wheel of fortune€¦ · r & d –9 years project management –15 years lean manufacturing...

WHEEL OF FORTUNE

Operational Benefits of Product Wheel

Scheduling

Peter L. King – Zinata

Alan Nall - Zinata

2 #APICS2017

APICS 2017 Session Evaluation

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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 [email protected]

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

5 #APICS2017

are caused by processes

outside the plant floor

IT HAS OFTEN BEEN SAID THAT …..

75% of the problems on the plant floor

6 #APICS2017

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

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

= $$

8 #APICS2017

PRODUCT WHEEL CONCEPT

A

C

B

D

E

FG

H

I

JK

PRODUCTS (SPOKES)

CHANGE-OVERS

A regularly repeating

sequence of the production of

the various products

The overall cycle time is fixed

o The cycle time is optimized

based on business

priorities

The sequence is fixed

o The sequence is optimized

for minimum changeover

loss (time or material)

9 #APICS2017

PRODUCT WHEEL CONCEPT

51381

19852

30282

13045

55347

3268913775

57601

30173

45211

53181

19955

380913412

46077

4162855412 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 on 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 on a wheel

10 #APICS2017

ONE CYCLE,

ONE REVOLUTION

A

B

CD

E

F

G

H

BREATHINGROOM

PRODUCT A

PRODUCT F

CHANGEOVER

SPOKE,

. CAMPAIGN

CHANGEOVER

BATCHES

WHEEL TIMEPRODUCT WHEEL CONCEPT

11 #APICS2017

Product wheels can be applied to a single major piece

of 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

12 #APICS2017

Product wheels support a Pull replenishment system

Each spoke is designed based on average historical demand

or 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

13 #APICS2017

PRODUCT WHEEL

DESIGN

𝐸𝑂𝑄 = 2 ∗ 𝐶𝑂𝐶 ∗ 𝐷

𝑉 ∗ 𝑟 ∗ (1 − 𝐷𝑃𝑅

)

14 #APICS2017

PRODUCT WHEELS ARE BASED ON A

THOROUGH ANALYSIS OF …

Frequency

Lot Size

1 Car/Day

190 K #

Transp time 7 Days

SUPPLIER 1

SUPPLIER 2

SHEET CASTING

(3)

SLITTING

(3)

BONDING

(HEAT TREATING)

(3)

INSPECTION

(1)

