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WHEEL OF FORTUNE
Operational Benefits of Product Wheel Scheduling
Peter L. King – Zinata Alan Nall - Zinata
2 #APICS2017
APICS 2017 Session Evaluation
Visit www.apics.org/Monday
- r
WHEEL OF FORTUNE Operational Benefits of Product Wheel Scheduling - - PowerPoint PPT Presentation
WHEEL OF FORTUNE Operational Benefits of Product Wheel Scheduling - - PowerPoint PPT Presentation
WHEEL OF FORTUNE Operational Benefits of Product Wheel Scheduling Peter L. King Zinata Alan Nall - Zinata APICS 2017 Session Evaluation Visit www.apics.org/Monday or download the APICS2017 app 2 #APICS2017 PETER L KING
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3 #APICS2017
- BS Electrical Engineering – Virginia Tech
- DuPont Company – 42 years
- R & D – 9 years
- Project management – 15 years
- Lean manufacturing & supply chain consulting – 18 years
- Lean Dynamics – 2007 to present
- Consult with companies in process industries
- Zinata – 2014 to present
- Consult on Product Wheel design/implementation , Value Stream Mapping
- Lean for the Process Industries – Productivity Press, 2009
- The Product Wheel Handbook – Productivity Press, 2013
- Value Stream Mapping for the Process Industries
– Productivity Press, 2015
- Several articles in IE Magazine, APICS Magazine, Target (AME)
- Frequent speaker at IIE, APICS, ASQ, OpEx conferences
PETER L KING peter.king@Zinata.com
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4 #APICS2017
- Why Product Wheels?
- Product Wheel concept
- Wheel Design Basics
- Case study - vitamin pill packaging
- Making it real – simplifying daily operation
- Other prominent Product Wheel users
- Q & A
AGENDA
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5 #APICS2017
are caused by processes
- utside the plant floor
IT HAS OFTEN BEEN SAID THAT …..
75% of the problems on the plant floor
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Production scheduling is often based on what needs to be produced within the next planning period
- Without any view of the full manufacturing system
- Without an understanding of the full product line-up
Therefore opportunities for optimization are often missed
- Opportunities to standardize schedules
- Opportunities to standardize sequences
- Opportunities to simplify changeovers
- Opportunities to optimize frequency of low volume items
PRODUCTION SCHEDULING IS OFTEN THE CULPRIT
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7 #APICS2017
PRODUCT WHEELS
- Allow you to optimize production scheduling
- In an integrated, holistic design process
- In a way that has enabled major manufacturers to save millions $$
- Higher throughput – higher revenue
- Reduced inventories – reduced working capital
- Improved customer service performance
– increased market share
- With increased stability – reducing the chaos
- With increased predictability – better forward planning
THE SOLUTION
= $$
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8 #APICS2017
PRODUCT WHEEL CONCEPT
A C B D E F G H I J
K
PRODUCTS (SPOKES) CHANGE-OVERS
- A regularly repeating
sequence of the production of the various products
- The overall cycle time is fixed
- The cycle time is optimized
based on business priorities
- The sequence is fixed
- The sequence is optimized
for minimum changeover loss (time or material)
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9 #APICS2017
PRODUCT WHEEL CONCEPT
51381 19852 30282 13045 55347 32689 13775 57601 30173 45211 53181 19955 3809 13412 46077 41628 55412 19097 53124 53125 53129
LINE 3 - CYCLE 1
- Spokes can have different
lengths, based on the Demand for each product
- The amount actually produced
can vary from cycle to cycle, based
- n actual consumption
- Some low-volume products may
not be made every cycle
- When they are made, it’s always
at the same point in the sequence
- Make-to-order and Make-to-
stock products can be intermixed
- n a wheel
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10 #APICS2017
ONE CYCLE, ONE REVOLUTION
A B C D E F G H
BREATHING ROOM
PRODUCT A PRODUCT F CHANGEOVER SPOKE, . CAMPAIGN CHANGEOVER BATCHES WHEEL TIME
PRODUCT WHEEL CONCEPT
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11 #APICS2017
- Product wheels can be applied to a single major piece
- f process equipment
- A resin reactor
- A paint mixer
- A vitamin tablet compression machine
- A ketchup homogenizer
- Or to an entire line
- A shampoo bottling line
- A potato chip packaging line.
PRODUCT WHEEL APPLICABILITY
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12 #APICS2017
- Product wheels support a Pull replenishment system
Each spoke is designed based on average historical demand
- r on the forecast
What is actually produced on any spoke is just enough to replenish what has been consumed from inventory
- Low volume products won’t be made unless needed
- Product wheels can be employed in a Make-to-Stock
(MTS) or a Make-to-Order (MTO) environment
MTS and MTO products can be made on the same wheel
PRODUCT WHEEL APPLICABILITY
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PRODUCT WHEEL DESIGN
𝐹𝑃𝑅 =
2 ∗ 𝐷𝑃𝐷 ∗ 𝐸 𝑊 ∗ 𝑠 ∗ (1 − 𝐸 𝑄𝑆 )
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PRODUCT WHEELS ARE BASED ON A THOROUGH ANALYSIS OF …
Frequency Lot Size 1 Car/Day190 K #
Transp time7 Days
SUPPLIER 1 SUPPLIER 2 SHEET CASTING (3) SLITTING (3) BONDING
(HEAT TREATING)
(3) INSPECTION (1) WRAPPING PACKAGING LABELING
3 2 3 3 6
Order Lead Time # SKUs1 Week 4
Order Lead Time # SKUs1 week 6
Invtry Days # SKUs8.9 M # 50 2,000
Invtry Hours # SKUs 60 K #8
1000
Invtry Days # SKUs2.6 M# 15 100
Invtry Days # SKUs3 M# 16 50
Invtry Days # SKUs1.2 M #
5.6 6 CUSTOMERS, DISTRIBUTORS
Quantity/time TAKT5.4 M #/Mo
7.5 K #/Hr
Lead time Exp4 Days
Frequency Lot Size 5 Trucks/Day 36 K#/Truck Transp time2 Days Eff Capac
10.6 8.3
TAKT Utilization
78% 15 Min
Lead time Yield
93% 85%
Reliability OEE
73% 50
# SKUs Batch size
1 roll 9 days
CYCLE C/O time
1 hr 1 Roll
C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd
K #/Hour
Eff Capac
13.8 8.1
TAKT
K #/Hour
Utilization
59% 18 Min
Lead time Yield
98% 82%
Reliability OEE
74% 100
# SKUs Batch size
1 roll 13 days
CYCLE C/O time
45 Min
~ 0 C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd Eff Capac
8.25 7.5
TAKT
K #/Hour
Utilization
91% 15 Min
Lead time Yield
92% 72%
Reliability OEE
55% 1000
# SKUs Batch size
1 roll 7 days
CYCLE C/O time
5 Min
~ 0 C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd Eff Capac
18 7.5
TAKT Utilization
42% 6 min
Lead time Yield
100% 100%
Reliability OEE
100% 1000
# SKUs Batch size 1 Slit Roll
N/A
CYCLE C/O time C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd
K #/Hour
Eff Capac
36 7.5
TAKT Utilization
21% 8 Min
Lead time Yield
