Sep 10, 2020

Decintell Falco Total Preventive Maintenance (TPM) Module

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Decintell Falco Total Preventive Maintenance (TPM) Module 

Decintell Falco Knowledge Platform is a complete enterprise suite consisting an array of modules to cover enterprise wide transactions and workflows. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity. Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre

The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customized workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform).  

For the scope of this blog we will discuss TPM module in detail. TPM stands for Total Preventive Maintenance. Frequently TPM is also as defined as "Total Productive Maintenance" or "Total Predictive Maintenance".  

 

Even at the cost of a little digression, I would like to discuss various definitions. Properly maintained machines and equipment does have high productivity, higher uptimes, higher quality reliability and of course longer machine working life. And collectively calling all these as "Productive"  may be the intent behind using the term "Total Productive Maintenance".

 

Let us look at another definition of TPM. Total Predictive Maintenance. Can we really have "predictive" maintenance.  For anything to be "predictive" one assumes that all potential failures of a machine, can be predicted. Yes, in theory it can be. But practically it is extremely difficult to achieve that, if not impossible. All the predictions are possible only thru past data. For any predictive pattern to be established, large amount historical data  is needed and that too, accurately recorded. If an organisation starts building record for every machine thru regular preventive maintenance, breakdowns, spares changes, over years, then that can certainly be used by an artificial intelligence algorithm to come up with certain predictions. But therefore, calling it Predictive is going a bit overboard. I would suggest, not to get influenced with terms like Artificial Intelligence or Block Chain etc.  As technologies, they may be advanced and effective, but the question is more about their actual utility in absence of consistent and large amount of data. 

 

I am, therefore, personally more aligned with "Total Preventive Maintenance" as a definition of TPM. Total Prevention is a feasible target for an organisation. The intent of TPM is to ensure equipment health, so the breakdowns are minimized. And as a consequence, capacity calculations get more reliable. TPM has to be part of culture and has to be sustained constantly. TPM is not a one-time project, an activity for the month, or some yearly program. It is a culture. Many a times TPM initiatives fade out over a period because of lack of consistent monitoring. 

 

Decintell Falco Knowledge Platform hosts a powerful TPM module. 

  

TPM module enables the maintenance team 

  1. Draw maintenance schedule for every equipment for the entire year
  2. Assign teams for the schedule
  3. Keep team attendance and holiday calendar especially because they will have staggered weekly off schedule and will be entirely different from the rest of the personnel. 
  4. Centrally prepare checklists for every equipment along with part replacement plan
  5. Plan spare parts
  6. End to end breakdown ticket handling
  7. Realtime feedback loop with Falco Capacity and Production Control (CPC)
  8. Analytics









Other relevant topics. decintellfalco.blogspot.com


Shantanu Joshi
Co-Founder
Decintell Tech Pvt. Ltd.

 

www.decintell.com

Sep 9, 2020

Decintell Falco My KRA Dashboards

Decintell Falco My KRA Dashboards 

Decintell Falco Knowledge Platform is a complete enterprise suite consisting an array of modules to cover enterprise wide transactions and workflows. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity. Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre)


The standard modules are My KRA (Business Intelligence Dashboards), DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customised workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform). 

For the scope of this blog we will discuss My KRA module in detail. Many mid size organisations today, have some ERP system or the other. ERP system is one of the most essential components of digitisation. ERP ensures basic hygiene in "Customer Order to Payment"  flow, as well as "Purchase Order to Vendor Payment" flow. ERP also brings good controls over material planning and inventory. 

Any ERP does have basic reports such as Inventory, P&L, Creditors, Debtors, Trial Balance etc. Beyond these basic reports, ERPs do not generate many other critical reports. ERP reports are not easily accessible by all. The report formats are very technical and complicated. Which makes them hard to decipher. ERPs do not have budgets and there is no comparative analysis of performance against budgets.

Any decision making process essentially involves processed, analysed, accurate and realtime data. 

