Orchestrate Version 6 Advanced Planning and Scheduling Software assists you in making more comprehensive plans and in being even more productive. This state of the art software now includes built in constructs for planning inventory levels, demand management and product expiration. Features like the new shift pattern editor and a Gantt chart that automatically scrolls (to display progress against a plan) have been designed to allow increased productivity. Orchestrate is now faster than ever and, to ensure that Orchestrate remains responsive, you can archive your finished tasks.
Read more about Orchestrate version 6 Advanced Planning and Scheduling software and download our "What's new in Orchestrate Version 6?" pdf document by visiting our website at www.simulation.co.uk/news/whats-new-in-orchestrate-version-6.0.html
Wednesday 25 May 2011
Sunday 22 May 2011
Printronix – ProModel Simulation Software Case Study
Summary
Printronix was suffering lost business due to an inability to fully meet customers shipping needs. The solution to shipping more quickly was, with the aid of an in-depth analysis exercise using a ProModel simulation software model, to construct an inventory of high level generic "printer plains". This inventory of generic "printer plains" allowed Printronix to configure and dispatch printers within three days of order receipt.
Case Study
Printronix standard manufacturing process was initially, to construct a printer from the ground up upon receipt of a customer order. The product lead time on a printer from order confirmation to time of shipment was, on average, 18 working days. The customer’s normal expectations were for their order to be shipped within 7 days. In an effort to meet these customers expectations, completed printers were built and inventoried based on a master scheduling forecast. It was discovered that the selection and quantity were not always sufficient to immediately meet the demand. In order to achieve complete customer satisfaction Printronix would need to accumulate three times the existing completed printer inventory.
Printronix then made the decision to construct a printer to it's highest generic level and then hold it in a kanban. Upon receipt of a customer order, the printer plain could then be very quickly, individually configured and made ready for shipment. This was achieved by dividing the printer manufacturing process into two separate stages: printer plain assembly and final printer configuration. A computer generated simulation was designed to model this process and to determine what quantity of the five printer plain assemblies would be needed to support the 110 different configurations of top level printer.
The outcome of the simulation software model exercise lead Printronix to a printer plain kanban size that cost 60% less than creating a completed printer inventory. They then carried out the changes and the outcome was almost exactly that which the computer simulation model had predicted.
Lead time was dramatically reduced from 18 days, down to 3 days. Completed goods inventory was completely eliminated and a floor controlled just-in-time delivery process was implemented.Read more…
Printronix was suffering lost business due to an inability to fully meet customers shipping needs. The solution to shipping more quickly was, with the aid of an in-depth analysis exercise using a ProModel simulation software model, to construct an inventory of high level generic "printer plains". This inventory of generic "printer plains" allowed Printronix to configure and dispatch printers within three days of order receipt.
Case Study
Printronix standard manufacturing process was initially, to construct a printer from the ground up upon receipt of a customer order. The product lead time on a printer from order confirmation to time of shipment was, on average, 18 working days. The customer’s normal expectations were for their order to be shipped within 7 days. In an effort to meet these customers expectations, completed printers were built and inventoried based on a master scheduling forecast. It was discovered that the selection and quantity were not always sufficient to immediately meet the demand. In order to achieve complete customer satisfaction Printronix would need to accumulate three times the existing completed printer inventory.
Printronix then made the decision to construct a printer to it's highest generic level and then hold it in a kanban. Upon receipt of a customer order, the printer plain could then be very quickly, individually configured and made ready for shipment. This was achieved by dividing the printer manufacturing process into two separate stages: printer plain assembly and final printer configuration. A computer generated simulation was designed to model this process and to determine what quantity of the five printer plain assemblies would be needed to support the 110 different configurations of top level printer.
The outcome of the simulation software model exercise lead Printronix to a printer plain kanban size that cost 60% less than creating a completed printer inventory. They then carried out the changes and the outcome was almost exactly that which the computer simulation model had predicted.
Lead time was dramatically reduced from 18 days, down to 3 days. Completed goods inventory was completely eliminated and a floor controlled just-in-time delivery process was implemented.Read more…
Monday 16 May 2011
Walkers Snack Foods Ltd Simulation Software Case Study
Simulation Modelling, performed by Coventry-based Production Modelling, has been a major factor in both the successful delivery, and the on-going management, of an extended warehouse and distribution premises for Walkers Snack Foods Ltd.