100% 70%
Reliability OEE
70% 2000
# SKUs Batch size 1 Slit Roll
N/A
CYCLE C/O time C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd
K #/Hour
Max Demo Rate
14.5
Max Demo Rate
18.6
Max Demo Rate
15
Max Demo Rate
18
Max Demo Rate
51
RAIL CARS
Your process as an integrated system
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15 #APICS2017
PRODUCT WHEELS ARE BASED ON A THOROUGH ANALYSIS OF …
ITEM FCST AVERAGE TABLET COLOR BOTTLE SIZE BOTTLE TYPE DESSICANT # BOTTLE COLOR HOURS PER MONTH HOURS PER 2 WEEKS HOURS PER WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR
73.6 36.8 18.4
AB302 49303 N/A 500CC SHORT-PET D546 CLEAR
35.6 17.8 8.9
AB206 52234 N/A 500CC SHORT-PET NONE CLEAR
33.0 16.5 8.2
AB203 12447 N/A 400CC PET NONE LT BROWN
6.8 3.4 1.7
AA105 9500 N/A 400CC PET NONE LT BROWN
4.8 2.4 1.2
AC101 25796 N/A 400CC PET NONE GREEN
23.7 11.8 5.9
AD401 32821 WHITE 400CC PET NONE GREEN
22.7 11.4 5.7
AD221 41221 N/A 400CC PET NONE YELLOW
20.8 10.4 5.2
AC301 29888 N/A 400CC PET NONE YELLOW
20.7 10.3 5.2
AC201 27207 N/A 400CC PET NONE YELLOW
18.1 9.0 4.5
AB205 12792 N/A 400CC PET NONE YELLOW
7.0 3.5 1.8
AA101 3200 N/A 400CC HDPE NONE LIME
3.1 1.6 0.8
AA104 6462 N/A 400CC HDPE NONE LIME
7.8 3.9 1.9
AA103 5247 N/A 400CC HDPE NONE LIME
5.1 2.5 1.3
AA102 3407 N/A 400CC HDPE NONE LIME
3.3 1.7 0.8
AB207 25262 N/A 400CC HDPE NONE EGGSHELL
16.8 8.4 4.2
AD201 33992 N/A 400CC HDPE NONE BLUE
40.9 20.4 10.2
AC441 44016 N/A 400CC HDPE NONE BLUE
30.5 15.2 7.6
Your product line-up as an interrelated group of things with varying degrees of similarity
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PRODUCT WHEEL DESIGN
Step 1 - Decide which assets would benefit
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SHEET FORMING VIRTUAL CELL GROUPING
Packaging
Roll Forming Machine 1 Roll Bonder 1 Chopper 1 Roll Forming Machine 2 Roll Forming Machine 3 Roll Forming Machine 4 Roll Bonder 2 Roll Bonder 3 Roll Bonder 4 Roll Slitting Machine 2 Roll Slitting Machine 3 Chopper 2 Chopper 3
Packaging
CELL 1 CELL 2 CELL 3 CELL 4
Roll Slitting Machine 1
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18 #APICS2017
ASSETS THAT MIGHT BE SCHEDULED BY PRODUCT WHEELS
Frequency Lot Size 1 Car/Day
190 K #
Transp time
7 Days
SUPPLIER 2 SHEET CASTING (3) SLITTING (3) BONDING
(HEAT TREATING)
(3) INSPECTION (1)
3 2 3 6
Order Lead Time # SKUs
1 Week 4
Invtry Hours # SKUs 60 K #
8
1000
Invtry Days # SKUs
2.6 M# 15 100
Invtry Days # SKUs
3 M# 16 50
Invtry Days # SKUs
1.2 M #
5.6 6
Eff Capac
10.6 8.3
TAKT Utilization
78% 15 Min
Lead time Yield
93% 85%
Reliability OEE
73% 50
# SKUs Batch size
1 roll 9 days
CYCLE C/O time
1 hr 1 Roll
C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd
K #/Hour
Eff Capac
13.8 8.1
TAKT
K #/Hour
Utilization
59% 18 Min
Lead time Yield
98% 82%
Reliability OEE
74% 100
# SKUs Batch size
1 roll 13 days
CYCLE C/O time
45 Min
~ 0 C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd Eff Capac
8.25 7.5
TAKT
K #/Hour
Utilization
91% 15 Min
Lead time Yield
92% 72%
Reliability OEE
55% 1000
# SKUs Batch size
1 roll 7 days
CYCLE C/O time
5 Min
~ 0 C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd Eff Capac
18 7.5
TAKT Utilization
42% 6 min
Lead time Yield
100% 100%
Reliability OEE
100% 1000
# SKUs Batch size 1 Slit Roll
N/A
CYCLE C/O time C/O loss Avail time 168 hr/wk 3 x 8 x 7 Shift schd
K #/Hour
Max Demo Rate
14.5
Max Demo Rate
18.6
Max Demo Rate
15
Max Demo Rate
18
RAIL CARS
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19 #APICS2017
Step 2 - Analyze product demand variability – consider MTO vs MTS
PRODUCT WHEEL DESIGN
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20 #APICS2017
ANALYSIS OF DEMAND VAIABILITY – PRODUCTS ON SHEET CASTING LINE 1
PRODUCT WEEKLY DEMAND D (Rolls)
sD
(Rolls)
COEFFICIENT of VARIATION CV = sD/D A 150 30 0.20 B 120 20 0.17 C 75 24 0.32 D 15 6 0.40 E 14 6 0.43 F 12 5 0.42 G 8 6 0.75 H 6 3.6 0.60
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AVERAGE DEMAND
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VARIATION IN DEMAND
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DECISION MATRIX – VOLUME VS DEMAND VARIABILITY
B A C G D E H F
MAKE TO ORDER (MTO) MTO? MTS? MAKE TO STOCK (MTS) MTO? MTS?
PRODUCT DEMAND PRODUCT VARIABILITY
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24 #APICS2017
PRODUCT WHEEL DESIGN
Step 5 - Calculate the most economic wheel time
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25 #APICS2017
Step 5 - Calculate the most economic wheel batch size
𝐹𝑃𝑅 =
2 ∗ 𝐷𝑃𝐷 ∗ 𝐸 𝑊 ∗ 𝑠 ∗ (1 − 𝐸 𝑄𝑆 )
Where
- COC = Changeover Cost
- D = Demand per time period
- V = Unit cost of the material
- r = % carrying cost of inventory per time period
- PR = Production rate in units per time period.
PRODUCT WHEEL DESIGN
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26 #APICS2017 2000 4000 6000 8000 10000 12000 14000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
TOTAL COST CHANGE-OVER COST INVENTORY COST CAMPAIGN LENGTH = WHEEL TIME COST
ECONOMIC ORDER QUANTITY – EOQ - CONCEPT
ECONOMIC ORDER QUANTITY
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27 #APICS2017
OTHER FACTORS ….
Shelf life, obsolescence Demand variability Minimum lot size
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- 7. Determine the optimum sequence
PRODUCT WHEEL DESIGN
PRODUCT SHEET WIDTH BASIS WEIGHT POLYMER TYPE
423 J 12 3 J 403 L 10 3 L 403 J 10 3 J 423 L 12 3 L 426 J 12 6 J 406 R 10 6 R 406 L 10 6 L 426 R 12 6 R 406 J 10 6 J 409 L 10 9 L 409 J 10 9 J 489 J 8 9 J 429 L 12 9 L 489 R 8 9 R 489 L 8 9 L 429 R 12 9 R
PRODUCT POLYMER TYPE SHEET WIDTH BASIS WEIGHT
489 J J 8 9 403 J J 10 3 406 J J 10 6 409 J J 10 9 423 J J 12 3 426 J J 12 6 489 L L 8 9 403 L L 10 3 406 L L 10 6 409 L L 10 9 423 L L 12 3 429 L L 12 9 489 R R 8 9 406 R R 10 6 426 R R 12 6 429 R R 12 9
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PRODUCT WHEEL DESIGN
Step 9 - Revise the scheduling process
Whatever production planning and scheduling system the operation is using
- SAP
- Oracle
- MIMI
- Manugistics
- Excel
- Etc.
must be coordinated with the product wheel design
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30 #APICS2017
NATURE’S BOUNTY VITAMIN PACKAGING
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31 #APICS2017
- Leading manufacturer/packager of vitamin tablets,
capsules, and gelcaps
- Revenue ~ $3B
- Five major manufacturing plants
- Four packaging operations
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32 #APICS2017
- One of four NBTY packaging operations
- 700 packaged products
- Several packaging lines
- As many as 14 parameters may change
- n any changeover
- Bottle diameter
- Bottle height
- Allergen content
- Cap type
- Tablet coating
- Etc.
