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Lots of theories and strategies revolve around optimum utilization of manufacturing capacities. Methodology working for a certain production line may not work for other lines because of product nature, skills etc. This POC is presented to get 360o view of capacities in an enterprise.This will provide details such as available and utilized capacities, Resource (Vessel) breakdown, maintenance history, production history, yield and vessel compatible details and many more which I left for imagination.

Manufacturing Capacities

Visibility of available capacity is prime criteria for better utilization of vessel capacities. Product loading becomes easier when planner knows what capacity is available and how much he has to load.

Capacity planning which involves maintaining data, scheduling and leveling, can be best performed with complete details of available capacity for a product range. Available capacity should be calculated after excluding breaks, maintenance time and preventive maintenance. And at any instance a 10% buffer is good to maintain to tackle contingency.

In process industries, we often find a relation between yield and a particular resource usage (may be chemical kinetics and vessel dynamics help in getting better yields). Though capacity and make of the vessels used in producing a particular batch remains same, in one case yield would be better than other (Considering all other variables and parameters are equally monitored).

It becomes inevitable to avoid these kind of information.

Maintenance of the resources helps avoiding frequent breakdowns and improving asset life. Maintenance engineer needs to keep information of resources which has to be overhauled without disturbing production.

Considering above requirements, we are bound to have complete details of resource.

There are various applications to capture and provide this information, but here we have designed an Ipad application which will integrate with SAP system as well as resource.

Resource start and stop will be performed using Ipad which in turn captures information of resource usage. Ipad application will interact with SAP systems to provide order schedule and resource loading information.

Order Master

Order Master provides complete details of orders to be executed at a particular resource on any day.

You need to select operations of a particular order and press start button to run the resource. System will capture the start and end times with this interface.

Also the this data is transferred to SAP  to provide information of usage of resource and availability real time.

Smart Tab Enterprise Apps

Resource 360

This application will provide complete details of resource as well as resource history for analysis. Following details are available but not limited

Available capacity            Maintenance History

Capacity Utilization          Product Capacity History

Break down                     Yield Information

Integration Architecture

In SAP we maintain Resource and capacity data. After performing MRP planner has to publish order schedule. This schedule will be fetched by Ipad application to process order and resource schedule.

*Logos and organization names used in this document are information purpose only