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Advanced logics
Advanced logics
TOC auto-analyzing feature

Reducing intermediate (Work-in-process) stock...

Shortening lead time is essential to reduce Work-in-process stock. The principal cause for unnecessarily long lead time results from waiting-times of sequential operation steps. If a process proceeds to the next step without a waiting-time as called just-in-time (JIT), the overall lead time can be reduced. PlanWizard effectively utilizes TOC(Theory Of Constraints) automatic analyzing function to solve this problem. The lead time reduction brings about substantial cut in inventory and strengthens your business with a lean make-up.

Scheduling result with TOC function
Scheduling result without TOC

Scheduling result without using TOC auto-analyzing function

An average lead time is prolonged because of neglect of TOC functionality.

Scheduling result with usage of TOC functionality

Assignment taking bottle neck step into consideration, results in shortening of the average lead time.
Creating a production plan in consideration of individual workers' skill, shift, personal schedule, etc.

When making production schedules, it is also able to make work plans for individual operators (with skills) , and resources. Work plans of individual operators are graphically displayed on the 'Individual Resource Gantt Chart.' Its details are written in the job assignment lists. In the following example, each operator has each skill. and priorities are given to each tasks. With this feature managers are able to know work lord condition of each operator and make reasonable production schedules very quickly.

Individual resource management feature
Dialgram for individual operators and their tasks
Individual resource job assignment list
Individual operators skill list
Gantt chart (Equipment)
Maximum assignment of workforces

Optimal allocation of workforce Making an effective schedule by means of optimal allocation of workforces

IThis feature brings about a maximum assignment of work force, by varying the number and the kind of resources (operators) during a single task

Assignment result which does not allow any idling hours for operators
Assignmenet result where only two out of four operators are able to work consecutively through the manufacturing (Simple scheduling systems are likely to create this plan)
Time-dependent allocation of changeover operators
Time-dependent allocation of manufacturing operators

Allocating operators having different shifts to a single task continuously...

Sometime a single task (manufacturing or changeover) takes so long that it is not completed within a single shift. In such cases the operators must take turns halfway. PlanWizard is able to make a schedule to deal with such assignment. (Ordinary schedulers cannot change operators halfway within a single assignment unit )

Allocation of operators taking turns halfway when a single changeover task does not end within one shift. (applicable to manufacturing case as well)
Switching workforce
Different workers must take a single task continuously when it extends across shifts.
Switching operators
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Minimization of workforce feature

Minimizing the number of necessary operators within a day...

Achieving two purposes at the same time is required now and then. The request is to keep the number of workers constant and as small as possible within a single day and to keep the due date. PlanWizard's function, 'minimization of workforce function' deals with these cases. Ordinary schedulers make plans to assign as many workers as possible to necessary jobs. On the other hand, PlanWizard makes plans to assign as few workers as possible within a day to each job and yet finish jobs before their due dates. In this plan, work times are shifted to avoid concurrent operations and the level of necessary workers is kept constant in a day.

Conventional scheduling result
Scheduling result with the minimization of workforce function
Fifteen workers work at the same time. All the orders are completed before noon. But what would they do in the afternoon? Are 15 workers necessary? In consideration of due dates, the least workers required to finish jobs are assigned. The number of operators within a day is set as constant and small as possible.
Ordinary assignment of workforce Minimization of workforce
Dynamic dispatching feature

Creating near optimal plans automatically...

In order to manufacture hundreds of products effectively, it is necessary to decide the order of manufacturing in consideration with each due date, changeover time, and other priorities. PlanWizard's dynamic dispatching feature makes an rearrangemnt to production orders so that total lead time becomes shorter mostly.

The following example shows scheduling results with and without using Dynamic Dispatching features. Changeover times are different depending on the specs of the products . For example, the following table shows necessary time to change colors

White(W) Yellow(Y) Green(G) Black(B)
W 00:00 01:00 02:00 03:00
Y 02:00 00:00 01:00 02:00
G 04:00 02:00 00:00 01:00
B 06:00 04:00 02:00 00:00
It takes 6 hours to change colors from black to white, while 3 hours from white to black. in this case.

Ohter specifications are Circle(Cir), Square(Sq), Triangle(Tri), Large(L), and Small(S).

Scheduling result without the dynamic dispatching feature
dispatching image 1
Production orders are assigned in the ascending sequence in the list, which results in long lead time due to many changeovers.
Scheduling result with the dynamic dispatching feature
Dynamic dispatching
. The number of changeovers decreases and direction of spec. change is conseidered., which results in by far shorter manufacturing time.
Dynamic selection of process routings

Selecting the most appropriate process steps out of several options...

When there are several methods for production besides a main process, such as roundabout paths or outsourcing, managers are required to make the best decision possible by considering many conditions. (Naturally each method has different process steps.) PlanWizard dynamically selects the best method based on the criteria given by users. Managers are also able to use PlanWizard as a tool for supply chain management.

Conventional scheduling result
Scheduling result with the dynamic selection of process routings
Since all the orders are processed at new factories only, two out of three orders are behind their due dates. In order to avoid this delay, old factories and outsourcing will need to be utilized. With this feature, all the orders can be completed in time for their due dates. The scheduler automatically takes advantage of outsourcing and manufacturing at old factories, as well as manufacturing at new factories.
Dynamic selection of process routings
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