WRAPPING

PACKAGING

LABELING 3 233

6

Order Lead Time

# SKUs

1 Week

4

Order Lead

Time

# SKUs

1 week

6

Invtry

Days

# SKUs

8.9 M #

50

2,000

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

CUSTOMERS,

DISTRIBUTORS

Quantity/time

TAKT

5.4 M #/Mo

7.5 K #/Hr

Lead time Exp 4 Days

Frequency

Lot Size

5 Trucks/Day

36 K#/Truck

Transp time 2 Days

Eff Capac 10.6

8.3TAKT

Utilization 78%

15 MinLead time

Yield 93%

85%Reliability

OEE 73%

50# SKUs

Batch size 1 roll

9 daysCYCLE

C/O time 1 hr

1 RollC/O loss

Avail time 168 hr/wk

3 x 8 x 7Shift schd

K #/Hour

Eff Capac 13.8

8.1TAKT

K #/Hour

Utilization 59%

18 MinLead time

Yield 98%

82%Reliability

OEE 74%

100# SKUs

Batch size 1 roll

13 daysCYCLE

C/O time 45 Min

~ 0C/O loss


3 x 8 x 7Shift schd

Eff Capac 8.25

7.5TAKT

K #/Hour

Utilization 91%

15 MinLead time

Yield 92%

72%Reliability

OEE 55%

1000# SKUs

Batch size 1 roll

7 daysCYCLE

C/O time 5 Min

~ 0C/O loss


3 x 8 x 7Shift schd

Eff Capac 18

7.5TAKT

Utilization 42%

6 minLead time

Yield 100%

100%Reliability

OEE 100%

1000# SKUs

Batch size 1 Slit Roll

N/ACYCLE

C/O time 0

0C/O loss


3 x 8 x 7Shift schd

K #/Hour

Eff Capac 36

7.5TAKT

Utilization 21%

8 MinLead time

Yield 100%

70%Reliability

OEE 70%

2000# SKUs


N/ACYCLE

C/O time 0

0C/O loss


3 x 8 x 7Shift schd

K #/Hour

Max Demo

Rate14.5

Max Demo

Rate18.6 Max Demo

Rate15

Max Demo

Rate18

Max Demo

Rate51

RAIL

CARS

Your process as an integrated system

15 #APICS2017

PRODUCT WHEELS ARE BASED ON A THOROUGH ANALYSIS OF …

ITEM FCST AVERAGE TABLET COLORBOTTLE

SIZEBOTTLE 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 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


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




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

16 #APICS2017

PRODUCT WHEEL DESIGN

Step 1 - Decide which assets would benefit

17 #APICS2017

SHEET FORMING VIRTUAL CELL GROUPING

Packaging

Roll Forming Machine 1

Roll Bonder 1

Chopper 1




Roll Bonder 2 Roll Bonder 3 Roll Bonder 4

Roll Slitting Machine 2


Chopper 2

Chopper3

Packaging

CELL 1CELL 2

CELL 3

CELL 4


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

36

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

8.3TAKT

Utilization 78%

15 MinLead time

Yield 93%

85%Reliability

OEE 73%

50# SKUs

Batch size 1 roll

9 daysCYCLE

C/O time 1 hr

1 RollC/O loss


3 x 8 x 7Shift schd

K #/Hour

Eff Capac 13.8

8.1TAKT

K #/Hour

Utilization 59%

18 MinLead time

Yield 98%

82%Reliability

OEE 74%

100# SKUs

Batch size 1 roll

13 daysCYCLE

C/O time 45 Min

~ 0C/O loss


3 x 8 x 7Shift schd

Eff Capac 8.25

7.5TAKT

K #/Hour

Utilization 91%

15 MinLead time

Yield 92%

72%Reliability

OEE 55%

1000# SKUs

Batch size 1 roll

7 daysCYCLE

C/O time 5 Min

~ 0C/O loss


3 x 8 x 7Shift schd

Eff Capac 18

7.5TAKT

Utilization 42%

6 minLead time

Yield 100%

100%Reliability

OEE 100%

1000# SKUs


N/ACYCLE

C/O time 0

0C/O loss


3 x 8 x 7Shift schd

K #/Hour

Max Demo

Rate14.5

Max Demo

Rate18.6 Max Demo

Rate15

Max Demo

Rate18

RAIL

CARS

19 #APICS2017

Step 2 - Analyze product demand variability

– consider MTO vs MTS


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

21 #APICS2017

AVERAGE DEMAND

22 #APICS2017

VARIATION IN DEMAND

23 #APICS2017

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

PR

OD

UC

T V

AR

IAB

ILIT

Y

24 #APICS2017


Step 5 - Calculate the most economic wheel time

25 #APICS2017

Step 5 - Calculate the most economic wheel batch size

𝐸𝑂𝑄 = 2 ∗ 𝐶𝑂𝐶 ∗ 𝐷

𝑉 ∗ 𝑟 ∗ (1 − 𝐷𝑃𝑅

)

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.


26 #APICS2017

0

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

CO

ST

ECONOMIC ORDER QUANTITY – EOQ - CONCEPT

ECONOMIC

ORDER

QUANTITY

27 #APICS2017

OTHER FACTORS ….

Shelf life, obsolescence

Demand variability

Minimum lot size

28 #APICS2017

7. Determine the optimum sequence


PRODUCTSHEET

WIDTH

BASIS

WEIGHT

POLYMER

TYPE423 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

PRODUCTPOLYMER

TYPE

SHEET

WIDTH

BASIS

WEIGHT489 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

29 #APICS2017


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

30 #APICS2017

NATURE’S BOUNTY

VITAMIN PACKAGING

31 #APICS2017

Leading manufacturer/packager of vitamin tablets,

capsules, and gelcaps

Revenue ~ $3B

Five major manufacturing plants

Four packaging operations

32 #APICS2017

One of four NBTY packaging operations

700 packaged products

Several packaging lines

As many as 14 parameters may change

on any changeover

Bottle diameter

Bottle height

Allergen content

Cap type

Tablet coating

Etc.

