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PlanWizard's enriched logics

Comparison between PlanWizard and other schedulers in terms of operation unit structure
Example: Multiple job assignment
Most other schedulers consider a single process step to consist of three operations; setup, net production, and cleanup, while PlanWizard considers it to be made of five operations; setup, pre-arrangement, net production, post-arrangement, and cleanup. Operations other than net productions are classified into changeovers (setup or cleanup work to change molds, wash machines, and so on), and arrangements (pre-arrangement or post-arrangement work to load, unload materials and products, and so on). This detailed definition allows PlanWizard to adapt to many manufacturing processes.
There are five machines and two operators who are in charge of three different operations; setups caused by product changes and pre-arrangements to change jigs or load matters, and post-arrangements to unload matters. Each operation except net production needs 1 operator (Net production is automatically carried out without operators) .Therefore sometimes a waiting time must result from lack of manpower when they both are unavailable (See a bar image within a red frame in the chart) Thus, PlanWizard is able to model the multiple job operations perfectly. In order to make real and feasible plans, consideration of the job structure consisting of setup, pre-arrangement, net production, post-arrangement, and cleanup is necessary. In addition, allowing idle times between changeovers and productions is also necessary.
Various logics for changeover

Changeover is one of the most important points for making plans

In order to make accurate production schedules, accurate changeover plans play an important role. Generally changeover operations have variety of styles and constraints depending on the industries and companies. Neglecting those changeovers ends up with a rough and impractical production schedule.
Changeover after long suspension function

Having long suspended time before next productions...

When the same products are consecutively manufactured, cleanup operations are often not necessary. However if an interval between two productions is too long, a changeover sometimes becomes necessary. If necessary, PlanWizard inserts changeover operations among productions after a long suspension.
An ordinary scheduling result where no changeover occurs
A scheduling result with the changeover after a long suspension
Regular changeover function

Needing changeovers regularly...

This function automatically generates changeovers between even the same products at the same machine when the number of consecutive lots or the cumulative manufacturing time exceeds any certain criteria.
Limit to the number of changeover function

Limiting the number of changeovers...

When the work load of changeovers is too heavy for workers, restricting the number of changeovers in a certain duration is necessary. In the following example, changeovers are limited to 2 times/day in total for the machine A and B, and once a day for the machineC.
Assignment control of C/O and MFG at prev/next step

Regulating preceding/succeeding relations between C/O and MFG...

This function deals with cases where: next mfg. starts after c/o at previous steps ends; c/o at next step starts after mfg at previous step ends; and other similar cases.
Specification changeover function

Generating C/Os out of prev/next combinations of specs which need different time...

Necessary time for changeovers depends on combinations of specs; color, shape, length etc.
The longest idle time allowed between C/O and MFG function

Regulating idle time between C/O and MFG...

This function regulates idle time between changeovers and manufacturings. Any period can be set before or after manufacturing at each step.
Maximum downtime during changeover function

Regulating breakdown time during changeover tasks...

Downtime allowed during changeover tasks can be specified to each process step. Downtime during setup and the one during cleanup can be set respectively.
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Inter-step resource retention function

Using the same resources continuously throughout several operation steps....

In order to retain the same resources (pallet, tray, etc.) throughout operation steps, PlanWizard uses the function- 'Inter-step resource retention'. Even when there are idle times between operation steps, these resources are retained and the same resources are continuously used in the following steps.
In this example, ResourceX for ProductX is released during idle hours between steps.
On the other hand, since ResourceY for ProductY is designated as an inter-step resource through steps 1 to 3, ProductY goes on using ResourceY
(e.g. namely, pallet or tray) without any break period.
Intermediate warehouse capacity constraints function

Taking capacity of warehouse for Work-in-process products into consideration...

When intermediate products need to be stored in a warehouse before going to the next step, and if the warehouse has a capacity limit, PlanWizard automatically creates plans that clear its capacity constraints.
Scheduling result without consideration of warehouse capacity
Scheduling result in consideration of capacity of warehouse for WIPs
Multi-purpose tank control function

Taking charge to and discharge from tanks into consideration...

When semi-finished products are manufactured in multi-purpose tanks, the next production cannot start before its content is used up by the following process and the tank becomes empty. PlanWizard's function,'Multi-purpose tank control' deals with this type of manufacturing. It is applicable to either when the tank plays two roles of mixing tank and storage tank, or when tanks are for storage only. In the latter case, PlanWizard can also creates a plan in which additional loading is allowed.
Scheduling result when a tank plays a role of mixing and storage tank at the same time
Semi-finished products are manufactured in the tank. The next production cannot start until the tank becomes empty when its content is used up by the filling line. The next production starts after washing operation. Since parallel discharge is not allowed in this example, the content is fed to each vialX, vialY, vialZ line sequentially one after another. Of course PlanWizard can handle simultaneous discharge as well if it is allowed.
Scheduling result when multi-purpose tanks are used for storage only and additional loading is allowed
Additional loading is scheduled by considering volume and the tank contents. Similar to the example above, because simultaneous discharge is not allowed to the storage tanks, the filling steps to vialX, vialY, and vialZ do not start at the same time.
Simulation function

Making a good choice from diverse options to deal with changing situations

At real shop floors, original production plans are always subject to change due to unexpected and sudden problems,
or interruption of urgent orders. PlanWizard's simulation function is instrumental in studying counter-measures.
M
S1
S2
S3
PlanWizard is loaded with three simulations, in addition to the main one. Each simulation is based on each order, calendar, material stock condition, and scheduling rule. Users are able to compare these four simulation results from different view points and choose the most appropriate production plan. Conducting simulation studies enables a more strategic production plan than a mere daily management of manufacturing.
One-by-one transfer function

Indispensable function for the lead time reduction

In order to shorten lead time and reduce inventory, it is much more effective to pass products to thenext step one by one as soon as produced than to pass them by the whole batch or lot. PlanWizardenables products to be sent by any packed number , which reduces overall lead time.
The scheduling result without individually transferring function
The method of production andtransfer per operation stepprolongs overall lead time andcauses delivery overdue !
The scheduling result using individually transferring function
By one-by-one production, lead time becomes shorter and the overdue problem is solved !
The scheduling result when a small number of production and transfer unit is given to the product
Products are sent to next stepsin small designated size.
A result when setting a transfersize as each, 3 pieces to the process step 1, and 2 to the step 2.

Assignment frame of the schedule
During scheduling execution, assignment is given to three operation frames; setup, lot production, and cleanup (a setup or clean up operation is not necessarily required).
And a lot production consists of pre-arrangement, net production and post-arrangement. Depending on necessity, resources to use are set to each of five operations; setup, pre-arrangement, net production, post-arrangement, cleanup. This enables a production plan to be created closer to the real shop work.
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