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    Capacity Planning ERP Module

    React to planning while respecting constraints

    Select a product category above to see how Glovia can improve a particular aspect of your business - or click on the chart below to see all current Glovia modules at once.

    Glovia Solutions

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    Material planning tools are helpful but have one major weakness – they assume infinite production capacity. The result is the creation of production schedules that are often impossible to achieve. This typically leads to production schedules that do not reflect reality and problems in fulfilling customer commitments on-time. For manufacturers to overcome this challenge, they must be able to apply constraints to their production plans.

    GLOVIA G2 Capacity Planning is a Java-based, memory resident planning tool that enables manufacturers to determine the most effective way to execute production schedules and respect material plan constraints. The module applies machine and inventory constraints to all production orders including those entered manually and those generated by GLOVIA G2 Material Requirements Planning, Master Production Scheduling or Project Requirements Planning.

    GLOVIA G2 Capacity Planning can provide many business benefits including:

    • Increased production throughput
    • Reduced changeover times via set-up optimization
    • Identification and elimination of production bottlenecks
    • Minimized costs associated with unplanned downtime, overtime and idle time
    • Reduced production disruption from machine repair and/or maintenance
    • Increased visibility into an accurate production plan that reflects an achievable production schedule after taking into account Capacity Constraints and the ability to accurately predict customer deliveries.

    Capacity Planning is a highly visual and graphical application that displays a view of the shop load based on both the existing released production orders and planned production orders that have not yet been created. This enables users to see the overall long term production picture and make any necessary adjustments. For example, a work order may be given a start date & time, and, a completion date & time based on material planning requirements. However, due to machine capacity constraints, the work order cannot be completed on time. Capacity Planning helps manufacturers to first see the problem exists and then determine the best way to overcome the problem by allowing them to simulate the impact of taking various actions like running more shifts, adding capacity or taking some other action.

    The solution increases productivity and throughput by accounting for constraints, minimizing changeovers and sequencing similar jobs together.

    Providing Production Visibility

    By scheduling production around both the material and machine capacity constraints – Capacity Planning provides manufacturers with realistic production and material supply plans. These plans are provided via a highly graphical, highly visual, user interface that displays information in Gantt and Bar charts that immediately identify future bottlenecks and shortages using color coding and visual alerts and indicators. This ability to have forward visibility of a realistic production plan and the problems that will occur if nothing is done – enables manufacturers to either change the plan or adjust capacity before production and customers are impacted.

    Real time Integration, with direct access to all GLOVIA G2 transactions

    Capacity Planning’s memory-resident data model is a seamless extension of GLOVIA G2’s real-time database. The information used in Capacity planning is always based on accurate, up-to-the-minute information and NOT on a snapshot.

    As events transpire throughout your company the changes are immediately reflected and the highly visual displays updated. When orders are added, changed, rescheduled or completed, inventory is received, materials are issued, production is behind or ahead of schedule, etc. – the changes are immediately visible and the impact of those changes on all orders in the future production schedule can be quickly assessed.

    Because Capacity Planning is a completely integrated part of the GLOVIA G2 ERP application, the GLOVIA G2 ERP screens can also be directly accessed from the Capacity Planning application. For example, a Work Order routing or BOM may be directly accessed and maintained in order to resolve a material constraint or machine capacity bottleneck. In solutions that are not fully integrated this ability to interact and see the result of making real time adjustments to production orders and supplies can be difficult or impractical.

    “What-if” Planning

    Capacity Planning allows manufacturers to run and compare multiple “what-if” planning scenarios to find the most effective use of available capacity and materials to meet commitments.

    Long Term and Short Term Planning

    Capacity Planning provides for the definition of short term, and, long term planning horizons and apply different planning rules and priorities for each. This powerful feature allows customers to create a highly personalized planning mechanism that best matches their needs.

    For example: A manufacturer may identify a ‘rolling’ short term planning horizon of 5 days and a Long term planning horizon of 3 months, 6 months, 12 months or even more.

    In the short term, they may want to keep production schedule very stable with the minimum changes, but, there will always be the ‘late’ orders to catch-up on, and some orders that become escalated as a high priority. Given this type of goal, they may decide to take all incomplete production orders that are past due or due to start in the next 5 days and prioritize them based on (1) order priority and (2) start date/time and then schedule them forward from the current date/time as soon as material and machine capacity is available.

    In the long term they would typically also wish to include production orders that are planned but not created yet. For longer term planning they may wish to schedule backwards based on due date. They may also wish to schedule with infinite capacity and infinite materials so that they can see how much they would need to increase the capacity by adding more equipment or changing shifts and/or changing the materials plan. In longer term planning these changes become more feasible.

    Capacity Planning includes the following capabilities:

    Planning of work orders, repetitive schedules and planned orders

    • Forward and backward scheduling with limited and unlimited machine capacity and material options
    • Multiple “what-if” planning
    • Scheduling in hours minutes and seconds
    • Providing “drag and drop” planning capabilities
    • Configurable, detailed order and operational information including “mouse over” and “annotation” capabilities that enable key information to always be available at the users ‘fingertips’
    • Unlimited shift patterns – Allow shift patterns to be associated to the whole plant, departments, work-centers, or specific to a machine

     

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