My KRA gets connected to ERP system thru smart ETL and fetches relevant data to Falco Cloud Platform. The data is analysed and presented realtime on intuitive dashboards, giving instant visibility of enterprise wide performance to the decision makersThese reports cover performance measurement against budgets for all Key Performance Indices (KPIs) such as Finance, Sales, Supply Chain, Quality and Engineering. 

My KRA dashboards present easy to understand comprehensive reports. All these reports are tailor-made and preconfigured specific to each organisation. There is no need to invest in IT expertise to configure reports, they come pre-made. Data confidentiality and integrity is maintained, by controlling access thru role management. 

My KRA brings all important reports just click away. No more waiting time for someone in the organisation to download data from ERP, work on it for days and then convert them into excel reports or powerpoint charts. By the time required report is presented, precious  time is already lost. Besides manual intervention gives scope for errors and often the data is disputed by all stakeholders, making the reports irrelevant. Thus the entire management time invested in creating these reports is completely wasted. Delayed data can create decision paralysis.

My KRA extends ERP 

(some examples of dashboards)

KRA Sales  > KPI Revenue


KRA Finance > KPI P&L

                   


KRA Finance > KPI Cashflow



KRA Finance > KPI Inventory 



KRA PMS Score > KPI CEO Score (Measurement of Organisation Score against Budgets) 



"Budgets and Masters (B&M)" is a sub-module of My KRA. B&M stores multiple revisions of Sales and Finance budgets, for current year and next year. My KRA always refers to the latest revision. My KRA dashboards compares the actual performance against budgets.   The next year budgets are automatically switched as current year budgets  at the start of a new Financial Year. (Admin Centre allows setting financial year and automatically switches to next FY on a user defined date.). Decintell Falco Admin Centre


B&M comes with a unique feature - CEO Control Panel.  The Control Panel allows CEO to set the tone for Balanced Score Card.  CEO can specify Min / Max limits for every KPI. Performance is graded  , based on the limits set by the CEO. 


Decintell Falco My KRA and BI Platforms

There are a number of BI platforms available off the shelf. Most of them are self service platforms. But this is precisely the problem. How many mid-size organisations have in-house IT resources as well as ability to invest substantial managerial bandwidth to adopt these platforms. No doubt these platforms are very powerful in data visualisation and have thousands of visualisation types. However, more often than not the user organisations are hardly in position to decide which of these thousands of visualisations will suite their needs. At least within manufacturing vertical not more than 10 to 15 visualisation types suffice to cover all important KPIs. What then is the use of these thousands of graphical presentations and self service features, to an industry which can hardly put it to use. Many of these platforms have complicated licensing policies and at times costly too. Most of the BI platforms publish the reports configured and users can access it using URL. These URLs lack security features in basic subscription versions. Easy to get unauthorised access. For any user level security features, the license fees sky rocket disproportionately. Ultimate objective is to consume relevant data and arrive at decisions and not get bogged down by the tedious adoption exercise. Whereas My KRA dashboards are pre-configured. Leveraging our domain expertise in manufacturing, we understand user needs and then design dashboards to suite them. 

Decintell Falco Knowledge Platform addresses specifically these gaps. Using deep domain knowledge, we map your existing flows outside of existing ERP, reengineer them and then digitise. These workflows form independent modules which are integrated to Falco platform to create seamless digitised enterprise.  With Falco Knowledge Platform we seek to provide enterprise solution for the entire white space left out in ERP. Become single sign on solution platform. 


My KRA module can be implemented within 4 to 6 weeks** 





** depending on the data readiness 

Once My KRA module is implemented other modules for critical workflow digitisation, can be implemented. These workflows mainly represent white spaces not covered by an ERP system, viz. Engineering Change Management (ECM), Constraint Based Capacity Planning (CPC), Total Preventive Maintenance (TPM), Customer Experience Management (CEM), Spares-Warranty-AMC-Service (SWAS).

Other relevant topics click decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder
Decintell Tech Pvt. Ltd.

 

www.decintell.com 

Decintell Falco Admin Centre

 



Decintell Falco Admin Centre

Decintell Falco Knowledge Platform is a complete enterprise suite consisting an array of modules to cover enterprise wide transactions and workflows. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity. Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre)



The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customised workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform).  

