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Production Planning

  • 1.  Production Planning

    TOP CONTRIBUTOR
    Posted Aug 01, 2019 09:27 AM

    I would like to understand how other companies govern their manufacturing processes?  We have customized NAV to help manage our jobs, but it's still largely a human process for us.  As we have grown and when a location reaches 80+ percent production capacity, our on-time delivery starts to take a hit.  Not every solution should involve adding more bodies or manufacturing equipment and we would like to make sure we are as efficient as we can be with our existing infrastructure and staff.

     

    We have been evaluating different planning and forecasting solutions, but I am hoping to learn how others address this and if you did introduce other software into the mix, can you share the benefits you recognized (before and after)?

     

    Thanks in advance!



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    Anthony Darden
    Vice President - IT
    Protective Industries, Inc.
    Buffalo NY
    NAVUG All-Star
    NAVUG CIO Council
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    Academy - Online Interactive Learning from Experts


  • 2.  RE: Production Planning

    TOP CONTRIBUTOR
    Posted Aug 02, 2019 11:16 AM
    @Anthony Darden are jobs equal to production orders?  What version of NAV/BC are you using?  Are you using infinite or finite planning?  What sort of customizations were needed?  Also, how many "jobs" are you trying to manage at one time on the floor?  How long is a job on the production floor from start to finish?  On the surface it sounds like a visual scheduling solution would help you see the bottlenecks coming when you near the 80% utilization.     ​

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    Jason Nicolaou
    Engagement Manager
    Sikich, LLP
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    Academy - Online Interactive Learning from Experts


  • 3.  RE: Production Planning

    TOP CONTRIBUTOR
    Posted Aug 02, 2019 12:57 PM
    Hi @Jason Nicolaou - you are correct, jobs are equal to production orders.  We are on NAV 2018 domestically and will be launching BC SAAS for our international locations later this year.  Our customizations were put in place years ago to help manage the volume of orders hitting the production floor, but it's still a manual process that tends to look at the current week and nothing beyond that...and so when an expedite hits or a machine goes down, the domino effect is just too much for a human to manage.  We have 200+ production machines and manage at least that number of orders each day.   I'm interested to know the different solutions people have experience with and what the immediate benefits were that came out of that?

    Thanks!​

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    Anthony Darden
    Vice President - IT
    Protective Industries, Inc.
    Buffalo NY
    NAVUG All-Star
    NAVUG CIO Council
    ------------------------------

    Academy - Online Interactive Learning from Experts


  • 4.  RE: Production Planning

    Posted Aug 05, 2019 07:59 AM
    Hi Anthony;
    I have worked with manufacturing software for over 30 years and when it comes to scheduling and throughput I have found that constraints are more often the problem versus capacity.
    Often on paper it looks like you can get the work done, however given that some work centers are constraints they hold up production for all the other work centers.
    Basic NAV allows you to define a work center as a constraint and finite schedule it.  The trick is identifying the constraints and understanding that you should limit the number of constraint work centers.

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    Fred Holst
    Sign Zone LLC
    Brooklyn Center, MN
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    Academy - Online Interactive Learning from Experts


  • 5.  RE: Production Planning

    Posted Aug 06, 2019 11:04 PM
    I agree with my friend Fred, it looks like you have 8 hours to schedule, 16 hours to schedule, or more, but you have an employee who really is a constraint because they needed to cut this item or operate that machine, the rest of employees are for machine setup and material movement. It is hard to find constraints vs capacity in real-time.

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    Greg Jankowski
    Concordia Publishing House
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    Academy - Online Interactive Learning from Experts


  • 6.  RE: Production Planning

    GOLD CONTRIBUTOR
    Posted Aug 02, 2019 01:50 PM
    Hi Tony,

    As we have discussed many times, every company reaches a stage where brute force will no longer suffice.

    The threshold can be many, but these are the three we typically encounter:
    • physical, too much work for for the number of personnel assigned to the scheduling 
    • risk, as typically just a small handful of people who most of the critical knowledge
    • Timing, it simply takes too long for the manual process to complete or respond to changes
    Regardless, there are several solutions available in the ISV/AppSource marketplace as well as outside of our typical Dynamics universe.  Defining with your team the most critical aspects of your scheduling process and how automation would help alleviate strain or improve throughput is a good first step.  From there, you can create a requirements list to begin to evaluate possible solutions.

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    Tom Doran
    Chief Marketing Officer
    Innovia Consulting
    niles IN
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    Academy - Online Interactive Learning from Experts


  • 7.  RE: Production Planning

    TOP CONTRIBUTOR
    Posted Mar 17, 2020 09:54 AM
    AS you know NAV / BC plans but doesn't really schedule in the way you an I think of scheduling.  Since th Due Date / End Date and Start date are hard linked / calculated it causes issues when you try to schedule a production order as the Due Date will no longer meet the demand date for planning and you may get reschedule messages.

    Ideally if you want a week for production scheduling time (able to schedule the order to a machine sometime that week) you would want the start date a week earlier so you have materials available for the earliest start of the order.  We have tried to use safety leadtime to do this but it doesn't work as when you move the start date it will move the end and due dates,

    Ideally we would love to have a "scheduling time" to add for an item and also decouple the end date from the due date.  The scheduling time would set the early start and then you could set the start date when you schedule the production order and the due date would not change unless you scheduled to a date that put the end date later than the due date.  This modification could be possible in an on-premise system but not in an SaaS or extension based BC system.

    The other option I have seen work was to do the actual scheduling outside of Business Central or using different custom dates on the production order for scheduling (this is how Planner One did their their scheduling without changing due dates).  Doing this allows you to schedule the orders and not effect MRP planning.  The drawback is it is disconnected from actual planning and your NAV system.

    This can get more complex as your scheduling needs become more complex (priorities, run orders based on color, etc.).

    I do have an idea on the Business Central Ideas site related to the scheduling period fields ad the disconnect of the end and due dates if you want to vote on it,

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    Kevin Fons
    Senior Application Consultant
    Innovia Consulting
    waunakee WI
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    Academy - Online Interactive Learning from Experts


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