DEERFIELD BEACH PACKAGING

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

PACKAGING LINE

TELLS GATE

KEEPER TO

RETURN

COMPONENTS

950cc

Can overwrap

Cannot bundle

COMPONENT

INVENTORY

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

AVAILABLE

A PLANNER CAN ENLARGE AN

ORDER TO CONSUME A

COMPLETE BULK LOT

RED LINE

CAPSULE

WORKS

DEERFIELD BEACH

VALUE STREAM MAP

Ver 10, MAY 30, 2016

SOLGAR

(N.J.)

BOTTLE

SUPPLIERS

CAP

SUPPLIERS

BLACK LINE

WHITE LINEHAZELTON,

PA

D.C.

SPRKS, NV

D.C.

BOCA RATON,

FL

D.C. 1297

DEMANTRAASCP

APS

AS 400PLANNER

PROCUREMENT

PLANNING

BOTTLES, CAPS,

CORROUGATED

THE BRAND:

COMMERCIAL,

MARKETING

SHIPMENT HISTORY

MARKET INTELLIGENCE

CURRENT ORDERS

FORECASTS

PROMOS & DISPLAYS

DEMAND

CONSENSUS

FORECAST

INVENTORY TARGETS

CURRENT INVENTORIES

BOMs

CYCLE TIMES (WHEEL TIMES)

CYCLE TIME INTERVALS

LEAD TIMES FOR EVERY

ROUTING

PLANNED ORDERS

FOR NEXT

12 MONTHS

BULK ORDERS

FOR NEXT

12 MONTHS

ORDER PRINTED COMPONENTS

LABELS

IFCs

SPECIAL PACKAGING

TRAYS, COUPONS, ETC.

(LOGIC SOURCE)

CREATE

WORK ORDERS

AS 400 CHECKS BULK

AVAILABILITY AND LABELS

AND IFCs BEFORE

ALLOWING WORK ORDER TO

BE CREATED

SCHEDULER

BUYS

BOTTLES, CAPS,

CORROUGATED

LABEL ROOM

OPEN WORK

ORDERS

SCHEDULE

PINK LINE

ORANGE LINE

BOCA RATON

ORVILLE ROAD

CAMPUS

YELLOW LINE

2145

RONKAKOMA

GARDEN

GROVE

NBTY – CHINA

PLUS OUTSIDE

SUPPLIERS

IFCs

Heavily utilized, 92%

Gold Line is backup

Ordered by the

Advertising Team

SCHEDULER

REQUESTS BULK BE

MOVED FROM LOCAL

WAREHOUSE TO ON-

SITE STORAGE

BROWN LINE

GREEN LINE

GRAY LINE

LAVENDER

LINE

– 120cc

Fish Oils, 500 – 750cc

Can overwrap

– 150cc

Twin Packs

< 250cc

150cc &150cc-t

– 950cc

Can overwrap

400cc – 750cc

Can overwrap

150cc-t, 200cc, 300cc

Can overwrap

3 - 6 Months

< 1 Hour

1 - 8 Weeks 6 Hours 24 Hours1 - 2 Hours

YENNY TRIGGERS

THIS VIA A GTS

ASCP TRIGGERS BULK PRODUCTION

(From the Consensus Forecast, Current

Inventories, Planned Orders, etc.)