DEERFIELD BEACH PACKAGING
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33 #APICS2017
BLUE LINE RACK LOCATIONS (24 HRS TO SEVERAL WEEKS) BULK SUPPLYING SITE WORK ORDER INFORMATION TO COMPUTER TERMINAL ON MEZZANINE RAW MATERIAL ORDERS TO MEET NEEDS FOR NEXT 12 MONTHS CAN GO TO ONE OF SEVERAL PLACES BASED ON THE PROBLEM FOUND BATCH PACKET WORK ORDER HAS BEEN COMPLETED (from all lines) 3PL – MONTHS BULK INVENTORY 1111 WAREHOUSE (UP TO 3 MONTHS OF INVENTORY) PRINT PALLET TAG PROCESS THE WORKBENCH- CHECK BULK, IFCs, LABELS, TRAYS, INSERTS, SHIPPERS
- CAN I DO IT? MOVE TO OPEN ORDER
- CAN T DO PUT A REASON ON WORKBENCH
- SCHEDULER ASSIGNS EACH W.O. TO A PKG LINE
- SCHEDULER WILL PUT IN THE SEQUENCE
- ORDERS CAN BE PUT ON HOLD IF ALL MAT L NOT
DEERFIELD BEACH VALUE STREAM MAP Ver 10, MAY 30, 2016
SOLGAR (N.J.) BOTTLE SUPPLIERS CAP SUPPLIERS BLACK LINE WHITE LINE HAZELTON, PA D.C. SPRKS, NV D.C. BOCA RATON, FL D.C. 1297 DEMANTRA ASCP APS AS 400 PLANNER PROCUREMENT PLANNING BOTTLES, CAPS, CORROUGATED THE BRAND: COMMERCIAL, MARKETING- SHIPMENT HISTORY
- MARKET INTELLIGENCE
- CURRENT ORDERS
- FORECASTS
- PROMOS & DISPLAYS
- INVENTORY TARGETS
- CURRENT INVENTORIES
- BOMs
- CYCLE TIMES (WHEEL TIMES)
- CYCLE TIME INTERVALS
- LEAD TIMES FOR EVERY
- PLANNED ORDERS FOR NEXT
- REGENERATED WEEKLY
- NEXT TWO WEEKS ORDERS
- TRANSACTIONS
- COMPONENT
- WORK ORDER
- PICK LIST
DEERFIELD VALUE STREAM MAP
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34 #APICS2017
PRODUCT ALLOCATION CONCEPT
PACKING #1
BREATHING ROOM
PACKAGING LINE 2
BREATHING ROOM
PACKAGING LINE 3
TIME REPRESETATIVE OF 700 SKUs
BREATHING ROOM
PACKAGING LINE 1
BREATHING ROOM
PACKAGING LINE 4
BREATHING ROOM
PACKAGING LINE 5
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35 #APICS2017
STEP 1- PRODUCT GROUPING & ALLOCATION TO SPECIFIC LINES
Data shown is for illustration only and is not actual
ITEM FORECAST AVERAGE BOTTLE SIZE BOTTLE TYPE BOTTLE COLOR CAP TYPE CAP SIZE CAP COLOR BUNDLE QTY ALLERGEN TABLET COLOR DESS ICANT SIZE RUN RATE AA356 22726 750cc PET ORNG CRC 53MM ORNG 6 D,U ORANGE NONE 500 20 AA378 18064 750cc PET ORNG CRC 53MM ORNG 6 NE,U N/A NONE 325 60 AA427 25331 750cc PET ORNG CRC 53MM ORNG 6 NE,U N/A NONE 500 50 AA502 62341 250cc PET ORNG CRC 53MM ORNG 6 NE,U WHITE 22-5700 500 50 AA503 52555 500cc PET ORNG CRC 53MM ORNG 6 NE,U WHITE 22-5700 500 50 AA532 16420 750cc PET ORNG FLIP 53MM ORNG 6 SE,NE,U BROWN NONE 500 50 AA756 14228 750cc PET ORNG CRC 53MM ORNG FULL WRAP NE,H,U GREEN 22-5700 375 50 AB112 1085 250cc HDPE SKY BLUE FLIP 45MM WHITE 3 OR NONE SE,NE,U N/A 22-5700 200 100 AB204 10301 750cc PET ORNG FLIP 53MM ORNG 6 SE,NE,HE,U ORANGE NONE 400 50 AB212 1058 200cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE SE,NE,U ORANGE NONE 400 100 AB306 2193 750cc HDPE BRN STD 53MM WHT 6 SE,NE,F,U N/A 22-5700 320 60 AB434 1018 250cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE U WHITE 22-5700 180 40 AC302 1166 250cc PET SKY BLUE FLIP 45MM WHITE 3 OR NONE SE,NE,FM,U PINK 22-5700 200 100 AC442 1103 200cc PET SKY BLUE CRC 45MM ORNG 6 NONE N/A NONE 120 40 AC518 1108 250cc HDPE SKY BLUE FLIP 45MM ORNG 6 SE,NE,LT,U PINK NONE 200 100 AC568 1991 250cc PET SKY BLUE FLIP 45MM WHITE 3 OR NONE SE,NE,U N/A NONE 200 100 AD256 1912 200cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE S,U WHITE NONE 120 40 AD348 1455 200cc HDPE SKY BLUE CRC 45MM WHITE 3 OR NONE SE,NE,F,U N/A 22-5700 150 40 AD442 577 500cc PET BRN CRC 53MM BRN 6 SE,NE,F,U N/A NONE 250 100 AD512 1406 200cc HDPE ORNG FLIP 45MM WHITE 3 OR NONE SE,NE,U N/A 22-5700 130 40 AF244 1364 750cc PET ORNG CRC 53MM ORNG 3 OR NONE SE,F GREEN NONE 300 60 AF351 1235 750cc PET BRN CRC 53MM BRN 6 SE,F,U COBALT 22-5700 400 50
CHANGEOVER CRITERIA SORT PRIORITY Bottle size 1 Bottle type 2 Allergen content 3 Cap type 4 Cap size 5 Bottle color 6 Dessicant 7
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36 #APICS2017
REDUCTION IN BOTTLE COUNT PER LINE
2 4 6 8 10 12 1 2 3 4 5 6 7 8 9 10 11 12 13
REDUCTION IN BOTTLE SIZES RUN ON EACH LINE
TRADITIONAL BOTTLE COUNT JULY ALLOCATION
“Just this gave us 3 – points of OEE improvement!”
- Jaci Souza - Packaging Director – Nature’s Bounty
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37 #APICS2017
DETERMINING THE:
- WHEEL CYCLE TIME
- FREQUENCIES FOR LOW VOLUMES
- OPTIMUM SEQUENCES
SLIDE 38
38 #APICS2017
ITEM FCST AVERAGE TABLET COLOR BOTTLE SIZE BOTTLE TYPE DESSICANT # BOTTLE COLOR HOURS PER MONTH HOURS PER 2 WEEKS HOURS PER WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR
73.6 36.8 18.4
AB302 49303 N/A 500CC SHORT-PET D546 CLEAR
35.6 17.8 8.9
AB206 52234 N/A 500CC SHORT-PET NONE CLEAR
33.0 16.5 8.2
AB203 12447 N/A 400CC PET NONE LT BROWN
6.8 3.4 1.7
AA105 9500 N/A 400CC PET NONE LT BROWN
4.8 2.4 1.2
AC101 25796 N/A 400CC PET NONE GREEN
23.7 11.8 5.9
AD401 32821 WHITE 400CC PET NONE GREEN
22.7 11.4 5.7
AD221 41221 N/A 400CC PET NONE YELLOW
20.8 10.4 5.2
AC301 29888 N/A 400CC PET NONE YELLOW
20.7 10.3 5.2
AC201 27207 N/A 400CC PET NONE YELLOW
18.1 9.0 4.5
AB205 12792 N/A 400CC PET NONE YELLOW
7.0 3.5 1.8
AA101 3200 N/A 400CC HDPE NONE LIME
3.1 1.6 0.8
AA104 6462 N/A 400CC HDPE NONE LIME
7.8 3.9 1.9
AA103 5247 N/A 400CC HDPE NONE LIME
5.1 2.5 1.3
AA102 3407 N/A 400CC HDPE NONE LIME
3.3 1.7 0.8
AB207 25262 N/A 400CC HDPE NONE EGGSHELL
16.8 8.4 4.2
AD201 33992 N/A 400CC HDPE NONE BLUE
40.9 20.4 10.2
AC441 44016 N/A 400CC HDPE NONE BLUE
30.5 15.2 7.6
LINE 4 - CYCLE 1
Data shown is for illustration only and is not actual
SLIDE 39
39 #APICS2017
Data shown is for illustration only and is not actual
ITEM FCST AVERAGE TABLET COLOR BOTTLE SIZE BOTTLE TYPE DESSICANT # BOTTLE COLOR HOURS PER MONTH HOURS PER 2 WEEKS HOURS PER WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR
73.6 36.8 18.4
AB206 52234 N/A 500CC SHORT-PET D546 CLEAR
33.0 16.5 8.2
AB302 49303 N/A 500CC SHORT-PET NONE CLEAR
35.6 17.8 8.9
AL402 31325 N/A 500CC SHORT-PET NONE CLEAR
22.6 11.3 5.7
AR229 9415 DARK GREEN 500CC SHORT-PET NONE CLEAR
11.3 5.7 2.8
AR201 21841 N/A 500CC PET NONE CLEAR
26.3 13.1 6.6
AF221 33211 N/A 500CC PET NONE YELLOW
24.0 12.0 6.0
AF241 30496 N/A 500CC PET NONE YELLOW
22.0 11.0 5.5
AG330 13324 N/A 500CC PET NONE YELLOW
16.0 8.0 4.0
AL302 5568 N/A 500CC PET NONE YELLOW
4.3 2.1 1.1
AL302 5239 N/A 500CC HDPE NONE LIME
4.6 2.3 1.2
AF401 9823 N/A 500CC HDPE NONE EGGSHELL
11.8 5.9 3.0
AR217 5252 N/A 400CC HDPE D472 LIME
2.9 1.4 0.7
AR314 5034 N/A 400CC HDPE D472 LIME
2.8 1.4 0.7
AR112 2232 N/A 400CC HDPE NONE LIME
1.1 0.6 0.3
AL221 1046 N/A 400CC HDPE NONE LIME
0.7 0.4 0.2
AR514 991 N/A 400CC HDPE NONE LIME
0.5 0.3 0.1
AC441 44016 N/A 400CC HDPE NONE BLUE
30.5 15.2 7.6
AD201 33992 N/A 400CC HDPE NONE BLUE
40.9 20.4 10.2
LINE 4 - CYCLE 2
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40 #APICS2017
ITEM FCST AVERAGE TABLET COLOR BOTTLE SIZE BOTTLE TYPE DESSICANT # BOTTLE COLOR HOURS PER MONTH HOURS PER 2 WEEKS HOURS PER WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR
73.6 36.8 18.4
AB302 49303 N/A 500CC SHORT-PET D546 CLEAR
35.6 17.8 8.9
AB206 52234 N/A 500CC SHORT-PET NONE CLEAR
33.0 16.5 8.2
AB203 12447 N/A 400CC PET NONE LT BROWN
6.8 3.4 1.7
AA105 9500 N/A 400CC PET NONE LT BROWN
4.8 2.4 1.2
AC101 25796 N/A 400CC PET NONE GREEN
23.7 11.8 5.9
AD401 32821 WHITE 400CC PET NONE GREEN
22.7 11.4 5.7
AD221 41221 N/A 400CC PET NONE YELLOW
20.8 10.4 5.2
AC301 29888 N/A 400CC PET NONE YELLOW
20.7 10.3 5.2
AC201 27207 N/A 400CC PET NONE YELLOW
18.1 9.0 4.5
AB205 12792 N/A 400CC PET NONE YELLOW
7.0 3.5 1.8
AA101 3200 N/A 400CC HDPE NONE LIME
3.1 1.6 0.8
AA104 6462 N/A 400CC HDPE NONE LIME
7.8 3.9 1.9
AA103 5247 N/A 400CC HDPE NONE LIME
5.1 2.5 1.3
AA102 3407 N/A 400CC HDPE NONE LIME
3.3 1.7 0.8
AB207 25262 N/A 400CC HDPE NONE EGGSHELL
16.8 8.4 4.2
