. On-Time Delivery Improvement
. Increased Throughput
. Higher Resource Utilization
. Reduced Queuing Time
. Reduced Inventory
. Efficient Bottleneck Management
. Extensive What-if Analysis
A White Paper on Scheduling
Job Shop Capacity Planning
Lean Job Shop Production
Our scientific software, Schedlyzer is the fastest and most versatile scheduling tool for a majority of job shops.
Its real strength lies in what-if analysis of resource-constrained job shop schedules.
A Free 60-Day Trial Copy:
We offer a free trial version of Schedlyzer only after presenting a web demo and configuring the software for your production system (without any commitment from you).
Job shops are mostly
make-to-order production units which try to meet a variety of
customer needs with minimal lead times. A common feature of
many job shops is order-driven, high-mix, low-volume (HMLV)
production with very limited resources. Some job shops may
have project-based production. Custom manufacturing units
belong to the class of job shops. Control and management of
production is tough in many job shops due to some of the
difficult issues listed on page, Job Shop Issues
important objective of job shop management is to extract
the best plant-level production performance from finite
capacity resources subject to those issues. This can be
done by reducing rejections and rework, improving resource
efficiency in individual operations and improving operations synchronization through production
scheduling. Operations synchronization is more
appropriate than flow (of lean manufacturing) in high variety
production systems where several work orders with different
routings and due dates simultaneously progress on shop floor
competing for limited multi-functional machines and
can help achieve the required operations synchronization and
predict workflow in a realistic manner in such shops. For
improving job shop productivity, we focus on operation synchronization in HMLV
systems. We offer best-of-breed software, Schedlyzer for operation
synchronization through scientific production scheduling in
high-variety manufacturing systems. Its development is based
on the premise:
The salient features of Schedlyzer include the following.
Optimal Utilization of Multi-Functional Machines and
Control and management of job shop production will be more efficient with the help of
(1) prediction of workflow, bottleneck occurrence and
job completion times, (2) what-if analysis of production schedules and (3) proactive capacity planning.
Nowadays, in many job
shops there is a shortage of skilled workers and many workers
have multiple skills (to perform a variety of operations).
Lean manufacturing philosophy promotes
multi-skilled workers for capacity balancing at work stations. An
operation may need only a machine or only a skilled worker or
both and in some production cells a worker may be able to run
two or more machines simultaneously. Therefore, there is a
need to schedule operations taking into account the
availability of both machines and workers. Schedlyzer is very
efficient to schedule limited multi-functional machines and
multi-skilled workers for achieving the best shop production
performance. The software automatically assigns a right
machine and a right worker to each operation if resource
requirements are specified for each operation in job routings
in terms of machine function and worker skill. The
synchronization enabled by the software will enhance shop
productivity, overall resource utilization, WIP, job lead
times and on-time delivery.
Handling Vendor Operations and Material Available Times
Schedlyzer efficiently incorporates vendor operations and material available times
into production schedule.
Fixing Rational Lead Times for New Orders
In many HMLV job shops
where bottlenecks keep moving over time, it is a challenge to
fix an appropriate due date (or lead time) for each new order. Shorter lead
time quotation can cause anxiety and firefighting while longer
quotation can disappoint customers. Balancing both risks,
Schedlyzer will find a right lead time for each new order
based on the existing workload and resource capabilities and
capacities (avoiding guesswork and standard, time-invariant
quotation of lead times).
Finding Optimal Start Times for Jobs
One of the most
difficult decisions to be made in HMLV job shops is to find a
right start time for each job. Early job start times can
result in higher WIP and longer lead times (as shown on the
page, Lean Job Shop Production
whereas late start may result in the reduction of shop
productivity, resource utilization and on-time delivery.
Schedlyzer finds right job start times balancing both risks by
taking into account process and resource requirements of jobs,
due dates and resource capacities.
Prediction of Workflow, Bottlenecks and Job Completion Times
A reliable prediction
of workflow, bottleneck formation and job completion times offers great confidence
to people who manage high-variety production. Control and
management by reliable workflow prediction is efficient in
high-variety production. Schedlyzer offers such prediction in
the form of schedule by taking into account both resource
availability and natural variation in the system.
What-If Analysis of Schedules
develop a schedule mostly for controlling production on shop
floor. However, if a simple and powerful solution is available
for quickly generating a meaningful schedule with minimal
effort, then it can be used for fast and extensive
what-if analysis of schedules. Proper what-if analysis greatly
helps in evaluating and comparing various alternative
decisions for efficient management of high-variety production.
As indicated in its name, Schedlyzer is developed with special
emphasis on what-if analysis for high-variety production.
Proactive Capacity Planning
This is very relevant
to a high-variety production system which does not have steady
demand for many types of products. The varying product mix
necessitates dynamic capacity adjustments at work stations.
Schedlyzer enables planners to foresee the need for such
adjustments and make appropriate decisions.
Generation of Dispatch Lists for Resources and Display of
production control, shop floor people need a display of job
status and a dispatch list (a sequence of jobs) for each
resource. Schedlyzer generates both of them as part of the scheduling
exercise. It can revise them instantaneously whenever required
if fresh job status information is available to it. Such
revision may be necessary for unexpected changes like machine
breakdown and worker absenteeism.
and Analysis of Dynamic Nature of High-Variety Production
Schedlyzer can also be used for
studying and analyzing the dynamic nature of
high-variety production systems.
benefits from our software are (1) significant improvements in
on-time delivery, job lead times, customer satisfaction, WIP,
shop throughput, and resource utilization and (2) ability to
generate a quick, reliable, flexible and meaningful production
schedule without exceeding resource capacity.
A Free 60-Day Trial Copy:
Contact us for a free, fully functional, 60-day trial copy of the software. Before giving the free trial copy, we would first present a live web demo of Schedlyzer and configure the trial copy
the underlying database as required for your system. We would also offer you free help during trial runs.