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May, 2018


What Does Lean Production Planning Really Look Like?


Continued from previous page


not be too significant. During preparation for a new product, SMT engineering is rarely


demands and limits the ability to change those decisions. The traditional approach to SMT


material logistics is to create kits of materials for work orders hours in


and are out on the shop floor. This requires a considerable


investment in materials and creates a physical barrier to making plan- ning changes. The prepared materi- als have to be collected and reallocat- ed or returned to the warehouse whenever a schedule change is made. The result is a moratorium in which the immediate schedules are planned with materials assigned and cannot be changed. This moratorium can


that share common setups can reduce this time, but the SMT machine program optimization depends on the material setup matching the layout of components on the PCB. So, when grouping prod- ucts together, the SMT machine pro- gram efficiency can reduce drastical- ly. Planning with Excel can easily incorporate times for existing SMT programs and use the calculated pro- gram times for each product on its


Production planners are challenged to organize the many work order sequences in high-mix manufacturing.


given the time to build in support for alternate configurations or materi- als. The designated programs and groups can be used for a long time. As new models are introduced and old ones become obsolete, perform- ance decreases. Whether the efficiency of the


dedicated product or group is actual- ly meeting the required completion demand is often overlooked. This lim- its choices that could be made by the planning system that might enable lines to better meet completion


advance, following the sequence of work orders on a spreadsheet. This is a result of a history of material inven- tory inaccuracies that lead to unex- pected shortages, which if found at the time of setting the materials at the machine, stop the line from work- ing. The kits of materials created in advance ensure that the machines have everything they need to run in the near-term, allowing time for material issues to be resolved. Unfortunately, this creates the sce- nario where a significant quantity of materials are allocated to production


Valor Production Planning software displays a range of KPIs, including total cost.


extend for days, reducing the oppor- tunity for any planning changes. The setup and verification of


materials that need to change between products on SMT machines takes a long time. Grouping products


designated line. If a planning system were al -


lowed to move a product from one SMT line configuration to another as part of


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