ASCP WORKBENCH

PLANNED ORDERS FOR NEXT

TWO WEEKS

REGENERATED WEEKLY

NEXT TWO WEEKS ORDERS

SHOULD INCLUDE PRODUCTION

NEEDED OVER COMPLETE

CYCLE INTERVAL DATA

VALIDATION

PROCESS

ERROR

LOG

PWT

SCHEDULER

OPEN WORK

ORDERS

NOTIFICATION THAT AS-400

HAS ACCEPTED THE

FIRMED ORDERS

FIRMED

ORDERS

REQUEST

BULK NEEDED

OVER NEXT 24

HRS

SCHEDULER

(YENNY)

STRETCH

WRAPPING

AREA

TRUCK LOADING

STAGING AREA

24 HOUR MAX

COPACKERS

& OTHER NBTY SITES

OFF-LINE

REWORK

BIG

OPPORTUNITY

(FROM ANY

PACKING LINE)

POMPANO

(OVERFLOW FOR 1111 OR 3PL)

INVENTORY ` 1 MONTH

SOME BULKS TO NY

PTRE-STAGING

(IN WAREHOUSE)

2 WORK ORDERS

~ 2.5 hr

STAGING

(AT BACK OF LINE)

3 WORK ORDERS

~ 4 hr

SHIPPER

SUPPLIER

PALLET

SUPPLIER

TRAY

SUPPLIER

LABELS

IFCs

SLEEVES

SUPPLIERS

# = 3

Inv = ~ 1 day

Lead Time = next day

# = 20

Inv = ~ 1 month

Lead Time = 6 weeks

# = 60+

Inv = ~ 3 – days

Lead Time = next day for some

6 weeks for Tray Shippers

(ordered by NY)

IFC # = 58

LABEL # = 600?

SLEEVE # = 12

Inv = ~ 3 months

Lead Time = 6 weeks

BOTTLE # = 54

Inv = ~ 1 - 3 days

Lead Time = 8 – hours

CAP # = 40

Inv = ~ 7 days

Lead Time = 8 – hours

QUALITY

DEPARTMENT

AS-400

BILL OF LADING

MATERIAL IS

RELEASED

GATE

KEEPER

SCHEDULE

TRANSACTIONS

COMPONENT

REPLENISHMENT

FOR REXALL WORK ORDER

PICK LIST

DC IS

IDENTIFIED

AS 400

PALLET BY PALLET

CLOSINGS

WORK ORDER

HAS BEEN

COMPLETED

(FROM ANY

DC)

DOCUMENTATION

ERRORS

10 Trucks / Week

2 Trucks / Week

10 Trucks / Week

60 - 80 Trucks / Week

INITIATE

MATERIAL

MOVEMENT

INTO PRE-

STAGING AND

INTO STAGING

LABELS &

SLEEVES

IFCs

GOAL IS TO STORE

GARDEN GROVE BULK

IN 1111 RATHER THAN

3PL TO REDUCE COST

COMPONENT

RETURN

AREA

UNUSED

COMPONENTS

M

E

Z

Z

A

N

I

N

E

BOTTLES

SEND MASTER

FOR LABELS

WORK

ORDER

WORK

ORDER

FIRM UP ORDERS

INITIATE BULK

TRANSFERS TO

FLORIDA

– 250cc

GTS

(General Transfer

System

transaction)

1111 + 3PL +

POMPANO

RACK

LOCATIONS

PRE-STAGING

AND STAGING TOTAL CYCLE TIME

FOR ONE BOTTLE

WAITING AT END OF LINE PLUS

LIFT TRUCK TRANSPORTATION

PACKAGING LINE TO STRETCH WRAPPER

STAGING AND TRUCK LOADING

WHY

PRE-STAGE?

