workers● DAILY overtime work for the person in chargeof planning to adjust the scheduleReason for Introducing Asprova● ASPROVA’s ease of installation● ASPROVA’s diverse standard features● ASPROVA’s bulk production capabilityBenefits of Introduction● ACHIEVED consistency between processes,enabling smaller lot sizes and reduction ofexcess inventory, which could now bemanaged visually.● IMPROVED the accuracy of the master dataand the schedule, enabling reduction of theload on workers.● ALLOWED the schedule to be created by oneemployee alone, rather than by two or moreemployees working overtime.● MADE it easy for the factory to increase thenumber of manufactured item types.Inconsistent Scheduling Among ProcessesShonan Unitec Corporation used to outputdocuments to each process once a week, generated basedon orders from customers using a standard lead time.These were calculated by a mainframe computer withoutchecking the load on the equipment. Although eachprocess was managed by scheduling specialists whoworked out weekly schedules relying on their intuition andexperience, processes were inconsistent because theywere scheduled independently of other processes. This ledto awkward situations in which produced parts were notused for a long time or production stopped for lack ofnecessary parts. Each process center would have tohoard inventory for fear of item shortages. If there was asudden change in schedule or inconsistency betweenprocesses, they had to work overtime to finish the lot intime for the customers due date. Scheduling managersalso worked overtime everyday adjusting the schedule toflatten the workload of the factory floor.To resolve these problems, they looked intointroducing a scheduling package that wouldenable ”scheduling that takes into account the load onfacilities for all the processes.” The factory wanted to selecta package that was easy to install, capable of leveragingthe data and capabilities of the existing system, andequipped with all required capabilities. In addition to loadleveling throughout the processes, they needed thecapability to assign lots for the press process combiningmultiple customer orders. According to Kenji Saito of theSystem Group, when they evaluated Asprova, they saw noproblem regarding ease of installation,Data VolumeFinished products 10,000Total items 20,000Resources 150Processes Avg. 3Scheduling period 3 weeksScheduling cycle dailyLots in scheduling period 1,200; 6,200Jobs in scheduling period 10,000; 60;000Shonan Unite Corporation.Main factory: 1919 Kurami, Samukawa-cho, Takaza-gun, KanagawaFujisawa factory: 50 Shobuzawa, Fujisawa-shi, KanagawaIwafune factory: Oaza Kyokugashima, Iwafune-cho, Shimotuga-gun, TochigiFukushima factory: 20 Fukasaku, Miharu-cho, Tamura-gun, FukushimaRepresentative director: Hiroo ItoCompany established: October 1992 (Merger)Employees: 600Annual sales: 14.7 billion yen (in 1997)Since its establishment, Shonan Unitec Corporation has manufactured auto parts suchas pedal assemblies (accelerator, brake, and clutch), pulleys, press parts for small-sized,medium-sized, and large-sized cabs, as well as various other products such as soundbarriers, pedestals (base parts for construction), etc.
  • 12. Case Study 3Figure 1: System ConfigurationThe mainframe sends data to Asprova via aserver and Asprova returns the result ofscheduling. The mainframe then sendsproduction instructions to terminals at eachprocess.and concerning functionality, "when we had looked intoVersion 3, it had still been lacking in features, but whenwe heard that Version 4 had a bulk production featurewe were impressed." Following this evaluation, theydecided to introduce Asprova.Figure 2: Gantt chart showing the result of assignment using the bulkproduction capabilityFigure 3: Aggregated list taken from Asprova’s time series data using anMicrosoft Access query‘Asprova’ a Byword For ProductionPlanningThe factorys System Group and the Factory WorksGroup played the central role in introducing Asprova.International Laboratory Corporation (ILC), an Asprovadistributor, helped with the installation work several timesa week. “Although it was hard to create new data that wehadn’t used before,” says Haruo Kasama, Factory WorksGroup, “we were able to start actual operation in arelatively short period of four months.” During the earlystage of actual operation, data was not very accurate.