AD201 33992 N/A 400CC HDPE NONE BLUE
40.9 20.4 10.2
AC441 44016 N/A 400CC HDPE NONE BLUE
30.5 15.2 7.6 ITEM FCST AVERAGE TABLET COLOR BOTTLE SIZE BOTTLE TYPE DESSICANT # BOTTLE COLOR HOURS PER MONTH HOURS PER 2 WEEKS HOURS PER WEEK
AB207 102000 N/A 500CC SHORT-PET D546 CLEAR
73.6 36.8 18.4
AB206 52234 N/A 500CC SHORT-PET D546 CLEAR
33.0 16.5 8.2
AB302 49303 N/A 500CC SHORT-PET NONE CLEAR
35.6 17.8 8.9
AL402 31325 N/A 500CC SHORT-PET NONE CLEAR
22.6 11.3 5.7
AR229 9415 DARK GREEN 500CC SHORT-PET NONE CLEAR
11.3 5.7 2.8
AR201 21841 N/A 500CC PET NONE CLEAR
26.3 13.1 6.6
AF221 33211 N/A 500CC PET NONE YELLOW
24.0 12.0 6.0
AF241 30496 N/A 500CC PET NONE YELLOW
22.0 11.0 5.5
AG330 13324 N/A 500CC PET NONE YELLOW
16.0 8.0 4.0
AL302 5568 N/A 500CC PET NONE YELLOW
4.3 2.1 1.1
AL302 5239 N/A 500CC HDPE NONE LIME
4.6 2.3 1.2
AF401 9823 N/A 500CC HDPE NONE EGGSHELL
11.8 5.9 3.0
AR217 5252 N/A 400CC HDPE D472 LIME
2.9 1.4 0.7
AR314 5034 N/A 400CC HDPE D472 LIME
2.8 1.4 0.7
AR112 2232 N/A 400CC HDPE NONE LIME
1.1 0.6 0.3
AL221 1046 N/A 400CC HDPE NONE LIME
0.7 0.4 0.2
AR514 991 N/A 400CC HDPE NONE LIME
0.5 0.3 0.1
AC441 44016 N/A 400CC HDPE NONE BLUE
30.5 15.2 7.6
AD201 33992 N/A 400CC HDPE NONE BLUE
40.9 20.4 10.2
CYCLE 2 CYCLE 1
Data shown is for illustration only and is not actual
SLIDE 41
41 #APICS2017
DEERFIELD BENEFITS
- 12 point improvement in OEE
- 35% increase in throughput
- Same capacity on 20% fewer lines
- Operating savings = 15% of direct labor
- Extrapolating to other NBTY packaging operations
Similar savings are being realized
- Have begun designing wheels for manufacturing operations
"The process addressed our real concerns and involved us in the solutions. We felt committed to using each new change because it fixed a real issue.“ Jaci Souza – Packaging Director – Nature’s Bounty
SLIDE 42
42 #APICS2017
- Eli Lilly & Co, The Procter & Gamble Co., DuPont – 28 years
- Plant Systems Manager
- Production Systems Integration
- Project & Program Manager
- CI Manager
- Supply Chain COE Lead
- Verrico Associates – 2009 to present
- Consulting with Responsible Care chemical companies
- Zinata – 2010 to present
- Process improvement, Change managements, project management
- Leadership team alignment and direction
- Product Wheel design/implementation , Value Stream Mapping
- Career has been about improving the way the supply chain and its
manufacturing component work - Whether intervention is a system, a process or the basic ways things get done
ALAN H. NALL alan.nall@Zinata.com
SLIDE 43
43 #APICS2017
DEERFIELD BEACH SUCCESS FACTORS
- A well defined, well understood need
- Low OEE (< 50%)
- Frequent schedule breaks
- Illogical run lengths
- Too many changeovers
- A well defined process for improvement
- A design method that was flexible for changing needs
- A strong cross-functional team
SLIDE 44
44 #APICS2017
- Tools to integrate the wheels with our existing ERP and
scheduling systems
- A simple, straightforward process for schedulers to
follow on a daily basis
- Presents new orders assigned to the proper line
- Presents new orders at proper point in wheel
sequence
- Allows scheduler to make changes if needed
- Tool capability enhanced to address concrete needs
- Strong coaching and follow-up from the consultants
DEERFIELD BEACH SUCCESS FACTORS
SLIDE 45
45 #APICS2017
DAILY WHEEL OPERATION
- Scheduling can be a complex task with a large # of SKUs
- One packaging plant has > 4,000 packaged SKUs
- They are packaged on more than a dozen lines
- The Oracle system generates hundreds of orders per day
- Wheels make this simpler to manage, but it can still be
complex and time consuming
- We have Excel-based execution
accelerators to help the scheduler
- the “Product Wheel Accelerator”
SLIDE 46
46 #APICS2017
PRODUCT WHEEL ACCELERATOR CONCEPT
PIT TIME PIT TIME PIT TIME PIT TIME PIT TIME SWING LINE PACKING LINE #3 PACKING LINE #5 PACKING LINE #2 PACKING LINE #4 PACKING #1 51381 19852 30282 13045 55347 32689 13775 57601 30173 45211 53181 19955 3809 13412 46077 41628 55412 19097 53124 53125 53129 51381 19852 30282 13045 55347 32689 13775 57601 30173 45211 53181 19955 3809 13412 46077 41628 55412 19097 53124 53125 53129PWT – Excel Macro Accelerators
Wheel Based Schedule By Line Open Orders - Extract Current Prod Schedule - Extract
Production Schedule Prim.: L04-Black-CWheel Item Description Selected Line Status WO# D.A . Prod. QTY Issue Date Slat # Forecast Bott le Size Bottle Type Allergen Dusty , Sticky Bulk Cap Type Bottle Color Cap Color Bulk Type Proposed Line Run Rate Anticipated Run length Anticipated start date Offset Cycle Wheel Seq Ideal Date aa333 Product description aa333 N Running 1 35400 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 9.00 01/12/2017 00:00 44 Cycle 142795 01/24/2017 22:36 aa333 Product description aa333 N Printed 2 23142 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 5.89 01/12/2017 09:00 44 Cycle 142795 01/24/2017 22:36 hh111 Product Description hh111 N Printed 3 35000 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 9.26 01/12/2017 14:53 Cycle 142751 01/12/2017 13:54 hh111 Product Description hh111 N Ready 4 28000 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.41 01/13/2017 00:09 Cycle 142751 01/12/2017 13:54 hh111 Product Description hh111 N Ready 5 19705 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 5.21 01/13/2017 07:33 Cycle 142751 01/12/2017 13:54 hh111 Product Description hh111 N Ready 6 30171 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.98 01/13/2017 12:46 Cycle 142751 01/12/2017 13:54 hh333 Product Description hh333 N Schedule 101 2709 06/01/2016 29201 100CC PET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 0.67 01/13/2017 20:45 3 Cycle 142754 01/13/2017 15:12 hh333 Product Description hh333 N Schedule 102 11600 06/01/2016 29201 100CC PET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 2.87 01/13/2017 21:25 3 Cycle 142754 01/13/2017 15:12 dd765 Product Description dd765 N Schedule 103 96061 06/01/2016 123921 100CC PET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 23.31 01/16/2017 00:17 8 Cycle 142759 01/16/2017 08:36 dd765 Product Description dd765 N Schedule 104 3441 06/01/2016 123921 100CC PET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 0.84 01/16/2017 23:36 8 Cycle 142759 01/16/2017 08:36 dd765 Product Description dd765 N Schedule 105 50000 06/01/2016 123921 100CC PET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 12.14 01/17/2017 00:26 8 Cycle 142759 01/16/2017 08:36 gg544 Product Description gg544 N Ready 7 24258 05/10/2016 64285 100CC PET Free 7892 STD GREEN WMLTYELLOW SG L04-Black 94 6.83 01/17/2017 12:34 9 Cycle 142760 01/16/2017 23:42 gg766 Product descritpion gg766 N Schedule 106 17788 06/03/2016 49077 100CC PET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 5.12 01/17/2017 19:24 11 Cycle 142762 01/17/2017 12:24 gg766 Product descritpion gg766 N Schedule 107 23926 06/03/2016 49077 100CC PET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.88 01/18/2017 00:31 11 Cycle 142762 01/17/2017 12:24 gg766 Product descritpion gg766 N Schedule 108 23765 06/03/2016 49077 100CC PET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.83 01/18/2017 07:23 11 Cycle 142762 01/17/2017 12:24 gg655 Product Description gg655 N Ready 8 29980 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 14:13 12 Cycle 142763 01/17/2017 19:30 gg655 Product Description gg655 N Ready 9 29999 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 22:56 12 Cycle 142763 01/17/2017 19:30 gg655 Product Description gg655 N Ready 10 29709 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.64 01/19/2017 07:40 12 Cycle 142763 01/17/2017 19:30 gg655 Product Description gg655 N Ready 11 4569 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 