REDUCE

3PL

STORAGE

INVENTORY

ACCURACY

NEED

STANDARD

SPECS

REDUCE

PSDs

MOVES

MIS-

TRACKED

LABELER

DATE CODES

MANUAL INPUT

CREATES

ERRORS

DEERFIELD VALUE STREAM MAP

34 #APICS2017

PRODUCT ALLOCATION CONCEPT

PACKING #1

BREATHING ROOMPACKAGING LINE 2


TIME

REPRESETATIVE OF 700 SKUs




35 #APICS2017

STEP 1- PRODUCT GROUPING & ALLOCATION TO SPECIFIC LINES

Data shown is for illustration only and is not actual

ITEMFORECAST

AVERAGEBOTTLE SIZE

BOTTLE

TYPE

BOTTLE

COLOR

CAP

TYPECAP SIZE CAP COLOR BUNDLE QTY ALLERGEN

TABLET

COLOR

DESS

ICANTSIZE 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

36 #APICS2017

REDUCTION IN BOTTLE COUNT PER LINE

0

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

37 #APICS2017

DETERMINING THE:

WHEEL CYCLE TIME

FREQUENCIES FOR LOW VOLUMES

OPTIMUM SEQUENCES

38 #APICS2017



BOTTLE

COLOR

HOURS PER

MONTH

HOURS

PER 2

WEEKS

HOURS

PER

WEEK



















LINE 4 - CYCLE 1


39 #APICS2017 Data shown is for illustration only and is not actual



BOTTLE

COLOR

HOURS PER

MONTH

HOURS

PER 2

WEEKS

HOURS

PER

WEEK




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


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


AR112 2232 N/A 400CC HDPE NONE LIME 1.1 0.6 0.3





LINE 4 - CYCLE 2

40 #APICS2017



BOTTLE

COLOR

HOURS PER

MONTH

HOURS

PER 2

WEEKS

HOURS

PER

WEEK





















BOTTLE

COLOR

HOURS PER

MONTH

HOURS

PER 2

WEEKS

HOURS

PER

WEEK




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



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


AF401 9823 N/A 500CC HDPE NONE EGGSHELL 11.8 5.9 3.0








CYCLE 2

CYCLE 1


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

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 [email protected]

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

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

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”

46 #APICS2017

PRODUCT WHEEL ACCELERATOR CONCEPT

PIT

TIME

PIT

TIME

PITTIME

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

3268913775

57601

30173

45211

53181

19955

380913412

46077

4162855412 19097 53124 53125 53129

51381

19852

30282

13045

55347

3268913775

57601

30173

45211

53181

19955

380913412

46077

4162855412 19097 53124 53125 53129

PWT – Excel Macro AcceleratorsWheel Based Schedule By Line

Open Orders - Extract

Current Prod Schedule - Extract

Production Schedule Prim.: L04-Black-CWheel

Item DescriptionSelected

Line Status WO#

D.A

.

Prod.

QTYIssue Date

Slat

#Forecast

Bott

le

Size

Bottle

TypeAllergen

Dusty

,

Sticky

BulkCap

Type

Bottle

ColorCap Color

Bulk

Type

Proposed

Line

Run

Rate

Anticipated

Run length

Anticipated start

dateOffset Cycle

Wheel

SeqIdeal Date

aa333 Product description aa333 N Running 1 0 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 0 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 0 35000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 9.26 01/12/2017 14:53 0 Cycle 142751 01/12/2017 13:54

hh111 Product Description hh111 N Ready 4 0 28000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 7.41 01/13/2017 00:09 0 Cycle 142751 01/12/2017 13:54



hh333 Product Description hh333 N Schedule 101 0 2709 06/01/2016 0 29201 100CCPET Free 52263 STD GREEN WMLTYELLOW SG L04-Black 107 0.67 01/13/2017 20:45 3 Cycle 142754 01/13/2017 15:12


dd765 Product Description dd765 N Schedule 103 0 96061 06/01/2016 0 123921 100CCPET Free 19934 STD GREEN WMLTYELLOW SG L04-Black 109 23.31 01/16/2017 00:17 8 Cycle 142759 01/16/2017 08:36



gg544 Product Description gg544 N Ready 7 0 24258 05/10/2016 0 64285 100CCPET 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 0 17788 06/03/2016 0 49077 100CCPET 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



gg655 Product Description gg655 N Ready 8 0 29980 95001 100CCPET 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




dd876 Product Description dd876 N Schedule 109 62 48070 05/27/2016 0 20266.66667 100CCPET 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 100CCPET 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 100CCPET Free 19934 STD AMBER YELLOW SG L04-Black 100 0.79 01/20/2017 10:01 19 Cycle 142770 01/19/2017 00:00



