Cloud Intelligent APS System

複雜條件產能規劃

Capacity planning in complex manufacturing environments

動態物料需求規劃

Dynamic material requirements planning

生產成本與產能平衡模擬

Simulation of production cost and capacity balance

挑戰 - 人工排程的極限

虛實整合系統是智能製造浪潮中的核心,而即時決策是其中關鍵,然而現行的人工排程將成為數位轉型的一大瓶頸。
人工排程缺點如下:
  • 排程速度慢無法及時回應
  • 無法有效揭露與充分利用產能
  • 排程無法考量複雜的生產限制邏輯
  • 因生產製程特性需多人分攤排程工作,無法產出全廠最有效益的生產排程。

Challenges—The Limit of Manual Planning and Scheduling

Cyber-Physical System (CPS) is the core of the intelligent manufacturing wave, and real-time decision-making is the key. The disadvantages of manual scheduling include the following: 1. Unable to respond in time due to manually scheduling, 2. Unable to disclose and effectively utilize production capacity, 3. Unable to consider the Shop floor production constraints and scheduling logic, 4. Unable to generate an integrated and effective production schedule due to multiple production planners’ manual planning. Manual scheduling will become a critical bottleneck in digital transformation.

快思解決方案 - IMPACTs 雲端智能 APS 系統

IMPACTs (Intelligent Manufacturing Planning Analysis Cloud Technology system) 雲端智能APS系統,可在雲端提供安全、即時性產能試算功能。該服務旨在成為工廠大腦解決各式複雜排程問題,並提供決策支援建議,以智慧動態模擬排程演算法作為核心,可以完全掌握工廠產能與生產資源。

結合二維碼行動報工系統與視覺化看板,掌握即時報工與分析、透明化生產進度、解決產銷協調問題,進而提升製造生產力與效率,降低產品庫存與衍生成本,並經由AI與IOT擴增模組優化決策能力與即時性。

The CRIS Solution—IMPACTs Cloud Intelligent APS System

IMPACTsTM (Intelligent Manufacturing Planning Analysis Cloud Technology System) performed as a factory's brain to solve complex scheduling problems and provide production decision suggestions. The core of IMPACTsTM is an intelligent dynamic simulation scheduling engine whose planning and scheduling can fully utilize a factory's capacity and production resources. Through the real-time shop floor monitoring, analysis, and transparent production progress reporting, the sales/marketing and production are effectively coordinated, thereby achieving the objective of high productivity, short order-to-delivery (OTD) time, and low inventory cost. Furthermore, managers may employ the extended AI and IoT modules to enhance and optimize management's decision-making.

特性

  • 快速上線
    標準化訪談快速鎖定使用者需求,基本資料備齊一個月內即可上線。
  • 跨系統整合
    以API或中介資料庫與企業已導入的ERP、MES與現場IoT設備無縫串接。
  • 即時同步規劃 串接ERP訂單、物料資訊並根據現場即時生產狀態以快速排程提供決策建議。
  • 智能決策
    根據企業營運目標提供決策建議、提升目標達成率(如最低存貨、最大產出率)並降低付出成本。

Features

  • Easily upgrade from manual scheduling to an intelligent decision support system.
    • Fast implementation
  • Standard and fast interviews to quickly capture user requirements. One month is our goal of implementation for a well-infrastructured company.
    • Synchronized and quick planning
  • An effective material and capacity plan/schedule may be generated by connecting with ERP, MES and concurrently considering shop floor manufacturing constraints, production status, and material availability.
    • Cross-system integration
  • Seamlessly connect with existing ERP, MES, and shop floor IoT-equipped devices through API.
    • Intelligent decision
  • Provide decision-making suggestions based on the company's operational goals, improve the way to achieve goals (such as minimum inventory, maximum throughput), and reduce costs.

功能

  • 企業領導者
    • 通過戰情儀表掌控權欲進行關鍵決策
    • 透過生產報表了解各訂單詳情
  • 生產管理人員
    • 實際產能揭露、訂單/詢單交期回覆
    • 生產進度快速試算與加班/減班試算
  • 採購人員
    • 以採購週期產出建議進料規劃
    • 試算多版本物料規劃比較與影響
  • 業務人員
    • 透過排程報表了解訂單生產進度總表
    • 掌握訂單管理總表.準確回應客戶需求及變動
  • 作業員
    • 清楚接收每日工作目標與預計完工時程
    • 掃碼確認物料並快速報工寫入生產資訊

Benefits

  • Business leader
    • Capture the whole company's performance through the war room dashboard to make critical decisions.
    • Understand the details of each customer order through the production report.
  • Production manager
    • Actual production capacity disclosure, order/inquiry delivery time reply.
    • Quick trial calculation of production schedule and overtime/work time.
  • Purchasing staff
    • Recommend material planning based on the output of the procurement cycle.
    • Trial calculation of material planning comparison and impacts with multiple versions.
  • Sales
    • Understand the sales order production schedule through the production schedule report.
    • Have an order management summary table, which can effectively respond to customer order changes.
  • Shop floor operators
    • Receive clear daily work goals and estimated completion schedule.
    • Scan QR code to confirm materials and quickly report to record production information.

Case Study

  • Challenge
    • The opaque production capacity caused the disconnection between production and sales, and the response to the order delivery was not timely. Different production centers cannot cooperate effectively, and eventually, it isn't easy to utilize the production capacity effectively.
  • Solution
    • Implementation of IMPACTs' production capacity and material planning modules while simultaneously considering the production characteristics of different processes and matching the material planning suggestions of the material planning module to generate a production schedule with high throughput and low inventory.
  • Results
    • The number of production scheduling management reduced from four to one. The schedule time dropped from hours to minutes. The OTD was shortened by 25%, the inventory turnover rate was increased by 15%, and the assembly rate increased to 95%.

案例 Case Study

  • Challenge
    產能不透明導致生產與銷售脫節,訂單交期回覆不及時,不同生產中心不易有效配合,終至產能無法有效發揮。
  • Solution
    導入IMPACTs的產能與物料規劃模組,同時考量不同製程的生產特性,搭配物料規劃模組的到料計畫建議,有效排程提升產量降低庫存成本。
  • Result
    生管排程人數由四位減少為一位。排程時間由數小時降為數分鐘。縮短OTD達25%,庫存周轉率提升15%,組裝齊套率提升至95%。