PC-Topp is a tool for the entire planning department, for corrugator scheduling, conversion machine planning, and even shipping. And it approaches those tasks the same way planners have been working manually, allowing the planner to build upon his experience.
Corrugator and conversion machine scheduling are perfectly integrated in PC-Topp, they both work off the same shared data base. Any change to the schedule is instantly visible in Production, each order end message from the plant immediately updates PC-Topp.
The Classic Approach to Scheduling
The planner can use PC-Topp to create a well thought-out corrugator program, and then line up the orders for production on the conversion machines in the best possible sequence. PC-Topp then tells him which orders will become available for shipping (and at what time), and even allows him to group these orders into truckloads.
Modern Pull Planning
Modern Pull Planning has many advantages over traditional methods: Rather than "pushing" from the corrugator to the conversion area, the planner can start with a refined conversion machine program for the day (and beyond), and then "pull" exactly the required orders from the corrugator.
PC-Topp helps him to create a lean corrugator schedule, with no adverse effects to corrugator production. This modern approach can drastically reduce work-in-progress, it increases the ability to react flexibly to last-minute orders, and makes the order progress transparent at a much earlier stage.
Pull-Planning in Detail
And this is how modern Pull Planning with the integrated scheduling system PC-Topp works:
The order that is currently running on a machine (as well as those that follow) has obviously been finished on the preceding operation and is ready, waiting in front of the machine. The subsequent orders are firmly scheduled on preceding machines, but havent been run there yet.
Further down the schedule, orders are just pre-scheduled in a preliminary sequence.
Those pre-scheduled orders automatically appear on the preceding operations on a suitable production day. The planner then fine tunes the sequence to further optimize productivity.
In Corrugator Scheduling, the system automatically identifies the orders that are required in conversion. As soon as the next set of corrugator schedules is ready, PC-Topp helps to determine the optimum production sequence that ensures that all orders are delivered on time to conversion.
New orders that are urgent are integrated into the existing conversion machine schedule, other, less urgent ones, are added at the end of the lineup. Thus, Planning has a consistent schedule for the next few days ready at all times.
In the event of a last minute order, a sudden breakdown or other mishaps, PC-Topp helps to identify and eliminate the resulting conflicts before they become production problems.
Advantages of Pull Planning
That approach has some remarkable advantages:
No more downtime for lack of orders: Pre-planning lets the planner identify bottlenecks at an early stage, giving him time to adapt his schedules.
Reduced work-in-progress: Only those orders are scheduled for the corrugator that will be converted promptly. This reduces work-in-progress to a level that is close to the required minimum.
Improved corrugator production: Contrary to some popular beliefs, corrugator productivity doesn't suffer, but is often greatly increased. Clearly, it cannot hurt to know in advance, which orders will really be required. And the reduced level of work-in-progress allows Planning to add optional orders to further improve the result of Optimisation.
Perfect conversion schedules with no trade-off at the corrugator
Pull Planning has Significant Advantages
- No more downtime for lack of work - Reduction of work-in-progress - Increased corrugator productivity - Flexible reaction to last minute orders or incidents in production
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