PLANSEE - Holding PLANSEE - Holding Plansee Holding High performance materials hard material matters

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  • PLANSEE - Holding

    Plansee Holding

    High performance

    materials

    hard material

    matters

    Sintered steel parts

    50%100% 100%50%

    Tungsten and powder

  • CERATIZIT – structure / organigramm

  • CERATIZIT Italia - Segments

    F1 – Cold heading dies F2 – Drawing dies

    F3 – Fastening Industry F4 – special metal forming

  • Identified Dysfunctions

     Not updated process standard times

     High variability of processes due to lack of standardization

     Not efficient estimation of the order delivery dates

     Very low levels of capacity control

     Long lead times

     High values of tardiness

     Low service levels

  • Estimation of order delivery dates

    All orders are managed with highest priority

    Due date

    delay

    standard

    Release date

    with priority

    Release date Time Reduction

    M

    Queue time

    machine

  • Lack of production control

     The MRP in the company works assuming infinite production capacity

     The MRP in the company assumes constant lead times

     Lead times are not updated

     No tool for shop floor control

    Due date

    fatherchildren MRP

    Shop floor

    Capacity

    Loading

    Modified

    Lead times

    waiting times increase with the

    machine loading

  • Production capacity control

    What piece will make the machine produce

    tomorrow ?

    Code Description May June July August September October November December January

    A1 Production flow analysis

    A2 Data collection

    A3 Definition of production objectives and

    constraints

    A4 Customization/development and testing of

    the TPS optimization algorithms

    A5 Customization of the TPS data base

    A6 First installation

    A7 Tuning and final installation

    A8 Re-engineering of production planning

    processes

  • TPS Project

  • TPS project

    release dates due dates

    production planproduction

    available capacity

  • Central Staff

    Periferic Staff

    Strategic Process Owner

    Process Owner

    A0 - Business Unit Organisation

  • L e

    a d

    T im

    e A8 - Re-engineering of production planning process

    Lean Organization Office

     Job Enrichment

     Job Enlargment

     Reduction Hierarchical Levels

     Reduction Lead Time

  • Production Planning,

    Master Scheduling

    Material Requirements,

    Resource Capability

    Scheduling

    and Rescheduling

    Dispatching

    Shop-Floor

    Management

    Shop-Floor

    FLOW

    MANAGER

    TEAM

    LEADER

    Schedule

    Job Loading Data Collection

    Detailed Scheduling

    Shop Status

    Schedule Performance

    PLANNING

    MANAGER

    Schedule Constraints

    Capacity Status

    Shop Orders, Release Dates

    Quantities, Due Date

    Orders

    Material Requirements

    TPS

    SAP + TPS

    SAP

    CUSTOMER

    SERVICE SAP + TPS

    L e

    a d

    T im

    e Dynamic ATP

    A0 - Business Unit Organisation

  • TPS (APS)

    Advance Planning Scheduling

    SAP (ERP)

    Enterprise Resource Planning

    • Central Planner: assign the workload to centers (group of affine machines) on the basis of the due date, availabilities

    and customer priorities. If some technological info is available also a specific machine is chosen

    • Flow Manager: modifies the assignment made by the central planner between some predefined range (2 days)

  • Problems

     The product information stored in the company ERP does not contain enough technological information

     Machine operators are the only persons able to assign properly a product to a machine

     Decision making: one central manager, local managers, flow managers

  • Solution: details

     Customer priorities are assigned by the marketing staff (yearly)

     Product & machine technological characteristics

     Third suppliers of components & processes

     Center modeling

     Finite capacity machines

     Batch working machines

     Release dates

     Finite number of tasks (of the same order) scheduled in a time window

     Integration with the company ERP

     Continuous update (15 mins)

  • T&P project

    Goal: to derive a procedure for estimating standard times in Ceratizit processes

    DIFF. EFF./STD.

    Fr e

    q u

    e n

    c y

    1086420-2

    350

    300

    250

    200

    150

    100

    50

    0

    Mean 0,3676

    StDev 0,9522

    N 660

    Histogram of DIFF. EFF./STD. Normal

  • Goal: to derive a procedure for estimating standard times in Ceratizit processes

    D a

    ta CODICE LUNGHEZZA

    Operaz. standardOperaz. effettivo

    *87654321*87654321

    12

    10

    8

    6

    4

    2

    0

    Boxplot of Operaz. effettivo; Operaz. standard vs CODICE LUNGHEZZA

    D a

    ta

    CODICE DIAMETRO INT. / CHIAVE

    Operaz. standardOperaz. effettivo

    *87654321*87654321

    12

    10

    8

    6

    4

    2

    0

    Boxplot of Operaz. effettiv; Operaz. standard vs CODICE DIAMETRO

    T&P project

  • Goal: to derive a procedure for estimating standard times in Ceratizit processes

    T&P project