Simulation Based Production Planning, Scheduling, and Control

Johannes Krauth Sim-Serv

Overview
Planning Steps Methods Applied The Contribution of Simulation Examples The Future

Planning Steps
Production Programme Planning / Plant or Process Design (time horizon: years) Production Planning (months / weeks) Detailed Scheduling (days / hours) Control

Overall Planning Objectives

Maximise Capacity Utilisation Minimise Delays Minimise Throughput Times Minimise Work in Progress Note: Conflicting Objectives!!

Facility Planning
Based on assumed demand Searches optimal match of needed and available capacity Planning horizon: years Not an ongoing activity

Optimal Match
Needed per year:
10,400 h milling

Available per year:

4 machines = 5376 h (1 shift, 80% utilis.);

= 10752 h (2 shifts)
______________ 8,500 h welding __________________

4 workers = 8400 h

5 workers = 10080 h

Limitations
no interdependencies taken into account based on estimated / experienced degrees of capacity utilisation adequate for strategic, long-term planning, when little information is available

Production Planning
Based on (expected) customer orders Using fixed throughput times per step (based on experience or assumptions) Accepts / rejects orders and fixes start and end dates

Example: Assumed and Real Durations

Department Lathing Machining Estimated Throughput Time 20 days 5 days Process Time 1 hour 20 hours 1.5 hours 10 hours 20 hours 52.5 hours

Surface Treatm. 7 days Polishing Assembly Total 7 days 15 days 54 days

Limitations
Capacity assumed available Actual shop floor status not taken into account Waiting times included and therefore fixed Applicable only when long delivery times are acceptable

Production Scheduling
Planning Horizon: 1 week 1 day Based on confirmed orders and actually available resources Must take into account technical restrictions Finds exact sequence of operations per work station

Production Scheduling

Must be fit for reality!

Contribution of Simulation
Detailed models Exact representation of all processes, all needed resources Realistic transition times, based on current shop floor status All kinds of rules and constraints can be taken into account

Ways to Use Simulation:

1. Offline, from outside
Simulation Model

controls
MRP /ERP System
feeds back

Ways to Use Simulation

2. Online, as part of planning toolbox
MRP / ERP System: Long Term Planning Module_____________________

Medium Term Planning Module___________________

Scheduling Module:
Simulation Model

Shop Floor

Typical Leitstand / APS tool

Contribution of Optimisation
Can use a large variety of criteria for optimal solutions Finds very good schedules quickly Takes away hours of routine work from the planners Allows them to focus on the essentials

Examples
2 Examples: Simulation helps optimise planning tool and process 4 Examples: Simulation and Optimisation modules as part of planning toolbox

Conclusion from Examples:

Broad range of industry sectors Leitstand / APS tools can complement existing MRP / ERP tools or run stand-alone Typical benefits include

Higher capacity utilisation Less WiP Less delays, shorter throughput times Payback often within a few months!!

Summary
Simulation Based Scheduling and Control offers substantial advantages Many approaches available for different special requirements Also useful for SMEs Sim-Serv assists with selection of best suited approach