The ever expanding snack food market, and the capability to gain an increasing portion of this market, in part due to some high profile marketing, has seen Walkers Snack Foods Ltd enjoy major business growth for the past few years. However, this growth has also meant that major new demands have been placed on its UK operations. To deal with these new demands, the company - which is now joined with the global giant PepsiCo Inc - has performed a considerable programme of upgrading and extension of manufacturing and distribution facilities. One of the recently completed major projects in this programme, an essential element in the business's remodelling of its distribution capabilities, has delivered an enormous warehouse extension at Walkers' Leicester based factory and warehousing facility.
Adding storage was just one of the necessities for this development. The project also had to enable operational process improvements in terms of picking efficiency and throughput, and so allow the output capability of the whole Leicester site to keep up with requirements. Therefore, in order to ensure that the end design solution was able to meet these requirements, Walkers, and their project partner, the warehouse solution provider Swisslog, decided to undertake a simulation modelling exercise, and approached the UK simulation software specialists, Production Modelling. As a result, not only has the modelling helped to prove the design concept, it has also enabled a detailed process analysis that has meant direct project savings. Additionally, a detailed simulation software generated model has also been developed that is currently being utilised by Walkers as an ongoing operational management and training tool.
The ever expanding snack food market, and the capability to gain an increasing portion of this market, in part due to some high profile marketing, has seen Walkers Snack Foods Ltd enjoy major business growth for the past few years. However, this growth has also meant that major new demands have been placed on its UK operations. To deal with these new demands, the company - which is now joined with the global giant PepsiCo Inc - has performed a considerable programme of upgrading and extension of manufacturing and distribution facilities. One of the recently completed major projects in this programme, an essential element in the business's remodelling of its distribution capabilities, has delivered an enormous warehouse extension at Walkers' Leicester based factory and warehousing facility.
Adding storage was just one of the necessities for this development. The project also had to enable operational process improvements in terms of picking efficiency and throughput, and so allow the output capability of the whole Leicester site to keep up with requirements. Therefore, in order to ensure that the end design solution was able to meet these requirements, Walkers, and their project partner, the warehouse solution provider Swisslog, decided to undertake a simulation modelling exercise, and approached the UK simulation software specialists, Production Modelling. As a result, not only has the modelling helped to prove the design concept, it has also enabled a detailed process analysis that has meant direct project savings. Additionally, a detailed simulation software generated model has also been developed that is currently being utilised by Walkers as an ongoing operational management and training tool.
Sunday 15 May 2011
Orchestrate planning and scheduling software at Steelite International
Although to some it would appear that the potteries is yet another industry sector that has been all but lost to overseas production, Steelite is one company that is not only thriving, but is also successfully developing its Stoke-on-Trent based production premises to cope with increasing global demand.
Upon recognising that in order to meet growth, better utilisation of existing facilities is required, the firm's latest action has been to replace it’s complicated, traditional spreadsheet based production planning, and invest in the Orchestrate planning and scheduling software system from Production Modelling.
It is fairly obvious that most UK manufacturers of ceramic tableware are facing a ferociously competitive business climate. All over the world, retail sales of china and earthenware is pretty much static, and the UK market has experienced a major decline over the last few years. The UK has previously enjoyed a far more favourable trade balance in china and earthenware but this has been waning steadily since 1998, and this decline is now being compounded as more of the remaining major UK sellers outsource their production overseas in an attempt to cut costs.
However, one section of the worldwide tableware market sector remains resilient, the hospitality sector. One UK company in a strong position in this sector is Steelite International. This company is an exclusive production and supply business, of tabletop products to the hospitality industry, and via a consistent programme of product innovation, together with exceptional product quality, the company is not only able to continually set high standards for strength and style, but has also managed to turn this into respectable sales growth.
This growing success has also delivered its share of challenges. In particular, this level of success has put extreme pressure on the company’s Stoke on Trent manufacturing facility to meet these demands. Yet, rather than simply aiming to outsource production, the company has addressed its manufacturing shortcomings and is now working towards eliminating any recognised manufacturing inefficiencies, and raise its performance.
One major area Steelite International is enjoying great success in tackling, is production planning and control. Up until just a few years ago, this was considered to be something of a black art. In fact, the manual system used at that time was so ineffective that it was accepted that any plans created were not realistically achievable; 'people just rolled their sleeves up and did the best they could.'
However, with a brand new management team who acknowledged that any future growth could be stalled by the lack of ability to plan products effectively through production, Steelite International has managed to rapidly advance in overcoming this problem. Read more…..