ff456 Product Description ff456 N Schedule 110 26 17333 05/27/2016 300 6273 100CCPET 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 100CCPET 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 0 9434.666667 100CCPET Free 16875 STD AMBER YELLOW T L04-Black 106 1.95 01/23/2017 05:44 25 Cycle 142776 01/19/2017 18:18


ff123 Product Description ff123 N Ready 16 77 36000 12325.66667 100CCPET 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 100CCPET 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 0 10016 06/03/2016 0 16874 100CCPET 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 0 43816 05/18/2016 0 24581 100CCPET 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 0 31392 24487 100CCPET Free 51815 STD GREEN WMLTYELLOW SG L04-Black 123 6.75 01/24/2017 12:39 35 Cycle 142786 01/20/2017 23:36



bb777 Product Description BB777 N Schedule 116 0 23600 05/27/2016 0 25241 100CCPET 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 0 7473 05/18/2016 0 36986 100CCPET Soy 19867 STD GREEN WMLTYELLOW SG L04-Black 122 1.62 01/25/2017 08:01 38 Cycle 142789 01/23/2017 07:42


cc234 Product Description cc234 N Schedule 117 0 75535 06/01/2016 0 30754 100CCPET 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 0 6000 34934.33333 100CCPET 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




aa222 Product Descr aa222 N Ready 27 0 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


hh222 Product Description hh222 N Ready 29 0 39060 05/18/2016 0 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


ff567 Product Description ff567 N Schedule 118 0 14409 05/26/2016 0 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



ff345 Product Description ff3454 N Schedule 121 0 18318 06/07/2016 0 15950.66667 100CCHDPE Free Dusty 1380 STD LIMEGRNGREEN T L04-Black 110 4.41 01/31/2017 14:05 48 Cycle 242799 01/25/2017 18:06


gg988 Product Description gg988 N Schedule 123 0 3232 06/01/2016 0 16121 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 0.71 01/31/2017 20:57 56 Cycle 242807 01/26/2017 18:18


gg877 Product description gg877 N Schedule 125 0 5000 06/03/2016 0 1534 100CCPET 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 100CCPET 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 100CCPET 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



bb333 Product Description BB333 N Schedule 127 0 11512 05/27/2016 0 9416 100CCPET 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 0 3666 05/27/2016 0 8627.666667 100CCPET 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 0 7011 05/19/2016 0 45574 100CCPET Free 19939 STD GREEN WMLTYELLOW SG L08-Pink 92 2.02 02/02/2017 03:08

Production Schedule Prim.: L04-Black-CWheel

Item DescriptionSelected

Line Status WO#

D.A

.

Prod.

QTYIssue Date

Slat

#Forecast

Bott

le

Size

Bottle

TypeAllergen

Dusty

,

Sticky

BulkCap

Type

Bottle

ColorCap Color

Bulk

Type

Proposed

Line

Run

Rate

Anticipated

Run length

Anticipated start

dateOffset Cycle

Wheel

SeqIdeal Date

aa333 Product description aa333 N Running 1 0 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 0 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 0 35000 128378 100CCPET Free 29618 STD GREEN WMLTYELLOW SG L04-Black 100 9.26 01/12/2017 14:53 0 Cycle 142751 01/12/2017 13:54









gg544 Product Description gg544 N Ready 7 0 24258 05/10/2016 0 64285 100CCPET Free 7892 STD GREEN WMLTYELLOW SG L04-Black 94 6.83 01/17/2017 12:34 9 Cycle 142760 01/16/2017 23:42








dd876 Product Description dd876 N Schedule 109 62 48070 05/27/2016 0 20266.66667 100CCPET 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 100CCPET Free 90 STD AMBER YELLOW C L04-Black 105 5.04 01/20/2017 04:59 15 Cycle 142766 01/18/2017 14:30