1.33 01/19/2017 16:18 12 Cycle 142763 01/17/2017 19:30 dd876 Product Description dd876 N Schedule 109 62 48070 05/27/2016 20266.66667 100CC PET Free Dusty 12610 STD AMBER YELLOW T L04-Black 112 11.35 01/19/2017 17:38 13 Cycle 142764 01/18/2017 09:18 ff234 Product Description ff234 N Ready 12 73 20000 6581 100CC PET Free 90 STD AMBER YELLOW C L04-Black 105 5.04 01/20/2017 04:59 15 Cycle 142766 01/18/2017 14:30 ee444 Product Description ee444 N Ready 13 118 2973 16421 100CC PET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.79 01/20/2017 10:01 19 Cycle 142770 01/19/2017 00:00 ee444 Product Description ee444 N Ready 14 118 2298 16421 100CC PET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.61 01/20/2017 10:48 19 Cycle 142770 01/19/2017 00:00 ee888 Product Description ee888 N Ready 15 42 23000 12077 100CC PET Free 29172 STD AMBER YELLOW SG L04-Black 71 8.57 01/20/2017 11:25 20 Cycle 142771 01/19/2017 04:18 ff456 Product Description ff456 N Schedule 110 26 17333 05/27/2016 300 6273 100CC PET Free 50402 STD AMBER YELLOW SG L04-Black 105 4.37 01/20/2017 19:59 21 Cycle 142772 01/19/2017 08:48 aa111 Product Descr aa111 N Schedule 111 71 22200 05/27/2016 9900 9296.666667 100CC PET Free 52714 STD AMBER YELLOW T L04-Black 109 5.39 01/23/2017 00:21 24 Cycle 142775 01/19/2017 16:00 bb111 Product Description bb111 N Schedule 112 93 7824 06/07/2016 9434.666667 100CC PET Free 16875 STD AMBER YELLOW T L04-Black 106 1.95 01/23/2017 05:44 25 Cycle 142776 01/19/2017 18:18 bb111 Product Description bb111 N Schedule 113 93 6886 06/07/2016 9434.666667 100CC PET Free 16875 STD AMBER YELLOW T L04-Black 106 1.72 01/23/2017 07:41 25 Cycle 142776 01/19/2017 18:18 ff123 Product Description ff123 N Ready 16 77 36000 12325.66667 100CC PET Free 447 STD AMBER YELLOW T L04-Black 109 8.74 01/23/2017 09:25 26 Cycle 142777 01/19/2017 20:42 cc456 Product Description CC456 N Schedule 114 109 29070 06/07/2016 300 18488.66667 100CC PET Free 3860 STD AMBER YELLOW T L04-Black 120 6.41 01/23/2017 18:09 28 Cycle 142779 01/20/2017 03:00 ff677 Product description ff677 N Schedule 115 10016 06/03/2016 16874 100CC PET Free 50126 STD AMBER YELLOW T L04-Black 109 2.43 01/24/2017 00:33 29 Cycle 142780 01/20/2017 07:06 hh444 Product Description hh444 N Ready 17 43816 05/18/2016 24581 100CC PET Free 52385 STD GREEN WMLTYELLOW C L04-Black 120 9.66 01/24/2017 02:59 34 Cycle 142785 01/20/2017 20:54 ff789 Product Description ff789 N Ready 18 31392 24487 100CC PET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 6.75 01/24/2017 12:39 35 Cycle 142786 01/20/2017 23:36 ff789 Product Description ff789 N Ready 19 9022 24487 100CC PET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 1.94 01/24/2017 19:24 35 Cycle 142786 01/20/2017 23:36 ff789 Product Description ff789 N Ready 20 25444 24487 100CC PET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 5.47 01/24/2017 21:20 35 Cycle 142786 01/20/2017 23:36 bb777 Product Description BB777 N Schedule 116 23600 05/27/2016 25241 100CC PET Soy 2090 STD GREEN WMLTYELLOW SG L04-Black 120 5.20 01/25/2017 02:49 37 Cycle 142788 01/23/2017 04:54 gg433 Product Description gg433 N Ready 21 7473 05/18/2016 36986 100CC PET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 1.62 01/25/2017 08:01 38 Cycle 142789 01/23/2017 07:42 gg433 Product Description gg433 N Ready 22 16640 05/18/2016 36986 100CC PET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 3.61 01/25/2017 09:38 38 Cycle 142789 01/23/2017 07:42 cc234 Product Description cc234 N Schedule 117 75535 06/01/2016 30754 100CC PET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 16.65 01/25/2017 13:15 40 Cycle 142791 01/23/2017 15:36 CC123 Product Description CC123 N Ready 23 6000 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 1.51 01/26/2017 05:54 41 Cycle 142792 01/23/2017 19:00 CC123 Product Description CC123 N Ready 24 25000 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.30 01/26/2017 07:24 41 Cycle 142792 01/23/2017 19:00 CC123 Product Description CC123 N Ready 25 24666 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.21 01/26/2017 13:42 41 Cycle 142792 01/23/2017 19:00 CC123 Product Description CC123 N Ready 26 8766 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 2.21 01/26/2017 19:55 41 Cycle 142792 01/23/2017 19:00 aa222 Product Descr aa222 N Ready 27 28960 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 6.96 01/26/2017 22:08 42 Cycle 142793 01/23/2017 23:24 aa222 Product Descr aa222 N Ready 28 24000 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 5.77 01/27/2017 05:06 42 Cycle 142793 01/23/2017 23:24 hh222 Product Description hh222 N Ready 29 39060 05/18/2016 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 9.94 01/27/2017 10:52 43 Cycle 142794 01/24/2017 08:42 hh222 Product Description hh222 N Ready 30 49163 05/18/2016 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 12.51 01/27/2017 20:48 43 Cycle 142794 01/24/2017 08:42 ff567 Product Description ff567 N Schedule 118 14409 05/26/2016 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 3.34 01/30/2017 09:18 45 Cycle 142796 01/25/2017 05:18 ff567 Product Description ff567 N Schedule 119 65232 05/26/2016 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 15.14 01/30/2017 12:39 45 Cycle 142796 01/25/2017 05:18 ff567 Product Description ff567 N Schedule 120 44382 05/26/2016 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 10.30 01/31/2017 03:47 45 Cycle 142796 01/25/2017 05:18 ff345 Product Description ff3454 N Schedule 121 18318 06/07/2016 15950.66667 100CC HDPE Free Dusty 1380 STD LIMEGRN GREEN T L04-Black 110 4.41 01/31/2017 14:05 48 Cycle 242799 01/25/2017 18:06 ff345 Product Description ff3454 N Schedule 122 10200 06/07/2016 15950.66667 100CC HDPE Free Dusty 1380 STD LIMEGRN GREEN T L04-Black 110 2.45 01/31/2017 18:30 48 Cycle 242799 01/25/2017 18:06 gg988 Product Description gg988 N Schedule 123 3232 06/01/2016 16121 100CC PET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 0.71 01/31/2017 20:57 56 Cycle 242807 01/26/2017 18:18 gg988 Product Description gg988 N Schedule 124 39376 06/01/2016 16121 100CC PET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 8.68 01/31/2017 21:40 56 Cycle 242807 01/26/2017 18:18 gg877 Product description gg877 N Schedule 125 5000 06/03/2016 1534 100CC PET Free Dusty 54801 STD AMBER WHITE T L04-Black 104 1.27 02/01/2017 06:20 63 Cycle 242814 01/30/2017 06:06 ee333 Product Description ee333 N Schedule 126 72 18000 06/01/2016 300 6808 100CC PET Free Dusty 1660 STD AMBER YELLOW C L04-Black 105 4.54 02/01/2017 07:37 64 Cycle 242815 01/30/2017 07:18 hh655 Product Description hh655 N Ready 31 130 8888 15543.66667 100CC PET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 2.03 02/01/2017 12:09 69 Cycle 242820 01/30/2017 18:30 hh655 Product Description hh655 N Ready 32 130 23000 15543.66667 100CC PET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 5.25 02/01/2017 14:10 69 Cycle 242820 01/30/2017 18:30 hh655 Product Description hh655 N Ready 33 130 15000 15543.66667 100CC PET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 3.42 02/01/2017 19:25 69 Cycle 242820 01/30/2017 18:30 bb333 Product Description BB333 N Schedule 127 11512 05/27/2016 9416 100CC PET Free 50402 STD AMBER WHITE SG L04-Black 102 2.99 02/01/2017 22:50 74 Cycle 242825 01/31/2017 04:12 dd987 Product Description dd987 N Schedule 128 3666 05/27/2016 8627.666667 100CC PET Free 7961 STD AMBER WHITE T L04-Black 74 1.31 02/02/2017 01:50 75 Cycle 242826 01/31/2017 06:36 ee999 Product Description ee999 N Ready 34 7011 05/19/2016 45574 100CC PET Free 19939 STD GREEN WMLTYELLOW SG L08-Pink 92 2.02 02/02/2017 03:08 Production Schedule Prim.: L04-Black-CWheel Item Description Selected Line Status WO# D.A . Prod. QTY