Advanced Planning and Scheduling
APSAdvanced Planning and Scheduling (APS) systems use algorithms to analyze materials and capacity, creating optimized production schedules.
Advanced Planning and Scheduling (APS) is a system for production planning and scheduling. It uses mathematical calculations to create feasible schedules. The system balances demand from customer orders with available plant capacity. This capacity includes machines, labor, and materials.
An APS system works by considering multiple constraints at the same time. It looks at material availability from the Bill of Materials (BOM). It also checks machine capacity and labor availability from routings and work center data. The system can then generate a production schedule that optimizes for specific goals. These goals could be minimizing changeover times or maximizing on-time delivery.
On the shop floor, APS creates realistic and achievable production plans. When an unexpected event occurs, like a machine breakdown or a rush order, the system can quickly regenerate the schedule. This allows planners to see the impact of the change across all orders. It helps reduce lead times, lower inventory levels, and improve customer satisfaction by meeting delivery dates.
Manufacturers implement APS software that works with their Enterprise Resource Planning (ERP) or Manufacturing Execution System (MES). Implementation requires clean, accurate data. This includes item masters, BOMs, routings, work center capacities, and current inventory levels. The system uses this data to model the factory's operations and generate schedules.
A custom metal fabrication shop receives a rush order for 50 parts due in three days. The planner enters the order into the APS system. The system reschedules the laser cutters and press brakes, pushing back two non-urgent jobs by one day to accommodate the new order.
How is APS different from Material Requirements Planning (MRP)?
MRP primarily plans for materials based on a master schedule. APS plans for both materials and capacity (machines, labor) simultaneously, creating a more constrained and realistic schedule.
Do I need an ERP system to use APS?
Most APS systems work with an ERP, which supplies essential data like orders and inventory. Some APS tools can run independently but require more manual data management.
What data does an APS system require to be effective?
APS needs accurate data on customer orders, bills of materials, inventory, work center capacities, labor resources, and production routings.
How does APS handle unexpected machine downtime?
The system can quickly re-calculate the schedule based on the new capacity constraint. It can re-sequence jobs on other machines to minimize the disruption to delivery dates.
Can APS help with 'what-if' scenarios?
Yes, planners can use APS to simulate different scenarios. For example, they can model the impact of adding a new machine or accepting a large, unexpected order.
Enterprise Resource Planning
ERPEnterprise Resource Planning (ERP) is a software system that integrates a company's core business functions into a single, shared database.
Manufacturing Execution System
MESA Manufacturing Execution System (MES) is software that tracks and documents the transformation of raw materials into finished goods in real time.
Master Production Schedule
MPSA detailed plan that specifies what end products to build, how many are needed, and when they are needed.
Material Requirements Planning
MRPMaterial Requirements Planning (MRP) is a system that calculates the materials and components needed to manufacture a product based on production schedules.
Production Scheduling
Production scheduling is the process of assigning specific jobs to specific resources and work centers over a specific period of time.