1. Manufacturing Simulation
and planning with limited
capacity
11/04/12

2. Agenda
 Presentation
 Target
 Principles
 Phase1:Technical Data and Capacities
 Presentation : Routing, Bill of materials, Capacities
 DEMO
 Phase2 : Simulation
 Presentation
 DEMO
 Phase3 : Planned
 Presentation
 DEMO
 Future development

3. Project target
 Simulate a customer's request to get the delivery
time, the production load according to hypothesis
(stock delay, current load, stock level…)
 Manage Multi-Sites and Sub-contracting
 Plan make orders in function of :
 Goods available
 Capacity available
 Simulation hypothesis
 Follow-up of the make order, purchases order, stock
moves relative to a sale Order
Semi-automatic scheduler able to be personalized for each
customer's request (production management by business)

4. Principle
Routings Bill of materials Stock
Customize Sales forecasts
procurement rules Simulation Stock rules
/ customer requests
and supply method,....
VALIDATION
PRODUCTION
capacities Plan Scheduler
Purchase
OF/WO Stock Moves Purchase Order

5. Technical Data and Capacities
 Modification of technical data
 Bill of materials
 Generating BOM from BOM Template
 Multi-Level Properties on BOM Template
 BOM Status...
 Routing
 A BOM can have several routings
 A routing can have several operations
 DEMO Routing
BOM
N Routings N Operations
N resources

6. Technical Data and Capacities
 Operation
 We can indicate the consumed products on each
operation
 Possibility to realize subcontracting operations
 Subcontracting operations can consume services
 Possibility to realize purchase order on consumed
services
 Management of intermediary products between
operations
 Addition yield on operation (Impact on consumed
product)
 One operation is validated on N production area
 ...
 DEMO

7. Technical data
 Resource
 An operation may consume one or more resources (human,
equipment, subcontracting)
 A resource can use a tool which can modify equipment throughput
 New functions
 Capacity
 Capacity per period. (week/month)
 Capacity Template
 The Shuttles
 Date
 Place of departure
 Route (succession of location)
 Duration
 DEMO

8. Simulation
 Step 1 : Product Configuration
 Goal : Choose different options that we want for the product (using multi-level
properties)
 Generating the BOM in function of the properties
 DEMO
 Step 2 : Display the raw materials
 In function of the given parameters, display
 Stock level to date
 Critical path
 Delay
 Modification of parameters
 Procurement method
 Supply method
 …
 DEMO

9. Planning
 Step 3 : Operation Plan
 Selection of capacity for each operation
 Manual
 Automatic
 Step 4: Validation
 Creation of M.O and work-order
 Creation of stock moves
 Creation of purchase orders of raw materials and
subcontracting
 DEMO

10. Future development
 Cost by simulation
 Estimated cost
 Real Cost
 Substitution products
 Sampling and quality controls in routings
 ...

11. Conclusions
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