Issue Date Slat # Forecast Bott le Size Bottle Type Allergen Dusty , Sticky Bulk Cap Type Bottle Color Cap Color Bulk Type Proposed Line Run Rate Anticipated Run length Anticipated start date Offset Cycle Wheel Seq Ideal Date aa333 Product description aa333 N Running 1 35400 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 9.00 01/12/2017 00:00 44 Cycle 142795 01/24/2017 22:36 aa333 Product description aa333 N Printed 2 23142 52633.66667 75CC PET Free 1400 STD GREEN WMLTYELLOW T L04-Black 104 5.89 01/12/2017 09:00 44 Cycle 142795 01/24/2017 22:36 hh111 Product Description hh111 N Printed 3 35000 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 9.26 01/12/2017 14:53 Cycle 142751 01/12/2017 13:54 hh111 Product Description hh111 N Ready 4 28000 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.41 01/13/2017 00:09 Cycle 142751 01/12/2017 13:54 hh111 Product Description hh111 N Ready 5 19705 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 5.21 01/13/2017 07:33 Cycle 142751 01/12/2017 13:54 hh111 Product Description hh111 N Ready 6 30171 128378 100CC PET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.98 01/13/2017 12:46 Cycle 142751 01/12/2017 13:54 hh333 Product Description hh333 N Schedule 101 2709 06/01/2016 29201 100CC PET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 0.67 01/13/2017 20:45 3 Cycle 142754 01/13/2017 15:12 hh333 Product Description hh333 N Schedule 102 11600 06/01/2016 29201 100CC PET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 2.87 01/13/2017 21:25 3 Cycle 142754 01/13/2017 15:12 dd765 Product Description dd765 N Schedule 103 96061 06/01/2016 123921 100CC PET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 23.31 01/16/2017 00:17 8 Cycle 142759 01/16/2017 08:36 dd765 Product Description dd765 N Schedule 104 3441 06/01/2016 123921 100CC PET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 0.84 01/16/2017 23:36 8 Cycle 142759 01/16/2017 08:36 dd765 Product Description dd765 N Schedule 105 50000 06/01/2016 123921 100CC PET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 12.14 01/17/2017 00:26 8 Cycle 142759 01/16/2017 08:36 gg544 Product Description gg544 N Ready 7 24258 05/10/2016 64285 100CC PET Free 7892 STD GREEN WMLTYELLOW SG L04-Black 94 6.83 01/17/2017 12:34 9 Cycle 142760 01/16/2017 23:42 gg766 Product descritpion gg766 N Schedule 106 17788 06/03/2016 49077 100CC PET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 5.12 01/17/2017 19:24 11 Cycle 142762 01/17/2017 12:24 gg766 Product descritpion gg766 N Schedule 107 23926 06/03/2016 49077 100CC PET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.88 01/18/2017 00:31 11 Cycle 142762 01/17/2017 12:24 gg766 Product descritpion gg766 N Schedule 108 23765 06/03/2016 49077 100CC PET Free Dusty 54801 STD GREEN WMLTYELLOW T L04-Black 92 6.83 01/18/2017 07:23 11 Cycle 142762 01/17/2017 12:24 gg655 Product Description gg655 N Ready 8 29980 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 14:13 12 Cycle 142763 01/17/2017 19:30 gg655 Product Description gg655 N Ready 9 29999 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.72 01/18/2017 22:56 12 Cycle 142763 01/17/2017 19:30 gg655 Product Description gg655 N Ready 10 29709 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 8.64 01/19/2017 07:40 12 Cycle 142763 01/17/2017 19:30 gg655 Product Description gg655 N Ready 11 4569 95001 100CC PET Free Dusty 3595 STD GREEN WMLTYELLOW T L04-Black 91 1.33 01/19/2017 16:18 12 Cycle 142763 01/17/2017 19:30 dd876 Product Description dd876 N Schedule 109 62 48070 05/27/2016 20266.66667 100CC PET Free Dusty 12610 STD AMBER YELLOW T L04-Black 112 11.35 01/19/2017 17:38 13 Cycle 142764 01/18/2017 09:18 ff234 Product Description ff234 N Ready 12 73 20000 6581 100CC PET Free 90 STD AMBER YELLOW C L04-Black 105 5.04 01/20/2017 04:59 15 Cycle 142766 01/18/2017 14:30 ee444 Product Description ee444 N Ready 13 118 2973 16421 100CC PET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.79 01/20/2017 10:01 19 Cycle 142770 01/19/2017 00:00 ee444 Product Description ee444 N Ready 14 118 2298 16421 100CC PET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.61 01/20/2017 10:48 19 Cycle 142770 01/19/2017 00:00 ee888 Product Description ee888 N Ready 15 42 23000 12077 100CC PET Free 29172 STD AMBER YELLOW SG L04-Black 71 8.57 01/20/2017 11:25 20 Cycle 142771 01/19/2017 04:18 ff456 Product Description ff456 N Schedule 110 26 17333 05/27/2016 300 6273 100CC PET Free 50402 STD AMBER YELLOW SG L04-Black 105 4.37 01/20/2017 19:59 21 Cycle 142772 01/19/2017 08:48 aa111 Product Descr aa111 N Schedule 111 71 22200 05/27/2016 9900 9296.666667 100CC PET Free 52714 STD AMBER YELLOW T L04-Black 109 5.39 01/23/2017 00:21 24 Cycle 142775 01/19/2017 16:00 bb111 Product Description bb111 N Schedule 112 93 7824 06/07/2016 9434.666667 100CC PET Free 16875 STD AMBER YELLOW T L04-Black 106 1.95 01/23/2017 05:44 25 Cycle 142776 01/19/2017 18:18 bb111 Product Description bb111 N Schedule 113 93 6886 06/07/2016 9434.666667 100CC PET Free 16875 STD AMBER YELLOW T L04-Black 106 1.72 01/23/2017 07:41 25 Cycle 142776 01/19/2017 18:18 ff123 Product Description ff123 N Ready 16 77 36000 12325.66667 100CC PET Free 447 STD AMBER YELLOW T L04-Black 109 8.74 01/23/2017 09:25 26 Cycle 142777 01/19/2017 20:42 cc456 Product Description CC456 N Schedule 114 109 29070 06/07/2016 300 18488.66667 100CC PET Free 3860 STD AMBER YELLOW T L04-Black 120 6.41 01/23/2017 18:09 28 Cycle 142779 01/20/2017 03:00 ff677 Product description ff677 N Schedule 115 10016 06/03/2016 16874 100CC PET Free 50126 STD AMBER YELLOW T L04-Black 109 2.43 01/24/2017 00:33 29 Cycle 142780 01/20/2017 07:06 hh444 Product Description hh444 N Ready 17 43816 05/18/2016 24581 100CC PET Free 52385 STD GREEN WMLTYELLOW C L04-Black 120 9.66 01/24/2017 02:59 34 Cycle 142785 01/20/2017 20:54 ff789 Product Description ff789 N Ready 18 31392 24487 100CC PET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 6.75 01/24/2017 12:39 35 Cycle 142786 01/20/2017 23:36 ff789 Product Description ff789 N Ready 19 9022 24487 100CC PET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 1.94 01/24/2017 19:24 35 Cycle 142786 01/20/2017 23:36 ff789 Product Description ff789 N Ready 20 25444 24487 100CC PET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 5.47 01/24/2017 21:20 35 Cycle 142786 01/20/2017 23:36 bb777 Product Description BB777 N Schedule 116 23600 05/27/2016 25241 100CC PET Soy 2090 STD GREEN WMLTYELLOW SG L04-Black 120 5.20 01/25/2017 02:49 37 Cycle 142788 01/23/2017 04:54 gg433 Product Description gg433 N Ready 21 7473 05/18/2016 36986 100CC PET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 1.62 01/25/2017 08:01 38 Cycle 142789 01/23/2017 07:42 gg433 Product Description gg433 N Ready 22 16640 05/18/2016 36986 100CC PET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 3.61 01/25/2017 09:38 38 Cycle 142789 01/23/2017 07:42 cc234 Product Description cc234 N Schedule 117 75535 06/01/2016 30754 100CC PET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 16.65 01/25/2017 13:15 40 Cycle 142791 01/23/2017 15:36 CC123 Product Description CC123 N Ready 23 6000 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 1.51 01/26/2017 05:54 41 Cycle 142792 01/23/2017 19:00 CC123 Product Description CC123 N Ready 24 25000 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.30 01/26/2017 07:24 41 Cycle 142792 01/23/2017 19:00 CC123 Product Description CC123 N Ready 25 24666 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 6.21 01/26/2017 13:42 41 Cycle 142792 01/23/2017 19:00 CC123 Product Description CC123 N Ready 26 8766 34934.33333 100CC PET Wheat,Gluten Dusty 51846 STD GREEN WMLTYELLOW T L04-Black 105 2.21 01/26/2017 19:55 41 Cycle 142792 01/23/2017 19:00 