ff456 Product Description ff456 N Schedule 110 26 17333 05/27/2016 300 6273 100CCPET 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 100CCPET Free 52714 STD AMBER YELLOW T L04-Black 109 5.39 01/23/2017 00:21 24 Cycle 142775 01/19/2017 16:00



ff123 Product Description ff123 N Ready 16 77 36000 12325.66667 100CCPET 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 100CCPET 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 0 10016 06/03/2016 0 16874 100CCPET 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 0 43816 05/18/2016 0 24581 100CCPET Free 52385 STD GREEN WMLTYELLOW C L04-Black 120 9.66 01/24/2017 02:59 34 Cycle 142785 01/20/2017 20:54




bb777 Product Description BB777 N Schedule 116 0 23600 05/27/2016 0 25241 100CCPET Soy 2090 STD GREEN WMLTYELLOW SG L04-Black 120 5.20 01/25/2017 02:49 37 Cycle 142788 01/23/2017 04:54



cc234 Product Description cc234 N Schedule 117 0 75535 06/01/2016 0 30754 100CCPET Soy 15592 STD GREEN WMLTYELLOW SG L04-Black 120 16.65 01/25/2017 13:15 40 Cycle 142791 01/23/2017 15:36
















gg877 Product description gg877 N Schedule 125 0 5000 06/03/2016 0 1534 100CCPET 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 100CCPET 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




bb333 Product Description BB333 N Schedule 127 0 11512 05/27/2016 0 9416 100CCPET 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 0 3666 05/27/2016 0 8627.666667 100CCPET 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 0 7011 05/19/2016 0 45574 100CCPET 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


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




110 ff123 Release Product Description ff123 41176 Planned order 9/20/2016 9/29/2016



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




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







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



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 7 ff789 90 Product Description ff789 9 31392 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 15 gg433 50 Product Description gg433 14 7473 L04-Black




Ready 19 ee999 200 Product Description ee999 35 7011 L04-Black

Line Allocation Wheel Sequences

Scheduling by Line

Navigation

47 #APICS2017


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.)


48 #APICS2017

SCHEDULING PRIOR TO WHEELS

Individual order by order decisions

Live production system for line state and

order 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


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,

or 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

?

50 #APICS2017

PRODUCT WHEEL ACCELERATOR – Selected Functions


• 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.

51 #APICS2017

ACCELERATOR BENEFITS

"I schedule every week using the wheels and tool - hundreds of

orders 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

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

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


It also provides a tool for better long range planning

Quantification of when difficult products will be run

Quantification of future component needs

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


A dramatic reduction in the time planners and schedulers

spend on routine scheduling more time for true crises

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:

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

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

58 #APICS2017

Compromise is often required

But ….. No matter what compromises

are required

You will almost always end up better

off

OBSERVATIONS

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

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

61 #APICS2017

OTHER PRODUCT WHEEL USERS

BG Products

Appvion

Dow Chemical

DuPont

62 #APICS2017

A ROSE BY ANY OTHER NAME …..

Exxon Mobil

“FSVV”

(Fixed sequence variable volume)

Pharmaceutical companies

“Rhythm wheels”

63 #APICS2017

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

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

65 #APICS2017

WE WROTE THE BOOK ON WHEELS ……

Productivity Press

May 2009

Productivity Press April 2013

http://click.email.taylorandfrancis.com/?ju=febc1d7370650d75&ls=fe251570716d027b7d1371&m=fe9313707560007a73&l=ff6a177174&s=fe551679736402757113&jb=ffce15&t=

http://click.email.taylorandfrancis.com/?ju=febc1d7370650d75&ls=fe251570716d027b7d1371&m=fe9313707560007a73&l=ff6a177174&s=fe551679736402757113&jb=ffce15&t=

66 #APICS2017

QUESTIONS?

67 #APICS2017

APICS 2017 Session Evaluation

Visit www.apics.org/Mondayor

download the APICS2017 app

68 #APICS2017

THANK YOU

wheel of fortune€¦ · r & d –9 years project management –15 years lean manufacturing...

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