Lechler | PLANNING STABILITY IN COMPONENT PRODUCTION

Due to the increasing internationalisation of the Lechler Group, the use of an SAP solution should create the conditions for growth and ensure the integration of international subsidiaries. Among other things, this includes the management of global business and production processes, the transferability of processes across locations, the mapping of global language and legal frameworks and the group-wide consolidation of business and balance sheet figures.

By using the CONSILIO add-on developed in PP/DS for stable production planning, not all orders are rescheduled in the event of last-minute changes - instead, only the new ones are actually planned and integrated into the process. Planned and production orders do not have to be reprioritised; instead, a stable sequence is maintained. Order sequence and resource utilisation are optimised for new orders, while at the same time the need for resources is reduced through improved production planning and consideration of alternative machines. Sophisticated planning functions such as the graphical detailed planning board, planning simulations and the Alert Monitor are also available.

As in the conventional APO PP/DS variant, it is also possible in ‘embedded’ PP/DS plus stable production planning to build up the automated production planning process from several steps. The result of the production planning run is a production and procurement plan in which as many general planning conditions as possible, such as capacity bottlenecks or deadline requirements, are taken into account.

With the ‘injection moulding tool solution’, the master data for tool planning is located in the ERP. Moulds are mapped as a work centre, stored as a sub-operation in the routing and subsequently integrated into SAP APO as secondary capacity requirements. Rescheduling and visualisation take place via the detailed planning board. Tool availability is taken into account when using PP/DS optimisation, as well as during manual or automatic rescheduling in the detailed planning board. This means that alternative machines cannot be occupied in parallel by orders for which the same tools or production resources are used. The capacitive load of tools is adapted to the operation duration of the main workstation - even in the case of dynamic set-up times. This also applies to sequence-dependent set-up times and in conjunction with alternative main workstations.