Ingenious PPS – THE tool for digital production
The ingenious PPS production planning and scheduling system combines all production processes from planning through production to monitoring and evaluation. The processes are controlled centrally and are digital and paperless at all levels.
Production planning and control
In production planning, the due work processes from the open orders are collected and optimized for one day or one shift. A work step can be derived from a project header, item, or BOM item. The individual work instructions are distributed to the various workstations, eg:
- Cutting profiles based on the lengths and quantities determined from a bill of material
- Composition / locking of a roller shutter curtain based on the overall dimensions determined from a parts list
- Assembly of a shutter according to the item data
- Packaging of all items from one order
- Shipping by project data
Any number of workstations can be defined for the varied sub-steps.
In production planning, it is specified which details the workstations will receive on their devices and in which order the PPS items are to be processed. Criteria for the sorting are, in addition to a prioritization in the order, the agreed delivery dates and for length articles an integrated cutting optimization.
Integrated cutting optimization
The cutting optimization specifies a sequence of cuts to reduce material waste for the same parts from different order lines and projects. So then not stubborn the same cuts of a single position are executed, but for example from a profile in stock length (usually 600 cm) individual bars cut from a variety of order items.
- Order A100 – Position 002: 2 bars à 115,5 cm
- Order A100 – Position 006: 3 bars à 86,5 cm
- Order B104 – Position 001: 1 bar à 102,8 cm
- Remaining 6,7 cm – equivalent to a waste of only 1%
Larger recyclable oddments can be taken into account in the cutting optimization of the next days.
So that at the end, nevertheless, all the bars of a position find together, it is determined by a trolly management, in which trolly, stillage or shelf or on which pallet the items are to be placed. So the employee at the follow-up station knows where to find the required parts.
Instead of a batch of various production papers, workers at each station receive their work instructions on stationary or mobile computers. Depending on the requirements, data can be displayed on industrial terminals, tablets or other devices. The only requirement that the terminal must meet is an installed Internet browser and a network connection to the server.
Each workstation receives for this work step all relevant details of diverse complexity.
For example, these are simple instructions for each individual cut or complex assembly drawings.
The benefits of paperless manufacturing are clear:
- The worker must follow the given order
- The work steps are clearly defined, the worker does not receive too much information
- Work instructions are not lost
One of the biggest advantages of a paperless manufacturing system is the traceability of processes. Every authorized employee can see at any time how far the production of an order has progressed and which station is currently being worked on. And he can provide information as to whether delivery dates can be maintained. The production manager sees the progress in the tables of the production planning, the order processing employees see it in the project.
However, the possibilities of monitoring and evaluation do not only provide answers to the question “Where is …?”. Also the duration of the production of a product can be evaluated. The calculation can be validated and, if necessary, corrected. Also optimization potential can be discovered.