“We received a lot of complaints if there were problemswith a schedule,” says Saito. "But now," Kasamaexplains, "the situation is completely different from how itwas in the early stage of introduction.” The accuracy ofthe master and scheduling has been improved a greatdeal because they corrected data every time theyreceived complaints.As a result of introducing Asprova, they have beenable to achieve consistency between processes, whichwas one of their initial objectives. This improved theoperation of the factory floor, enabling a reduction in thesize of production lots. “Inventory quantity has reducedsignificantly and housekeeping is now properlyperformed,” Saito says. Scheduling used to beperformed by several people but now can be done byone person alone, resulting in substantial savings inman-days. The load on the factory floor has also beenconsiderably reduced because the accuracy ofscheduling has been improved to balance the amount ofwork for each day. Recently, items which were previouslymanufactured in other factories are being moved over tothe main factory, but they have had no trouble inmanaging the increased production.Now, says Saito, everyone in the factory thinks ofAsprova when it comes to production planning. Thefactory floor counts on Asprova and makes numerousrequests. These requests are being met one by one withthe cooperation of ILC Corporation. In the future,Shonan Unitec plans to improve the mainframe as wellas upgrade Asprova to better meet requests from thefactory floor.Asprova CorporationGotanda Mikado Bulding 8F, 2-5-8 Hiratsuka, Shinagawa-ku, Tokyo 142-0051, JapanPhone: +81-3-5498-7071 Website: www.asprova.com e-mail: universal@asprova.com
  • 13. Case Study 5Auto Parts ManufacturerAuto Parts Manufacturer Chooses Asprova For Its Good User InterfaceReduces Labor of Adjusting The ScheduleAn auto parts manufacturer had been using a custom-made scheduler running on DOS beforeswitching to Asprova. As the number of products and the required number of production lots in theirfactory increased, they eventually exceeded the capability of the scheduler, and were forced to limit thenumber of products and to break orders into several groups to be scheduled in separate scheduling runs.Other problems, such as the inability to restrict color for each facility, worsened this scheduler’s usability.After introducing Asprova, they became able not only to schedule all of the products simultaneously, butalso to automatically assign jobs, taking into account the color restriction of each facility. Theseimprovements, along with the ease of rescheduling using the Gantt chart, have considerably reduced thelabor of adjusting the automatically generated schedules.Problems Prior to Introduction● INADEQUATE data processing capability of theexisting custom made scheduler, leading toimpracticalities such as having to limit thenumber of products and divide orders intoseveral scheduling runs● NUMEROUS typing misses when manuallyscheduling products that were left out of theschedule● INABILITY to restrict colors in each facility,leading to inevitable manual schedulemodification by an experienced schedulemanagerReason for Introducing Asprova● EASE of understanding the schedule in Ganttchart form● EASE of modifying the schedule bydrag-and-drop on the Gantt chart● ABILITY to restrict colors in each facilityBenefits of Introduction● ENABLED all products to be scheduledsimultaneously.● ENABLED scheduling of many times the originaldata size in the same amount of time.● REDUCED schedule adjustment work due to theability to restrict colors in each facility.● STANDARDIZED most of the scheduling work,by codifying schedule managers’ know-how inthe form of master data set into Asprova.Data VolumeFinished products 60Total items 60Resources 46Processes 1Scheduling period 3 daysScheduling cycle DailyLots in scheduling period about 3,000Jobs in scheduling period about 3,000A System That Became PracticallyUselessBefore introducing Asprova, the auto partsmanufacturer had been using a custom-madescheduler running on DOS. But because theprocessable number of lots was inadequate, theirincreasing number of finished products and theirincreasing number of production lots eventuallyexceeded this scheduler’s data processingcapability. Consequently, the factory had toartificially limit number of finished products, anddivide the orders into groups that they scheduled inseparate scheduling runs. This became quite aburden. Products that were left out at the schedulewould be handled manually, but, as one managersaid, “Manual scheduling was prone to typing errorsand many other problems.” Furthermore,diversification in the color of the products made itcrucial to have a color restriction function in theschedule. But since the custom-made scheduler didnot have that function, an experienced schedulemanager would inevitably have to modify theschedule manually. Considering these problems, themanager says that the custom-made scheduler hadbecome “practically useless.”They did think about ways to improve theexisting custom-made scheduler, but as one of themanagers said, “With the year 2000 at hand,introducing a scheduling package was much betterthan going through the hassle of improving thesystem.”After initially fruitless efforts in finding apackage that would match their needs, they thenfound out about Asprova, and immediatelyrequested a demonstration. Besides having theability to restrict colors for each facility, “[Asprovas]GUI is incredibly easy to understand visually, andthe ability to correct schedule using a mouse is justamazing,” said one astonished manager. Afterlearning more about Asprovas functions by using atrial version of Asprova and attending a trainingseminar, they decided to introduce Asprova.