aa222 Product Descr aa222 N Ready 27 28960 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 6.96 01/26/2017 22:08 42 Cycle 142793 01/23/2017 23:24 aa222 Product Descr aa222 N Ready 28 24000 77109 75CC PET Free Dusty 12605 STD GREEN WMLTYELLOW T L04-Black 110 5.77 01/27/2017 05:06 42 Cycle 142793 01/23/2017 23:24 hh222 Product Description hh222 N Ready 29 39060 05/18/2016 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 9.94 01/27/2017 10:52 43 Cycle 142794 01/24/2017 08:42 hh222 Product Description hh222 N Ready 30 49163 05/18/2016 109788 75CC PET Free 50709 STD GREEN WMLTYELLOW SG L04-Black 104 12.51 01/27/2017 20:48 43 Cycle 142794 01/24/2017 08:42 ff567 Product Description ff567 N Schedule 118 14409 05/26/2016 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 3.34 01/30/2017 09:18 45 Cycle 142796 01/25/2017 05:18 ff567 Product Description ff567 N Schedule 119 65232 05/26/2016 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 15.14 01/30/2017 12:39 45 Cycle 142796 01/25/2017 05:18 ff567 Product Description ff567 N Schedule 120 44382 05/26/2016 85552 75CC PET Free 41141 CRC GREEN YELLOW T L04-Black 114 10.30 01/31/2017 03:47 45 Cycle 142796 01/25/2017 05:18 ff345 Product Description ff3454 N Schedule 121 18318 06/07/2016 15950.66667 100CC HDPE Free Dusty 1380 STD LIMEGRN GREEN T L04-Black 110 4.41 01/31/2017 14:05 48 Cycle 242799 01/25/2017 18:06 ff345 Product Description ff3454 N Schedule 122 10200 06/07/2016 15950.66667 100CC HDPE Free Dusty 1380 STD LIMEGRN GREEN T L04-Black 110 2.45 01/31/2017 18:30 48 Cycle 242799 01/25/2017 18:06 gg988 Product Description gg988 N Schedule 123 3232 06/01/2016 16121 100CC PET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 0.71 01/31/2017 20:57 56 Cycle 242807 01/26/2017 18:18 gg988 Product Description gg988 N Schedule 124 39376 06/01/2016 16121 100CC PET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 8.68 01/31/2017 21:40 56 Cycle 242807 01/26/2017 18:18 gg877 Product description gg877 N Schedule 125 5000 06/03/2016 1534 100CC PET Free Dusty 54801 STD AMBER WHITE T L04-Black 104 1.27 02/01/2017 06:20 63 Cycle 242814 01/30/2017 06:06 ee333 Product Description ee333 N Schedule 126 72 18000 06/01/2016 300 6808 100CC PET Free Dusty 1660 STD AMBER YELLOW C L04-Black 105 4.54 02/01/2017 07:37 64 Cycle 242815 01/30/2017 07:18 hh655 Product Description hh655 N Ready 31 130 8888 15543.66667 100CC PET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 2.03 02/01/2017 12:09 69 Cycle 242820 01/30/2017 18:30 hh655 Product Description hh655 N Ready 32 130 23000 15543.66667 100CC PET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 5.25 02/01/2017 14:10 69 Cycle 242820 01/30/2017 18:30 hh655 Product Description hh655 N Ready 33 130 15000 15543.66667 100CC PET Free Dusty 12605 STD AMBER YELLOW T L04-Black 116 3.42 02/01/2017 19:25 69 Cycle 242820 01/30/2017 18:30 bb333 Product Description BB333 N Schedule 127 11512 05/27/2016 9416 100CC PET Free 50402 STD AMBER WHITE SG L04-Black 102 2.99 02/01/2017 22:50 74 Cycle 242825 01/31/2017 04:12 dd987 Product Description dd987 N Schedule 128 3666 05/27/2016 8627.666667 100CC PET Free 7961 STD AMBER WHITE T L04-Black 74 1.31 02/02/2017 01:50 75 Cycle 242826 01/31/2017 06:36 ee999 Product Description ee999 N Ready 34 7011 05/19/2016 45574 100CC PET Free 19939 STD GREEN WMLTYELLOW SG L08-Pink 92 2.02 02/02/2017 03:08 WO# New Prod Action Description Prod.Qty For release Firm Order Type Issue date Sugg Due Date 101 aa111 Release Product Descr aa111 29584 Planned order 8/23/2016 8/30/2016 102 aa111 Release Product Descr aa111 21979 Planned order 11/11/2016 11/18/2016 103 bb111 Release Product Description bb111 22946 Planned order 8/25/2016 9/5/2016 104 cc456 Release Product Description CC456 37541 Planned order 9/7/2016 9/16/2016 105 dd876 Release Product Description dd876 58336 Planned order 9/28/2016 10/7/2016 106 ee444 Release Product Description ee444 48032 Planned order 8/31/2016 9/9/2016 107 ee888 Release Product Description ee888 50295 Planned order 8/23/2016 8/30/2016 108 ee888 Release Product Description ee888 31134 Planned order 11/11/2016 11/18/2016 109 ee333 Release Product Description ee333 14645 Planned order 10/5/2016 10/14/2016 110 ff123 Release Product Description ff123 41176 Planned order 9/20/2016 9/29/2016 111 ff234 Release Product Description ff234 15113 Planned order 10/5/2016 10/14/2016 112 ff456 Release Product Description ff456 16970 Planned order 9/21/2016 9/30/2016 113 hh655 Release Product Description hh655 51641 Planned order 8/31/2016 9/9/2016 114 bb333 Release Product Description BB333 26397 Planned order 8/25/2016 9/5/2016 115 dd987 Release Product Description dd987 22751 Planned order 9/12/2016 9/21/2016 116 ff345 Release Product Description ff3454 44741 Planned order 8/24/2016 9/2/2016 117 ff345 Release Product Description ff3454 38466 Planned order 11/11/2016 11/18/2016 118 ff677 Release Product description ff677 63295 Planned order 9/22/2016 10/3/2016 119 gg766 Release Product descritpion gg766 71801 Planned order 8/23/2016 8/30/2016 120 gg766 Release Product descritpion gg766 45931 Planned order 9/12/2016 9/21/2016 121 gg766 Release Product descritpion gg766 36711 Planned order 10/12/2016 10/21/2016 122 gg766 Release Product descritpion gg766 55266 Planned order 11/11/2016 11/18/2016 123 aa222 Release Product Descr aa222 91008 Planned order 9/5/2016 9/14/2016 124 aa222 Release Product Descr aa222 67762 Planned order 10/3/2016 10/12/2016 125 aa222 Release Product Descr aa222 99931 Planned order 11/4/2016 11/11/2016 126 aa333 Release Product description aa333 240073 Planned order 8/23/2016 8/30/2016 127 aa333 Release Product description aa333 130588 Planned order 11/11/2016 11/18/2016 128 bb777 Release Product Description BB777 64172 Planned order 9/13/2016 9/22/2016 129 cc234 Release Product Description cc234 85886 Planned order 8/23/2016 8/30/2016 130 cc234 Release Product Description cc234 58744 Planned order 11/11/2016 11/18/2016 131 gg988 Release Product Description gg988 27647 Planned order 9/16/2016 9/27/2016 132 dd765 Release Product Description dd765 40254 Planned order 8/23/2016 9/1/2016 133 dd765 Release Product Description dd765 54468 Planned order 9/6/2016 9/15/2016 Status WO# Product Size Description DA Prod.Qty Line Running 1 aa333 250 Product description aa333 16 35400 L04-Black Printed 2 aa333 250 Product description aa333 16 23142 L04-Black Printed 3 hh111 120 Product Description hh111 6 35000 L04-Black Ready 4 hh111 120 Product Description hh111 6 28000 L04-Black Ready 5 hh111 120 Product Description hh111 6 19705 L04-Black Ready 6 hh111 120 Product Description hh111 6 30171 L04-Black Ready 7 ff789 90 Product Description ff789 9 31392 L04-Black Ready 8 ff789 90 Product Description ff789 9 9022 L04-Black Ready 9 ff789 90 Product Description ff789 9 25444 L04-Black Ready 10 hh222 150 Product Description hh222 13 39060 L04-Black Ready 11 hh222 150 Product Description hh222 13 49163 L04-Black Ready 12 aa222 100 Product Descr aa222 17 28960 L04-Black Ready 13 aa222 100 Product Descr aa222 17 24000 L04-Black Ready 14 hh444 30 Product Description hh444 13 43816 L04-Black Ready 15 gg433 50 Product Description gg433 14 7473 L04-Black Ready 16 gg433 50 Product Description gg433 14 16640 L04-Black Ready 17 gg544 200 Product Description gg544 17 24258 L04-Black Ready 18 gg655 200 Product Description gg655 23 29980 L04-Black Ready 19 ee999 200 Product Description ee999 35 7011 L04-BlackLine Allocation Wheel Sequences Scheduling by Line Navigation
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47 #APICS2017
PRODUCT WHEEL ACCELERATOR CONCEPT
- The upper section shows orders currently scheduled on the line
- The lower section new orders that need to be scheduled.
