Client Overview
The client is the third largest exporter of Sofa and Curtain upholstery fabric in the world. The client is based out of Mumbai and has multiple plants in Tarapur, Maharashtra.
SCM Initiative
The client implemented SAP ERP about 7 years ago. Pre Planvisage implementation, all the production and inventory planning was done in Excel. It was looking for an advanced planning solution to plan their production and inventory in order to overcome some of the SCM issues. It looked for several vendors who can provide a solution and after a thorough analysis, went ahead with Planvisage solution.
Pain Points
Some of the points were
SAP MRP considers infinite capacity for production planning which does not give visibility on the exact completion date of an order
As capacity of machines are not considered for planning, material planning is independent of the time at which it is actually required causing a rise in inventory levels
SAP MRP is not able to consider the business specific requirements for certain operations like Weaving, Fabric Dyeing, Yarn Dyeing, etc.
Unable to do what-if analysis to find out the optimum balance between setup time
reduction and order delivery performance.
Planvisage Solution
Planvisage Advanced Planning and Scheduling solution was used to take care some of the
deficiency of SAP MRP. Here the solution was integrated with SAP to pull relevant data like BOM, inventory and demand. Some of the data which is not available in SAP was maintained in Planvisage solution itself. This includes dyeing machine capacity, batching rules, weaving WIP, Loom capability and routing information.
Weaving Logic
Logic was written to handle following constraints:
Allocate the running looms to the demand
Create batch with similar beam code after netting out the demand with running looms
Allocate the batch to the resource running with similar item group or create a changeover
Split the batch and run on multiple looms to meet the due date
Decision of single width or double width loom based on beam quantity
Weaving Reports
Work Order Wise Loom Plan - Detailed work order wise loom plan with beam-code wise schedule of all the looms with quantities.
Warping Sequence - Gives the sequence for beams and lengths to be loaded on which loom
Item Group Wise Balance to Weave & Product Category wise balance to weave - Gives information for Item group wise balance to weave lengths with total number of beams, average beam length and weekly interval wise looms to run
Fabric and Yarn Dyeing
Logic was written to handle following constraints:
Batching of items with similar item code and matching
Minimum batch quantity constraints
Selection of resource based on batching quantity and capacity of resource to process a single batch
Resource availability
Dyeing Reports
Fabric Dyeing Batch Creation - Detailed work
order wise batches created with resource and dyeing
time
Fabric Dyeing Queue - Resource wise Product
Category wise break up of batches