  • 14. Case Study 5Figure 1: System ConfigurationScheduling is performed based onorder data from the mainframecomputer. Asprovas master data isentirely created on the PC. A dailyreport is generated after scheduling.Figure 2: Gantt chart created from scheduling with Asprova. Productspecifications are made easy to understand by intelligent use of colors.Figure 3: Customized screen of Asprova Utility. A variety of needs from theproduction site are reflected.Reduces Labor of Adjusting TheScheduleIt was recommended that initialimplementation work, such as workers’education, creation of the master data based onschedule managers’ knowledge, anddevelopment of peripheral functions, were to bedone mainly by the company itself, with thesupport of the distributor International LaboratoryCorporation. Development of peripheral functionswas done in parallel with the test run. However,as one manager noted, designing and alteringthe functions to meet the demands from theproduction site was not easy.Since the installation of Asprova, they havenot only become able to schedule all of theproducts simultaneously, but they can now createthis complete schedule in the same amount oftime it took to create one of the partial schedulebefore, which had only included a fraction of thetotal data set. Regarding the time required tomake a working schedule, one managerexplains, “Since Asprova automatically creates aschedule that takes into account the colorrestriction of each facility, we don’t need to donearly as much adjusting work.” Whats more,they have been able to standardize most of thescheduling work by codifying schedulemanagers’ know-how in the form of master datathat was set into Asprova at the initial installation.In addition, while it has previously been difficult toexplain the procedure for scheduling to newemployees, this has became much easierbecause of how simple it is to verify and modifythe schedule using Asprova’s Gantt chart..In the future, the company intends totransmit the schedule directly to facilities, toexpand the number of processes in the schedule,and to meet various needs of the production siteby more effectively using Asprova and bydeveloping peripheral functions. Additionally, indeveloping the peripheral functions, the companyplans to built an even easier-to-use system byreconstructing the utility in Microsoft Access andusing Asprova plugin architecture.Asprova CorporationGotanda Mikado Bulding 8F, 2-5-8 Hiratsuka, Shinagawa-ku, Tokyo 142-0051, JapanPhone: +81-3-5498-7071 Website: www.asprova.com e-mail: universal@asprova.com
  • 15. Introduction to the sample dataThe sample data, the case studies of our clients who installed Asprova, is introduced here. IfIndustry sample data is needed, please sign up at the membership registration page of ourwebsite or athttp://www.asprova.com/en/asprova/document_library.html
  • 16. (Industry Solution (Automobile and Auto parts industry)Automobile Bumper (injection molding)Industry Sample Data No.2Asprova MS+Option not in useDefining setup times which occur every time items are changedAutomobile bumper(injection molding).ar4Order Gantt ChartScheduleSet up table (Item)Integrated Master EditorDataThe scheduling only in the injectionmolding process. Schedule withinfinite capacity, considering bothmetal casts and setup workersconstraints.Different metal casts are usedfor each productSetup timesto changemetal castsoccur everytime productsare changedSchedule forworker tosetup
  • 17. (Industry Solution (Automobile and Auto parts industry)Metal Plate/Auto body (repeated process)Industry Sample Data No.4Asprova MS + Option not in UseTo elevate the strength of the metal plates, the processes of annealing,shotting, lubricating, and pressing are repeated.In the cutting process, setup for spec changeover occursevery time items’ designated specs(A/B) are changedOther factor is to reduce the setups for spec changeover incutting process. Scheduling parameter can reduce thenumber of the setup for spec changes occurring.This data is the sample 3 which is installed from Asprova’s trial version.spec for each item and the setting of itschangeover setupOther factorsFlow ChartCCuuttAAnnnneeaallSShhoottLLuubbrriiccaatteePPrreessssSShhoottAAnnnneeaallLLuubbrriiccaatteePressSShhoottLubricateTTrreeaattmmeennttIInnssppeeccttDataThe processes ofannealing, shotting,lubricating, pressingare repeated in thesame orderSetup for specchangeover occursIt is veryimportant forauto partsmanufacturingto keep duedate.Unceasing operations inthe processes ofannealing, lubricating,pressing, unceasingoperations are important
