Modern Machine Shop

JUN 2018

Modern Machine Shop is focused on all aspects of metalworking technology - Providing the new product technologies; process solutions; supplier listings; business management; networking; and event information that companies need to be competitive.

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BETTER PRODUCTION MMS JUNE 2018 132 SHOP MANAGEMENT resource planning (ERP) system to achieve this goal. The typical ERP system uses a material requirements planning (MRP) or manufacturing resources planning (MRP-II) engine to plan production and schedule operations. MRP assumes infinite capacity, fixed lead times and batch production to reduce setup times. An alternative to relying on an ERP system is to use finite capacity schedulers (FCSs) that employ either the drum-buffer-rope method of scheduling (DBR+, Infor Visual EasyLean) or advanced dispatching heuristics and user-defined rules (Preactor, Tactic, Schedlyzer). However, in the case of a manufacturing cell, there may not even be a need for scheduling software. Ideally, a cell contains all equipment needed to produce any part in the cell's part family (except vendor operations or true monu- ments such as heat treat). At the daily morning huddle, the cell's team could meet with the pro- duction controller. They could eyeball the jobs in process or in queue from the previous day and determine whether the cell could process any new jobs if they were released that day. A cell guarantees start-to-finish control of the f low of its orders within a small area of the shop. So, except for unforeseen emergencies, the cell team members can execute as a team to easily ensure on-time completion of all jobs by their due dates. Never underestimate the do-or-die determination of a cell's team to deliver customer service by completing orders at the right time with the right quality at (or below) cost. Use "Water Spiders" to Manage Logistics Let's assume that after its ERP system is integrated with a commercial FCS, a machine shop can gen- erate a feasible daily schedule, both for each cell and for external monuments that are shared by the cells and support departments (receiving, shipping, inspection and so on). Next, the shop must release that schedule to the floor, execute it and, at the end of each shift, publish the current status of all active jobs to the ERP system. The role of schedule execution and status updating in the ERP system is fulfilled by a manufacturing execu- tion system (MES). There is merit in implementing a fully integrated system comprising an ERP, FCS and MES if the facility is large. However, in the case of a single-location, high-mix, low-volume TURN YOUR VERTICAL INTO A HORIZONTAL

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