Upon recognising that in order to meet growth, better utilisation of existing facilities is required, the firm's latest action has been to replace it’s complicated, traditional spreadsheet based production planning, and invest in the Orchestrate planning and scheduling software system from Production Modelling.
It is fairly obvious that most UK manufacturers of ceramic tableware are facing a ferociously competitive business climate. All over the world, retail sales of china and earthenware is pretty much static, and the UK market has experienced a major decline over the last few years. The UK has previously enjoyed a far more favourable trade balance in china and earthenware but this has been waning steadily since 1998, and this decline is now being compounded as more of the remaining major UK sellers outsource their production overseas in an attempt to cut costs.
However, one section of the worldwide tableware market sector remains resilient, the hospitality sector. One UK company in a strong position in this sector is Steelite International. This company is an exclusive production and supply business, of tabletop products to the hospitality industry, and via a consistent programme of product innovation, together with exceptional product quality, the company is not only able to continually set high standards for strength and style, but has also managed to turn this into respectable sales growth.
This growing success has also delivered its share of challenges. In particular, this level of success has put extreme pressure on the company’s Stoke on Trent manufacturing facility to meet these demands. Yet, rather than simply aiming to outsource production, the company has addressed its manufacturing shortcomings and is now working towards eliminating any recognised manufacturing inefficiencies, and raise its performance.
One major area Steelite International is enjoying great success in tackling, is production planning and control. Up until just a few years ago, this was considered to be something of a black art. In fact, the manual system used at that time was so ineffective that it was accepted that any plans created were not realistically achievable; 'people just rolled their sleeves up and did the best they could.'
However, with a brand new management team who acknowledged that any future growth could be stalled by the lack of ability to plan products effectively through production, Steelite International has managed to rapidly advance in overcoming this problem. Read more…..
Tuesday 10 May 2011
Case Study: CORUS Construction & Industrial
A Model Investment
Upon seeking justification for a major investment, Corus Construction and Industrial has discovered that the ProModel simulation software, from Production Modelling, has proven itself to be a vital new decision making tool.
For all businesses in the manufacturing sector, making the correct investment decision has always been a difficult task. But, in the current business climate, pin-pointing the right options in terms of new plant and equipment, has become seriously daunting. Businesses can no longer afford to simply make the assumption that new technology will deliver improvements and, unfortunately, any errors of judgment can quickly prove much more costly than the actual amount invested.
Therefore, it has become essential that before any investment decision is made, both the financial returns and measurable performance improvements are calculated as accurately as is possible, and the case for investment acknowledged and verified at every level. One method of achieving this is to carry out experiments and evaluation of any new equipment using a computer model generated using simulation software, before making the actual investment.
ProModel simulation software provides the ability to assess the effects of new equipment on key performance criteria, assisting with identification of financial and performance improvements, and will also effectively compare alternative investment options. As such, this approach can remove much of the risk factor from any investment.
Read more…….
Upon seeking justification for a major investment, Corus Construction and Industrial has discovered that the ProModel simulation software, from Production Modelling, has proven itself to be a vital new decision making tool.
For all businesses in the manufacturing sector, making the correct investment decision has always been a difficult task. But, in the current business climate, pin-pointing the right options in terms of new plant and equipment, has become seriously daunting. Businesses can no longer afford to simply make the assumption that new technology will deliver improvements and, unfortunately, any errors of judgment can quickly prove much more costly than the actual amount invested.
Therefore, it has become essential that before any investment decision is made, both the financial returns and measurable performance improvements are calculated as accurately as is possible, and the case for investment acknowledged and verified at every level. One method of achieving this is to carry out experiments and evaluation of any new equipment using a computer model generated using simulation software, before making the actual investment.
ProModel simulation software provides the ability to assess the effects of new equipment on key performance criteria, assisting with identification of financial and performance improvements, and will also effectively compare alternative investment options. As such, this approach can remove much of the risk factor from any investment.
Read more…….
Monday 2 May 2011
Production Planning at Wyeth Pharmaceuticals
Modern production planning software tools provide vital decision support for pharmaceutical process design whilst streamlining production.
Planning and scheduling software solutions have major significance in the pharmaceuticals industry sector. Complicated processes, raw materials management, cost, value and the rate of development and change all come together to allow these technologies a particular place in strategic capacity planning, supply chain planning and also operationally to streamline resource usage and production throughput.
