Production

apintra® production control (ERP/PPS)

Of course, you want to have an optimal production planning and control system (PPS) that can flexibly react to changing production processes. It offers variability and the simplest correction options. All items can subsequently be dynamically changed until
sent for production at the item level.

In the event of changes or different variants of individual products, many systems require the laborious reconfiguration of parts lists data. apintra’s different:

just enter the desired changes into the apintra production system. Our network planning technology uses this calculates the changed material requirements, your production capacities, and generates a new production plan. The result is a fully optimized production plan, complete with parts lists up to the Xth level as well as the entire work plan for personnel and machines (no more than 10 levels are necessary to be able to map the complete production of a small car).

You will benefit from this if:

you manufacture variable products,
you produce complex products,
you want to make changes to the parts list or the parts used up to the actual production process,
you want to make a variable decision as to whether you want to buy or have some components produced externally instead of producing them in-house,
you simply need flexibility in production,
you …

All apintra solutions are based on the same technology and have the same advantages. These include multi-client capability, plausibility check, open interfaces, availability in terms of location and time, and the ability to quickly find each individual data record.

The apintra® parts list system

In our parts list system, we differentiate between so-called master and production parts lists. A master parts list serves as a type of template for the actual production parts list.

It contains all master data such as the associated materials, work plans with the times required for the work steps, as well as idle, waiting and possible overlapping times.

Since the parts list header (ID key and description) is stored in materials management by the recursive function, it can also be reused in other parts lists like a material master record.

This procedure also makes it possible to trigger separate production orders for sub-parts lists or to have them produced externally. The network planning technology recognizes the open purchase order and does not break down the parts list any further.

All of the items in a parts list can still be dynamically changed until the production papers are created. Here, too, the network planning technology recognizes the changes.

The apintra® parts list system is unique in offering a range of options for variant processing:

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Variant as a duplicate

A master parts list is generated for a new production order by duplication. The resulting production parts list can then be changed as required.

This is done by simply editing the production parts list (i.e. deleting and/or adding materials, work plans and times)
In order to make the changes traceable, this can also be done by using plus and minus parts lists.

The correct resolution of material and time requirements is handled by the network planning technology.

[A production parts list can in principle also be generated from another production parts list]

Variant through stored formulas

In the master parts list processor, characters with formulas can be stored in the fields number, length and width. Any letters can be used that are processed recursively (from top to bottom) and take into account the subsequent calculations:

addition +
subtraction –
multiplication *
division /
modulo %
exponent ^
greater than >
less than <
round up ~

When a production parts list is generated, the master parts list is resolved recursively and the formulas are converted into absolute values.

What is behind the apintra® variant solution?

The production processor: automatically precise

The production processor is the control center for product management. This is where a recursively generated parts list with all materials, work plans and time requirements for the individual capacity positions are located.

In the production processor, the individual production tasks can be released and the working papers generated. Up to this point in time, changes in the materials and the work plan can be readily made.

Zusatz Produktion

Network planning technology: the heart of production plannin

If changes are made in the production processor and thus in the product flow, the material composition or size, the network planning technology recognises this and changes all dependencies from material requirements (for ordering and storage) to reserving personnel and machine capacities.

Even if an order is triggered for a sub-parts list contained in the production processor because the assembly is to be purchased, the network planning technology recognizes this and knows the materials for this assembly are not needed. The need is reduced accordingly.

Our network planning technology does not work according to the usual NetChange procedures as they are too imprecise for us. So that the system reacts correctly and optimally to changes at all times, we calculate a completely new network plan (materials and times).
By using degrees of efficiency both for the material and for the system, recalculations and capacities are optimised and more precise.

Depending on requirements, the computing process begins either with the start processes and, based on these, sets the earliest possible start date for the subsequent processes (forward planning) or with the last processes in the network (which no longer have a successor) and then sets the latest completion dates for the respective upstream processes (backward planning). By combining both methods based on a defined start and end date, the following four other important properties result for each process in addition to the duration:

earliest start time (from forward planning)
earliest end time (from forward planning and respective duration)
latest end time (from backward planning)
latest start time (from backward planning and respective duration)

Schedule buﬀer:
The schedule buffer is extra time to complete a process. This buffer can be used to postpone the process and/or stretch the duration of the process.

Integrated PDA / TNA / MDA

The PDA (production data acquisition), TNA (time and attendance data acquisition) and MDA (machine data acquisition) modules allow you to record operating and personnel time data

using additional electronic devices. This data is then processed according to the stored working time models. Interfaces for further processing in wage and salary programs are also available. Different working time models and functions for flextime and piecework accounting can also be defined.

There are different options for identifying the respective employee, depending on the device: RFID, barcode and magnetic card. An access control extension is also available.

The PDA module records all of the company’s operating data. Times that can be assigned to a production order are assigned to the originators with the times used and the “actual” costs.

Reasons for disruptions, interruptions and numbers of items are recorded. There are evaluations for production orders and capacity points. The efficiency of a capacity point is automatically optimized and the data processed in the network plan. Work progress, order status and all order-related work can be seen at any time.

Fully automatic MDA (machine data acquisition) is one option. The PDA/MDA modules can also be readily coupled with a GUI-control station.