- Information about each order is readily visible, e.g. size of order, product days available,
key product characteristics (light green) that drove wheel scheduling, other product characteristics, and how long the order should run (based on latest rates and OEE by line.)
Data shown is for illustration only and is not actual
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48 #APICS2017
SCHEDULING PRIOR TO WHEELS
- Individual order by order decisions
- Live production system for line state and
- rder information
- Order placement is "live" in the
production system
- Massive mental library required
SCHEDULING WITH THE PRODUCT WHEEL ACCELERATOR
- Weekly load of line state and orders
- Tool proposes line for orders and then
proposes sequence on each line
- Scheduler reviews / adjusts line by line
- Safe place to get schedule right
- Export for production system update
PRODUCT WHEEL ACCELERATOR CONCEPT
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49 #APICS2017
WHEEL ACCELERATOR INTERFACE FOR SCHEDULER
49
Monthly update of Characteristics – Place New copy over old After PWR or Other Updates – Rebuild line Allocation and Wheels To Schedule – 1) place Open, Production and/or Hold order extract in Folder and 2) select Any Time - To View (and use) Select Appropriate line (or Overall) To Schedule – 3) Update “Actual” in CWheels To Schedule – 4) Use Functions in dashboard,
- r by hand to sequence
Production & Open Orders
PRODUCT WHEEL ACCELERATOR
Current Month PWR Master Line - Mline Master Wheels for Line Current Wheels for Line Update MLine Load Mwheels Load CWheels Load Production & Open Orders Go to Current Month PWR template Go to Mline ?
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50 #APICS2017
PRODUCT WHEEL ACCELERATOR – Selected Functions
Data shown is for illustration only and is not actual
- Advance Wheel
- Freeze zone
- Sequence all
- Sequence a
selected set
- Move to another
line
- Export Schedule
- Show Key
statistics
- Reason for Break
- Spokes skipped
- Reset
- Etc.
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51 #APICS2017
ACCELERATOR BENEFITS
"I schedule every week using the wheels and tool - hundreds of
- rders across two dozen lines. We built the best sequence,
people on the floor can see the simplification and have confidence in the schedule the Wheel Accelerator generates”
Ivy Garcia – Planner/Scheduler – Nature’s Bounty
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52 #APICS2017
ADDITIONAL PW ACCELERATOR BENEFITS
- The PWA enables the inherent benefits of wheels
- Simplified planning and scheduling
- Fewer, simpler, faster changeovers
- Improved OEE, higher throughput
- Reduced inventories
- Greater stability and predictability
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53 #APICS2017
“Wheels provide a great report tool …….. to access information about the products packaged, filtering by any criteria needed”
Yenny Yataco – Nature’s Bounty – Planner/Scheduler
ADDITIONAL PW ACCELERATOR BENEFITS
- It also provides a tool for better long range planning
- Quantification of when difficult products will be run
- Quantification of future component needs
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54 #APICS2017
"I can schedule the weeks orders to the wheel on all lines in a few hours, then work on improvements…“
Ivy Garcia – Planner/Scheduler – Nature’s Bounty
ADDITIONAL PW ACCELERATOR BENEFITS
- A dramatic reduction in the time planners and schedulers
spend on routine scheduling more time for true crises
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55 #APICS2017
“The product wheel is so powerful that you will notice when it’s not being followed. A couple of months ago our throughput numbers went down. … I went to the Planning Manager and asked her, are we following the product wheel? Her response was no, due to a programming issue. I knew right away that the wheel was not being followed since our change overs had been reduced by 20% when we implemented it”.
Adelino Rivera – FLA Operations Director – Nature’s Bounty
THE BUSINESS LEADERSHIP VIEW:
SLIDE 56
56 #APICS2017
Product wheels are key part of an integrated set of Lean tools
- Value Stream Mapping
- Cellular Flow
- Changeover reduction (SMED)
- Total Productive Maintenance (TPM)
- Pull replenishment systems
OBSERVATIONS
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57 #APICS2017
Addressing the day to day use of the wheel in scheduling unlocks the power of the wheels.
- Freeing time for exceptions
- Cementing the wheels gains
- Supporting the wheel driven rhythm
OBSERVATIONS
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58 #APICS2017
Compromise is often required But ….. No matter what compromises are required You will almost always end up better
- ff
OBSERVATIONS
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59 #APICS2017
BENEFITS OF PRODUCT WHEELS
- 1. Levels production
- 2. Optimizes sequences
- 3. Optimizes campaign lengths
- 4. Enables inventory target setting
- 5. Reduces inventory
- 6. Improves delivery performance
- 7. Bring order to chaos – stop the insanity!
Brings order and structure to complex scheduling decisions
- 8. Provides a mathematical basis to support decision making
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60 #APICS2017
BENEFITS OF PRODUCT WHEELS
Are realized in stages, when
- 1. Product families are grouped
- 2. Ideal campaign lengths are set
- 3. Sequencing reaches the line
- 4. The scheduling process settles in
- 5. The rest of the supply chain responds to the production
rhythm
- 6. Analysis takes advantage of wheel informed data
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61 #APICS2017
OTHER PRODUCT WHEEL USERS
- BG Products
- Appvion
- Dow Chemical
- DuPont
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62 #APICS2017
A ROSE BY ANY OTHER NAME …..
- Exxon Mobil
“FSVV” (Fixed sequence variable volume)
- Pharmaceutical companies
“Rhythm wheels”
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POTENTIAL APPLICATIONS
- Industries that can benefit from Product Wheels
- Food: ketchup, mayonnaise, cereals, snack items, etc.
- Beverages: water, beer, soda, etc.
- Paints and coatings
- Pharma
- Extruded polymers, synthetic rubbers
- Sheet goods: paper, plastic
- Personal care: toothpaste, shampoo, creams and lotions
- Automotive fluids: power steering fluids, oils, lubricants, etc
- Metal forming
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64 #APICS2017
A FINAL THOUGHT “ Using Product Wheels with our large product mix and running them in the most optimal sequence to create better flow , reduce our changeovers and free up capacity ………… PRICELESS !! “
Cheryl Alker – Planning Manager – Nature’s Bounty
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65 #APICS2017
WE WROTE THE BOOK ON WHEELS ……
Productivity Press May 2009
Productivity Press April 2013
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QUESTIONS?
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67 #APICS2017
APICS 2017 Session Evaluation
Visit www.apics.org/Monday
- r
download the APICS2017 app
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68 #APICS2017