As Mike Straiton, Director at specialist planning and scheduling software company, Production Modelling, says: "When a pharmaceuticals company considers designing a factory, it not only needs to ensure that it has the capacity to meet the weekly demand, but also that it has the flexibility to accommodate developments pre-production. That means ensuring installation of all the correct equipment in the correct locations at the right time - as well as its efficient use when it comes to scheduling batches of product".
"That's where we come in with our Orchestrate production planning software. We use Orchestrate to look at supply chain processes before they become a problem. Businesses need to plan work now for drugs that may go to market a long way into the future," explains Straiton. "So companies like Wyeth Pharmaceuticals use our systems to help them understand their future global supply chain requirements. Based on estimated market demand, plant production capability, capacity and cost, they can then use Orchestrate to optimise the supply chain to ensure achievement of demand at minimum cost. Individual plants can then use the same software for day-to-day production scheduling."
Brian Kielty, Vaccine Planning Manager at the Grange Castle site of Wyeth Pharmaceuticals in Ireland, says that this is extremely important for his business as it operates in the biotech end of the pharmaceuticals industry, which invariably sees complex, high value production in expensive manufacturing facilities - the investment in the Grange Castle site is over $2 billion.
"Orchestrate production planning software has been invaluable in understanding the dynamics of how the many sections of the organisation interact with each other," he says.
"The software is utilised all across the various levels of our business, from strategic long term capacity planning to everyday operational planning and scheduling."
"We have many validated cGMP systems such as SAP, LIMS, and specifically tailored weigh and dispense systems, to support production, but their current limitation is finite scheduling," explains Kielty.
"These systems enable the tracking of the current status of material and operations throughout the whole manufacturing process, but are less effective in capturing constraints such as skilled personnel, equipment and process cycle times that must be considered to carry out a work plan in a timely manner."
"Orchestrate production planning software has been vital for closing the gap between these systems and providing feasible, robust schedules for supervisors and managers to carry out their respective tasks. Longer term, we believe that integrated finite schedules will considerably improve our performance, reduce variability and aid overall process time improvements."
Planning and scheduling software solutions have major significance in the pharmaceuticals industry sector. Complicated processes, raw materials management, cost, value and the rate of development and change all come together to allow these technologies a particular place in strategic capacity planning, supply chain planning and also operationally to streamline resource usage and production throughput.
As Mike Straiton, Director at specialist planning and scheduling software company, Production Modelling, says: "When a pharmaceuticals company considers designing a factory, it not only needs to ensure that it has the capacity to meet the weekly demand, but also that it has the flexibility to accommodate developments pre-production. That means ensuring installation of all the correct equipment in the correct locations at the right time - as well as its efficient use when it comes to scheduling batches of product".
"That's where we come in with our Orchestrate production planning software. We use Orchestrate to look at supply chain processes before they become a problem. Businesses need to plan work now for drugs that may go to market a long way into the future," explains Straiton. "So companies like Wyeth Pharmaceuticals use our systems to help them understand their future global supply chain requirements. Based on estimated market demand, plant production capability, capacity and cost, they can then use Orchestrate to optimise the supply chain to ensure achievement of demand at minimum cost. Individual plants can then use the same software for day-to-day production scheduling."
Brian Kielty, Vaccine Planning Manager at the Grange Castle site of Wyeth Pharmaceuticals in Ireland, says that this is extremely important for his business as it operates in the biotech end of the pharmaceuticals industry, which invariably sees complex, high value production in expensive manufacturing facilities - the investment in the Grange Castle site is over $2 billion.
"Orchestrate production planning software has been invaluable in understanding the dynamics of how the many sections of the organisation interact with each other," he says.
"The software is utilised all across the various levels of our business, from strategic long term capacity planning to everyday operational planning and scheduling."
"We have many validated cGMP systems such as SAP, LIMS, and specifically tailored weigh and dispense systems, to support production, but their current limitation is finite scheduling," explains Kielty.
"These systems enable the tracking of the current status of material and operations throughout the whole manufacturing process, but are less effective in capturing constraints such as skilled personnel, equipment and process cycle times that must be considered to carry out a work plan in a timely manner."
"Orchestrate production planning software has been vital for closing the gap between these systems and providing feasible, robust schedules for supervisors and managers to carry out their respective tasks. Longer term, we believe that integrated finite schedules will considerably improve our performance, reduce variability and aid overall process time improvements."
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