For the scope of this blog we will discuss Admin Centre. Admin Centre effectively controls every aspect of user interaction with Decintell Falco Knowledge Platform.

Role Management - The admin can create roles to suite your internal requirements and grant access to various modules.  Access can also be controlled down to specific event within a module. Event such as Edit/Submit/Approve/Reject etc. can be assigned to specific roles. This will ensure integrity of data and workflow.

User Management - The admin can create new users and assign a specific role to a user. This enables a user thru the access rights assigned only to that specific role.  Every new user goes thru approval process. User gets alert to sign-in, only post approval. Upon first sign-in user is required to change password for security reasons. User can start access based on the rights assigned to the role.

Alert Management - The admin can configure event specific alerts for every module. Alerts can be configured for specific users, the message body of an alert also can be configured. Alerts are sent via email.

Schedule Maintenance - The admin can schedule maintenance or updates and testing for Decintell Falco Knowledge Platform. While the updates are being configured, users will continue to get message on sign-in page and tentative time when it will resume.
  
Settings - The admin can set the start of financial year, holiday calendar, date format, currency settings as well as  set number of days required to switch financial month after every month end.   Every organisation may follow a different financial year calendar and the same can be easily configured. Decintell Falco Knowledge Platform is configured to handle month end and year end automatically.

Financial Period Switchover Decintell Falco Knowledge Platform is configured to handle month end and year end automatically. At the end of every financial month, transaction posting of trial balances, cash flow, inventory, revenue etc. automatically switches over to next financial month. Whenever financial year ends all the financial and revenue budgets as well as actual postings are transferred to pervious years and next year budgets are transferred as current year to resume actual transaction posting. (for more about Budgets and Masters click Decintell Falco My KRA Dashboards )  


Other relevant topics. decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder

Decintell Tech Pvt. Ltd.

         

www.decintell.com




Digitise with Decintell Falco Knowledge Platform

      

Digitise with Decintell Falco Knowledge Platform

What is digitisation? Some may call it Industry 4.0 or Dark Factory which is sometimes referred to as Industry 5.0.  Interesting terms, but are not within the scope of this post.

In a very simplified definition digitisation as it is referred to, is automating workflows which are operated manually.  The whole idea of digitisation is to bring consistency, transparency and therefore accountability. Digitisation helps bring a culture change

©Decintell Tech Pvt. Ltd.

Digitisation helps creation of a central knowledge repository KRè. Every organisation builds thousands of man-years' worth knowledge base, which remains fragmented and proprietary to individual contributor. This entire knowledge base needs to be collated, sanitised and centralised so that it can be drawn upon by the entire organisation. Once centralised this valuable knowledge base, KRè, can be further strengthened.      

©Decintell Tech Pvt. Ltd.

Decintell Falco Knowledge Platform is a complete enterprise suite hosting an array of modules to cover enterprise wide transactions and workflows. There are multiple sources of transaction data getting generated within an organisation. They are primarily ERP,  White Space workflows not covered in ERP, and equipment performance data. Decintell Falco Knowledge Platform combines the data from all these sources and consolidates into single database on cloud. This data is analysed, processed and presented on intuitive dashboards using latest data visualisation tools. The dashboards give quick and accurate overview of organisation level performance. Decision making becomes more accurate and timely, substantiated by data.   

Decintell Falco Knowledge Platform  connects to your ERP systems, connects with your equipment on IoT and at the same time hosts an array of customised workflows. Falco architecture is completely based on Azure ecosystem.


 

Decintell Falco Knowledge Platform is a combination of various modules. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity.  Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre)


The standard modules are

My KRA - These are business intelligence dashboards. Falco has a powerful ETL to connect with your ERP or any other transactional data source. Transfer the data to a centralised cloud database. Data analytics and visualisation tools process the data and display them on user friendly intuitive dashboards to cover all Key Performance Indices (KPIs) viz. Sales, Finance, Supply Chain, Engineering and Quality. These dashboards do away with the need to invest high cost managerial time to prepare management reports. Dashboards are real time and accurate. They free up management bandwidth enabling decision making and execution. 

