ASPROVA

1
ASPROVA

• DEREK FRYFOGLE
• CURTIS LANE
• TONY LOVELL
• TOM ROGERS
• MIKE SIMENC

2
Data Entry B.O.M.

• Data entry is in the form of a B.O.M. pick list
  of parts needed
• Use existing B.O.M. or create new products by
  adding, deleting, copying, or recreating new
  materials
• Use the chart to edit data from the item table,
  parts table, and resource capacity table.

3
Scheduling Parameters

• Designate various dispatching rules
• Lot size
• EDD
• FIFO
• Choose a weighted scale to assign importance to
  each job
• Resource priorities
• Load leveling
• Optimization functions

4
Scheduling Parameters

• Designate finite/infinite capacity
• Direction of scheduling around the bottleneck
• Forward loaded
• Backward loaded
• Middle loaded
• Ability to install Poke-Yoke instructions in
  case of job delays

5
Setup Constraints

• Creates changeover sensitive schedule
• According to Production
• According Man Power
• Parallel machines
• Selects what jobs can be run on machines in
  parallel
• Utilizing Man Power in parallel

6
Material Availability

• Quick representation of on-hand inventory levels
• Calculates the feasibility of current jobs being
  scheduled
• Maintains a safety stock and minimum inventory
  level

7
Resources Available

• Tracks all tangible and intangible resources
  being consumed in production
• Humans
• Machines
• Tools/Electric Power
• Quantifies all resources being expended on a
  standardized scale
• Calculates feasibility of jobs being scheduled

8
Inventory Graph

• Run Chart to display
• Production and Consumption
• Shipping and Receiving
• Actual and Safety Stock inventory levels
• Monitoring inventory levels
• Supermarket
• WIP at each station
• Finished goods inventory

9
Production Monitoring

• Gantt Chart displays
• Jobs on each resource
• Processing time
• Due date
• Expediting Jobs
• Drag and drop
• Shifts jobs to adjust to constraints

10
Production Monitoring

• Lot by lot progress
• Job cycle time
• Resources used
• Takt time remaining
• Late jobs
• Increase production
• Modify start time

11
Production Monitoring

• Load Leveling Chart
• Time period
• Resource groups
• Job orders
• Production according to the level schedule
• Shortages
• Overages
• Overtime necessities

12
Production Monitoring

• Lead Time Histogram
• Distribution of waiting times for jobs in the
  system
• Takt time according to customer demand
• Visual display of what products are causing delays

13
Performance Measures

• Tardiness Chart
• Alerts of jobs scheduled to be completed late
• Drag and Drop to reschedule
• Recalculates schedule

14
Performance Measures

• Lateness Histogram
• Lots completed early or late according to due
  date
• Waiting Histogram
• Distribution of lots waiting in system
• According to item produced or the resource used

15
Applications To Dynalab

• Scheduling
• Assign weighted priority to product according to
• P Q R analysis
• Finite capacity cap on product pushed into system
• Reduce WIP at SMT, Slide Line, AOI, and Coating
• Middle loaded scheduling around shifting
  bottlenecks
• Daily observation of bottleneck process

16
Applications To Dynalab

• Setup Constraints
• Allows similar board scheduling on SMT
• Reduce setup time on parts prep area
• Allocate proper man power at the correct time
• Material/Resource Availability
• Greater understanding of inventory on-hand
• Rapid response reordering system from suppliers

17
Applications To Dynalab

• Production Monitoring
• Lot Gantt Chart allows the tracking of smaller
  batch size process to reduce WIP
• Load Level Chart shows min and max levels of
  production that should be performed daily
• Lead Time Histogram locate the biggest
  bottleneck area buffer to reduce WIP

18
Applications To Dynalab

• Tardiness Chart
• Rapidly locate what jobs need to be expedited
• Use as a metric for production improvement
• Lateness and Waiting Histogram
• Locate what areas create the largest queue
• Jobs are delayed in the system
• Create SPC charts to define performance measures
  and customer satisfaction

19
Questions

• Contact Information
• Tony Lovell
• Lovell.28_at_osu.edu
• Derek Fryfogle
• Fryfogle.1_at_osu.edu
• Tom Rogers
• Rogers.382_at_osu.edu
• Mike Simenc
• Simenc.3_at_osu.edu
• Curtis Lane
• Lane.175_at_osu.edu