|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
 |
|
|
|
|
|
|
|
|
|
|
|
|
|
 |
 |
 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
 |
|
|
|
|
|
|
|
|
|
|
|
|
|
 |
|
 |
|
Planning
the World's Schedule |
|
|
|
|
|
|
|
|
|
|
|
|
| |
The
OPT Solution
The OPT Solution Suite consists of thoughtware, software, educational
tools and implementation methodology which implement constraint
based synchronous control of your business utilising the OPT
principles. The implementation process in any company follows
a step by step procedure that is both logical and proven to
work in a variety of widely differing businesses across the
globe.
The OPTR Approach
OPT thoughtware and software seeks to balance the flow of materials
through a business by confirming and exploiting the constraints
present in a manufacturing process, managing them intelligently
to maximise their throughput and then synchronising the rest
of production to ensure that unnecessary work in progress inventory
is not built up, time lost or shortages created. Adding logistics
to the equation brings the whole supply chain into focus where
even greater benefits can be gained. |
|
|
|
|
|
|
|
|
|
|
|
|
|
 |
|
 |
|
|
|
|
|
|
|
|
|
 |
|
 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The
OPTR Principles
There are nine fundamental principles in the OPT approach:
1. Balance flow not capacity
2. The level of utilisation of a non-constraint is not determined
by its own potential but by some other constraint in the system
3 Utilisation and activation of a resource are not synonymous
4. An hour lost at a constraint is an hour lost for the total
system
5. An hour saved at a non-constraint is just a mirage
6. Constraints govern both throughput and inventories
7. The transfer batch may not, and many times should not, be
equal to the process batch
8. The process batch should be variable not fixed
9. Schedules should be established by looking at all of the
constraints simultaneously. Lead times are the result of a schedule
and cannot be predetermined.
Drum - Buffer - Rope |
|
|
|
|
|
|
|
|
|
|
|
|
|
 |
|
OPTR applies
a simple three step solution. First, the plant is scheduled
to produce at the rate of the major constraints. This schedule
is the 'drum' beating out the pace at which the whole plant
will produce. Next, the constraints are protected from the inevitable
problems caused by statistical fluctuations in the performance
of non-constraints feeding this critical resource by creating
time buffers (not inventory buffers) in front of the constraints.
Last, all non-constraints are synchronised to a rate at which
the constraints can produce, like a |
|
|
|
|
|
|
|
|
|
|
'rope' linked to the
constraint, opening and closing the material gating operation.
The diagram illustrates this concept.
All About OPT Tools
The OPT approach to manufacturing is unique and is used by many
thousands of companies as they try to manage the ever increasing
complexity of their business. OPT, applied manually can achieve
substantial benefits, however in today's demanding manufacturing
environments where supply chain considerations extend planning
far beyond the shop floor, software systems have to be applied.
The OPT Solution Suite provides a range of software tools to
suite many different industries and to provide a variety of
capability. STG's feasibility analysis carried out as part of
our implementation process identifies the appropriate tools
to maximise return on investment.
The following details some of the software tools employed:
OPT Advanced Planner puts in place
the OPT approach by synchronising and optimising the flow of
materials through an enterprise. This is a UNIX based client/server
application built around the ORACLE database, which is particularly
suited to complex discrete manufacturing and process industries.
OPT Planner & Scheduler is
an OPT based solution focused on Just-In-Time material procurement
and best Due Date Performance which aims to produce no sooner
than necessary to meet customer due date utilising available
capacity. This is a Microsoft Windows 95 and NT application
suited to small and medium sized make-to-order businesses that
need a tool to help them meet their customer requirements and
give them comprehensive visibility of their forward plan.
OPT Available & Capable to Promise
provide an important element of Demand Management by ensuring
that customer delivery dates are promised on the reality of
stocks and manufacturing capacity available. 100% Customer Service
can only be achieved if feasible, but competitive, delivery
performance is promised at the time of order. OPT Order Promising
products gives the sales team a direct tool that will provide,
a promise of availability, an accurate delivery date, or check
the feasibility of a requested date, instantly. All without
compromising existing manufacturing plans and schedules.
Demand Management functionality is further supported by OPTR
Forecasting, Replenishment Planning and Advanced Forecasting
modules.
Providing a planning environment that utilises powerful, highly
proven statistical techniques and experience-based system design,
they enable businesses to rapidly increase the cost-effectiveness
of planning decisions, by reducing forecast error and clearly
linking improved demand forecasting and replenishment planning
to corporate goals. |
|
|
|
|
|
|
|
|
|
|
|
|
|
 |
|
|
|
|
|
 |
|
FOR INFORMATION PURPOSES
ONLY
This document is intended for information purposes only. It
is not a commitment to deliver, and may not be incorporated
into any contract. All rights reserved.
OPT and ST-POINT are registered trademarks of Scheduling Technology
Group Limited.
SAP and R/3 are registered trademark of SAP AG.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