  • 18. (Industry Solution (Automobile and Auto parts industry)Auto parts(Make to stock manufacturing)Industry Sample Data No.5Asprova MS+ Sales Order OPThis data contains much data so that reschedule function does not work on trial version.Make to stock manufacture is carried out with monthlytemporary orders and weekly confirmed orders from clients.Auto-replenish production function is used for production orders whichare automatically made upon receiving temporary sales orders.Although backward scheduling is basically adopted, forward scheduling for continuous manufacturing is used when the total numberof orders is large.Auto Parts(Make to stock manufacturing).ar4Inventory Graph (green line shows safety inventory)Setting up auto-replenish production and safety inventory(Item table)Schedule of receiving orders (sales order optionis required)Other FactorsFlow ChartDataSales orderinformationis displayedin the GanttchartSales orderinformationandproductioninformationin factorysite arepegged.Productiondelays todue date isclearlyshown.Both outsourceand in-factorymanufacturingare displayedwithout anydiscriminationSafety inventory isset up to deal withsales order changes24-hour continuousoperation with athree-shift systemDailyquantityMonthlyquantity
  • 19. (Industry Solution (Automobile and Auto parts industry)Key points of Make-to stock ManufacturingMaster data is used repeatedlyProduction plans are accompanied with accuracy including temporary and confirm ordersand have safety inventories in order to deal with changes of sales ordersAccurate estimation of production plans is important to avoid parts shortageMaking middle or long-period plans to make purchase plans of material and parts whichrequire long term from purchase date to delivery dateMid and long-term plans are often made with MRPs before short-term plans which aremade by production schedulersInputting timing of prototypes and small-number orders into the production lines whichcontinuously manufacture same items is very important because setup times etc arerelatedSimulation for facility investment can be carried out with KPI functionalitySales order option, Purchase option, Sales order schedule, Auto-replenish production,Safety stock, Material constraints, Assigning workers, Skill map, Inventory graphs, Loadgraphs, Production/purchase schedule, Sequence control option, evaluate schedule,Operation split, KPI optionKey points of Make-to order ManufacturingRegistering new master data can be done efficiently in short hours. Or plans can made withoutmaster data registration.Changing plans such as changing designs, time, resources, and workers after plans are made can beeasily carried outConfirming inventories immediatelyStart orders should be made up in order to reduce setup times efficientlyProducing common parts togetherUtilizing resources efficientlyYou sometimes have safety inventories which are in-progress inventories of semi-finished productsGraphical BOM window, Parametric BOM, Auto-replenish production, Safety stock, Materialconstraints, Assigning workers, Skill map, Inventory graphs, Load graphs, Production/purchaseplans, Sequence control option, Evaluate schedule, Operation splitRelated featuresRelated featuresfunction76542137654213APS Practical Training Seminar (held regularly at Asprova Distributors)http://www.asprova.jp/seminar/file/seminar_expl2aps.html
  • 20. (Industry Solution (Automobile and Auto parts industry)ElectricElectronicsLEDs, connectors, solderless terminals, microprocessors, printed circuit boards, silicon wafers, air conditioner cases (plasticmolding), speakers, ceramics, watches, semiconductors, lead frames, CD-ROMs, CD-R / DVD / CD-ROM drives, electric wire,LCDs, stereos, photo masks, WF cables, sockets, mobile phones, connectors for mobile-phones, IC packages, aluminumelectrolytic capacitors, photoresist, TFT modules, piston rings, needles, piano wire, printer pins, automotive meters,photoelectric board, digital cameras, car navigation systems, refrigerators, light fixtures, sensors, signal controllers,solar-powered battery modules, vacuum fluorescent displays, batteries, multipolar connectors, power cables, mainframecomputers, projection equipment, quartz transmission equipment, desktop PCs, carbon electrodes, projectors, printers, powerboards. heating equipment controllers, solar cell wafers, medical electrical equipment, SD cards, portal media players,connectors, bar code readers…Automotive Engine parts, doors, chassis, interior (plastic molding), metal molds, shock absorbers, vehicle inspections, pipes, tubes,engines, cranes, rubber, aircraft parts, test bodies, brake parts, high-pressure hose, seat fabrics, wire rope, transmissions,camshafts, crankshafts, cases, wire harnesses, motorcycles, bicycles, railway carriages, external parts for ships, anti-vibrationequipment for vehicles, tires, movable cranes…Machinery Looms, kitchen appliances, machine tools, agricultural machinery, industrial machinery, optical instruments, light fixtures, airconditioners, heating appliances, plastic parts for office equipment, control computers, material handling equipment, powertransmission equipment, power-driven hand tools, internal combustion engines, in-line instrumentation systems, wafer visualinspection equipment, centrifuges, sewing machines, heat treatment equipment, tanks, water tanks, turbines, condensers,model engines, vacuum pumps, wafer precision equipment, food products machinery, electric facilities, gas and water-relatedtools, water supply-related instruments, electric welders, stage lighting fixtures, sewing machine parts, pumps, ultrasonicdiagnosis equipment, CNC, robot transfer machines, nuclear equipment, crystal units, rubber hose. Fire alarm equipment…Metal Drills, screws, cannons, wire, plumbing fixtures, guard rails, pipes, magnet wire, steel, sheet metal parts, fences, metal bridgeparts, blades, connecting rods, nuts, industrial precious metal products, drawing alloys, aluminum for beverage cans, bladesfor cutting machines, gears, metal springs, timer parts, precision gears, aluminum foil, sheet copper, ship plates, drawn copperproducts, specialty steel products, cutting tool tips, lubricating oil packaging, beverage cans, magnets, seamless pipes, largescale pumps, process pump, coupling, clad steel sheet, transmission gear…Non-metal Corks, packaging, textiles, paper, shipping blocks, camera films, rubber products, ABS resin, synthetic resin, UV ink, gravureink, printing of packing materials, coated abrasives, resin hose, coating materials, dental materials, film sheets, ceramic basefor electronic parts, tiles, firebricks, new ceramics, catalysts, paper clay, fasteners, glass for LCD displays, adhesives, packingtape, stencil paper for wigs, sensitized resin, natural resin, cosmetics materials, inorganic pigments, lenses for microscopes,nonwoven fabric, aluminum foil, man-made leather, aluminum cans, resin mold, silicon wafer…ConsumergoodsFermented soybeans, detergent, flour, plastic bags, plastic food containers, plastic models, office goods, fishing reels,microwave dinners, wood processing, socks, cans, cosmetics, rubber stamps, ballpoint pens, shampoo, shopping bags,cardboard, home exterior products, drinking water, entranceways, underfloor storage units, fixture components, shoes, toyparts, necklaces, stockings, office furniture & fixtures, coffee beans. Labels, envelopes, stationery, candy, gummy, seasoning,steel furniture, toner cartridge, curtains, food trays…Medical Medical products, test drugs, medical equipment, laboratory testing reagents, granulated powder, pills, endoscope, dentalmaterials, clinical test medicine, chemicals…Chemical Adhesives, plastic, asphalt, silicon, motor oil, polyethylene, polypropylene, molding materials, rubber, fluorine chemicalproducts, polyvinyl chloride, polyvinyl chloride paste, plastic paint products, make up products, chemical substances…The fields of Asprova users
  • 21. (Industry Solution (Automobile and Auto parts industry)Item RequirementMemory At least 1GBHard Disk space At least 300MB hard disk spaceCPU Faster than 1GHz(If 64bit, it’s compatible to x64)OS Windows Server 2003Windows 2000 ServerWindows VistaWindows XP ProfessionalWindows 2000Other If using 64bit-CPU, compatible to x64※The requirement of Memory, hard disk space, and CPU depends on its usage and the amount of data dealt with.Asprova Corporation E-mail info@asprova.com Web http://www.asprova.com/Head Office(Tokyo, Japan)Gotanda Mikado Building 8F, 2-5-8 Hiratsuka,Shinagawa-ku, Tokyo 142-0051 JapanTEL 81-3-5498-7071 FAX 81-3-5498-7072Osaka Office Fukushima Building 708, 5-13-18 Fukushima,Fukushima-ku, Okasa city, Osaka 553-0003TEL 81-6-6458-7722 FAX 81-6-6458-0622China Asprova Software Technology Co., LTD. http://www.asprova.cn info@asprova.cnKorea Asprova Co., Ltd. http://www.asprova.co.kr asprova@asprova.co.kr※Product specs are sometimes changed upon version-ups.Copyright© since 2003 Asprova Corporation All Rights Reserved2009.9System requirements