Kevin A. BrownSenior Business Analyst2006 NorCal OAUG Training Daykbrown@symmetricom.com

A Journey from Unconstrained to Constrained:Implementing Manufacturing Scheduling and ASCP

At a Glance Global leader providing mission critical time and

frequency solutions

Headquartered in San Jose, CA.

Offices throughout the US, as well as the United Kingdom, Germany and Malaysia

Manufacturing in SF Bay Area, Massachusetts and Puerto Rico

FY05 revenue $181M

~800 employees

Markets We Serve

Government Communications

Space, Defense and Avionics

Enterprise and IT Networks

WirelineNetworks

Wireless Networks

A Sampling of Customers

Telecom

Government

Enterprise

Oracle Environment

Hosted by Oracle On Demand

E-Business Suite 11.5.10 CU1

Dell Servers running Red Hat Linux

Live since June 2001

Oracle Modules Financials

• AR• AP• GL• Projects• FA• Time&Labor• iExpense

Procurement• PO• iSupplier• iProcurement

Manufacturing• INV• WIP (Discrete)• ENG• BOM• MRP

Order Mgmt/CRM• OM• TeleService• Contracts

Miscellaneous• HR• ICM

Project Madison

Overall Project Goal• Project Madison will implement three distinct yet

interdependent modules of Oracle: Manufacturing Scheduling, Advanced Supply Chain Planning and Global Order Promising

Primary Project Goal• Provide accurate Ship Dates to our customers

quickly

Project Madison

Initial Rollout in our Aguadilla, PR facility• Includes about 80% of production

Focus on ASCP and Manufacturing Scheduling First• Fine tune GOP once ASCP and MS are stable

Use Internal Resources Primarily• Gain a deep understanding of products and

processes• Less Expensive• Longer Project Timeline

Selling It

Problem Mfg Scheduling ASCPSupply/Demand across organizations not visible in one screen (see total supply/demand for all orgs) XNo short-term resource capacity planning X XNo long-term resource capacity planning XMust open multiple MPS or MRP workbenches to release orders for multiple orgs X

Operations Challenges

Project Challenges

Dirty Data• PO & WO Dates not Maintained• Sales Order Ship Dates not Maintained• Short Orders Left Open (PO and WO)• Inaccurate Lead Times• Scrap not Scrapped

Systems and Application Issues Team Resources Change Management

Keys to Capacity Planning

Accurate Routings

Accurate Capacity for Machines and People

Routing Update

Existing Routings Primarily Supported Costing• Only contained Human Resources• Used “Transit” resource to simulate extended

machine time• Resources and Departments used legacy

nomenclature

Sample Routing Here

Routing Update

Rules of Engagement• Don’t Change Standard Costs• Don’t Interrupt WIP

Complex Process Steps to Model• Test Operations• Operator Attended and Autonomous Processes• Shared Resources• Batchable Resources• Variable Process Times

Routing Update

Example:

Test Fixture Example Here

Routing Update

>1000 Routings to Update• Map Old Depts and Resources to New Depts and

Resources• Insert Appropriate Machine Resources• Evaluate Scheduling Sequence for Depts with

People and Machines

Prioritization• Items Averaging > 1 Job per Month• Items with Planned Orders

Routing Update

Keeping Things Simple• All Updates Made on Spreadsheets

Item Seq Op. Desc.Dept Resource BasisUsage Inverse 24 HrsDisableSch SeqAssigned UnitsSched Std Rate46162 50 STAGE KITT050 T050 ITEM0.0001 10000 NO Y 0.04 YES YES46162 50 STAGE KITT_STAGE/ KT STORE ITEM0.0001 10000 NO 0.04 YES YES46162 150 SMT T160 T160 ITEM0.0583 17.15 NO Y 0.04 YES YES46162 150 SMT T_SMT MACH OP 2 ITEM0.0583 17.15 NO 10 0.04 YES YES46162 150 SMT T_SMT SMT 0.0583 1046162 300 2ND OP T350 T350 ITEM0.0666 15.02 NO Y 0.04 YES YES46162 300 2ND OP T_2ND OP ASSY 2 ITEM0.0666 15.02 NO 0.04 YES YES46162 999 QA T850 T850 ITEM0.0166 60.24 NO Y 0.04 YES YES46162 999 QA T_QA QA ITEM0.0166 60.24 NO 0.04 YES YES

Routing Update

More Simplicity• Use Standard Interface Tables and Processes• Insert Statements Created Using MS Word Mail

Merge Functionality -- to add new resourcesinsert into bom_op_resources_interface(RESOURCE_SEQ_NUM,ASSIGNED_UNITS,USAGE_RATE_OR_AMOUNT,SCHEDULE_FLAG,OPERATION_SEQ_NUM,ORGANIZATION_CODE,ASSEMBLY_ITEM_NUMBER,RESOURCE_CODE,SCHEDULE_SEQ_NUM,basis_type,EFFECTIVITY_DATE,PROCESS_FLAG,TRANSACTION_TYPE)values(10,1,0.001,1 -- need 1 or 2, 50,‘PRT',‘TT-T654/RB/GPS','STORE',NULL, 1 -- basis_type,to_date('07-SEP-2005','DD-MON-YYYY')+1/24/60,1 -- process_flag,'CREATE');

Production Cutover

Challenges• Lots of Work in Process• Reporting• Scheduling Process During Transition

The Plan• Leave WIP Alone (for now)• Ensure All New Jobs have Updates Routings• Tweak Capacity to Create ‘WIP Resistance’• After X Weeks Update any Open Jobs with Old

Routings

Open Issues

Production Control Reorg??• Currently Personnel Segregated by Product Family

Maintaining Capacity

Fine Tuning• Mfg Sched Time Fence vs. ASCP Time Fence• Use of Penalties• Capacity/Usage/Assigned Units

Lessons Learned

Separate Project for Routing Update

Allow Time for WIP to Fill with Updated Routings

Emphasize Clean and Well Maintained Data

Expect and Allow Changes to Standard Costs

What We Did Right

Used Mostly Internal Resources

Completely Revamped Routings

Started in Largest Plant

Questions?