{"id":244,"date":"2013-08-05T10:19:42","date_gmt":"2013-08-05T08:19:42","guid":{"rendered":"http:\/\/e3mag.com\/?p=244"},"modified":"2019-04-01T10:57:06","modified_gmt":"2019-04-01T08:57:06","slug":"biss-to-the-locomotive","status":"publish","type":"post","link":"https:\/\/e3mag.com\/en\/biss-zur-lokomotive\/","title":{"rendered":"Up(s) to the locomotive"},"content":{"rendered":"

Single-unit and small-batch manufacturers in the mechanical engineering sector usually produce complex products with customized features. Production is usually project-related, with customer-specific variants often being developed.<\/p>\n

Due to the numerous Components<\/span> is the timely Production<\/span> a challenge for the Production planning and control<\/span>. With the SAP ERP<\/span>-Module PS<\/span> a tool is available with which the large quantity structure can be structured and mapped.<\/p>

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Since this system is transaction-oriented, it quickly and clearly presents information about individual Components<\/span> ready. It is just as suitable for accompanying and documenting production.<\/p>\n

Since the module PS<\/span> but only a few functions for gaining an overview and Planning<\/span> is possible through the replacement of a common Database<\/span> with a faster Database<\/span> alone, no improvement can be expected.<\/p>\n

Discussed is the manufacture of Diesel locomotives<\/span>, mainly for shunting operations. Such a Locomotive<\/span> consists of 25,000 to 30,000 individual parts.<\/p>\n

This Locomotives<\/span> are offered in various basic types and then modified to a greater or lesser extent according to specific customer requirements. Considering that the annual output comprises more than 55 machines, one can easily get an idea of the quantity structure to be processed.<\/p>\n

The Planning<\/span> of the customer-specific characteristics of complex technical products can be achieved using the ERP<\/span>-PS<\/span>-Module from SAP<\/span> for make-to-order production and the Small series<\/span> well. The main production steps - in this example, the main assemblies - are mapped in networks.<\/p>\n

Bills of material are assigned to these networks at the individual network activities. These BOMs can contain both purchased parts and anonymously produced standard assemblies. The standard assemblies can be broken down further over several production levels.<\/p>\n

Thus, there is a mixture of customer-oriented and customer-anonymous production.<\/p>\n

At Frame<\/span> A customer is given a delivery date for a product on the basis of coarsened capacity estimates. Locomotive<\/span> notified. This estimate is made on the basis of Data<\/span> for standardized prototype locomotives and coarsened capacity requirements outside the SAP<\/span>-System.<\/p>\n

The challenge now is to transform this coarse into a fine Planning<\/span> to transfer. On the one hand, this naturally concerns the scheduling of the production steps of a Locomotive<\/span>. It is complicated by the fact that during manufacturing several Locomotives<\/span> compete for the same capacities and materials.<\/p>\n

The difficulty does not usually arise during final assembly, as this is not carried out until all the Components<\/span> are available. The problem rather lies in the coordination and Planning<\/span> of customer-anonymous manufacturing.<\/p>\n

A single component or assembly can be manufactured in multiple Locomotives<\/span> be obstructed. Here, for reasons of economic Warehousing<\/span> the principle of \"first come - first served\" is applied.<\/p>\n

If you were to work with order reservations, it would be easier to assign an assembly to a certain order. Locomotive<\/span>but this would also have a correspondingly higher Stock<\/span> as a result.<\/p>\n

In practice, one usually helps oneself by referring to individual Locomotives<\/span> the so-called backlog hours are determined. The backlog hours are calculated by means of SAP<\/span> calculated.<\/p>\n

With the help of this information, priorities are then set in production when deadlines are tight in order to meet the production dates promised to customers. However, this is not Planning<\/span>but reactive control.<\/p>\n

Therefore, in this context, users want a dynamic Pegging<\/span> and a simultaneous Material-<\/span> and resource allocation planning in order to be able to estimate the consequences of any change (new orders, postponement of deadlines, change in available capacity material deliveries or orders).<\/p>\n

Solution approach<\/h3>\n

The aim must be to ensure the timely completion of the Locomotive<\/span> to be able to plan. The aforementioned backlogs, which inevitably arise in the operating business, must be recalculated at any time for the future and firmly incorporated into the advancePlanning<\/span> be integrated.<\/p>\n

As a result, you get a statement about the production status of an Locomotive<\/span>. Usually, the safety and float times that are required for the initial scheduling of a network or for the MRP<\/span>-run are taken into account, reduced.<\/p>\n

This reduction is not made across the board, but by finite Planning<\/span> of the individual workstations, taking into account the dependencies of the individual Components<\/span> to each other. However, this is only possible if a software tool is available that transparently displays the relationships in the order network and enables the desired finite scheduling.<\/p>\n

Modern APS<\/span>-systems meet the requirement of simultaneous Material-<\/span> and capacity planning and are in principle suitable for fulfilling the tasks outlined here. However, it must be mentioned restrictively that only a few systems are currently capable of processing the complex interrelationships in a mixed customer-oriented and customer-anonymous order network.<\/p>\n

Vossloh<\/span> Locomotives has decided to use OR Soft's Enterprise Workbench. The decisive advantage of this solution is the complete integration with SAP ERP, especially its PP modules, PS<\/span>, PM. The OR Soft system does not have its own master and transaction data.<\/p>\n

All Data<\/span> are made from the ERP<\/span> extracts the results in the form of planned orders and production orders, purchase requisitions, network activities or WBS elements in SAP<\/span> written. As a result, it is not necessary to maintain separate master data, establish interfaces or learn new terminology. As an additional benefit, this means that the operation of the ERP<\/span> simplified with the help of an intuitive, graphical interface.<\/p>\n

Thanks to the 64-bitTechnology<\/span> of the Microsoft<\/span>-There are no technical limits to the amount of data that can be processed with the Enterprise Workbench operating system. The Enterprise Workbench is usually installed locally on a PC; corresponding computers with 8, 16 or more GB of main memory are available on the market at low cost.<\/p>\n

The Enterprise Workbench interface is accessed via a browser. There, all networks or all networks under construction are displayed. Locomotives<\/span> is displayed. Three icons in the right area provide information about the current status of the Locomotive<\/span> in the system:<\/p>\n