   

Budgets and Masters - B&M module allows you to upload Sales and Financial budgets against which My KRA performance will be measured.  All critical masters required for My KRA can be uploaded thru this.  B&M also has a unique feature, "CEO Control Panel". With the control panel CEO can set Measurement parameters for every KPI.  (more about My KRA and B&M click Decintell Falco My KRA Dashboards



DOIT - DOIT stands for Data Over Internet Transfer.  DOIT module is designed to collect equipment data on cloud analyse the same and present it on Field Performance dashboards. (for more about DOIT click Decintell Falco DOIT Module)

WAC - WAC stands for Weighment Accuracy Calibration.  WAC app is a multipurpose application. WAC can be used to calibrate packaging machine for “weighment accuracy” to ensure that packed product weight is accurate. In case you are packing some products manually due to lower volumes, WAC can be extremely useful to track the manual packing. (for more about WAC click Decintell Falco WAC Module)


The  quickest way to be on board Decintell Falco Knowledge Platform, is to implement standard module suite of Admin CentreMy KRA, Budgets and Masters, DOIT and WAC . This implementation will take anywhere between 4 to 6 weeks depending on the business data accessibility.  


Once on board we can work to digitise more critical workflows. Decintell has deep domain knowledge in manufacturing vertical. That helps us map your existing Workflows which are generally not covered by ERP. We map existing workflows, reengineer them to make them more efficient and optimised. Then we digitise them. These digitised workflows are then hooked to Decintell Falco Knowledge Platform. 

Using our domain expertise, we also collate and organise entire product knowledge and critical process knowledge within your organisation. Label and store the same in libraries to create the Knowledge Repository KRè. This repository can be then drawn upon. 

The workflows that are generally left outside of ERP and being done manually, are 

  • ECM: Engineering Change Management including Part Number Generation
  • CPC: Constrained based Capacity Planning and Loading
  • SWAS: Spares Management, Warranty Management, AMC management, Service calls
  • CEM: Customer Experience Management (CRM + Proposal Generation)
  • TPM: Total Preventive Maintenance  
  • PCM: Part Costing Management. this is most time consuming, recurring and complicated.
  • NPD: New Product Development- efficient management of NPD budgets and timeline.

We will collaborate with your team to digitise these flows and bring them on single sign-on Falco platform. Decintell Falco Knowledge Platform is complimentary to existing ERP and it extends the ERP benefits.

Other relevant topics click decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder

Decintell Tech Pvt. Ltd.

         

www.decintell.com

Business Transformation - Sustaining with Digitisation



Business Transformation - Sustaining with Digitisation. 

Change is "constant" accelerating. Requiring Business Transformation or Turnaround.  It can also be defined as recalibrating the value proposition of business in line with changing ecology. There is a slight difference though, between Turnaround and Recalibration. While "Turnaround" means responding to the change, be it external or internal,  "Recalibration" is about anticipating the change and acting proactively. 

Any such need to recalibrate, is largely driven by a combination of factors. Internal factors can be; ignoring customer voice, severe working capital stress, either excess or under capacity, unserviceable loans, product quality, deterioration in industrial relations. Internal factors such as those listed earlier, cause more harm than external factors like competition, changing customer preferences, business cycle, tightening interest rates, liquidity in money markets, other structural factors, statutory or policy changes. 

External factors affect the entire industry and not just one or two businesses in isolation. Even while entire industry gets affected because of sweeping changes in external environment, there are still a few nimble ones who make it thru and emerge even stronger. Businesses with weak balance sheets are normally worse off. 

The internal factors that I mentioned above are merely the symptoms but the root causes are buried deep down.  Let us consider some of the most important internal factors.


Ignoring Customer Voice
This is one of the most critical causes of why a turnaround or recalibration is needed. Losing relevance to the customer is the fastest way to go downhill. Being complacent and refusing to innovate product or processes is a sure recipe of trouble. Partnering with customer is the only way to stay relevant to the customers. Partnering also means being truthful and upfront. Customers in the long run appreciate and value true partnership.  

Working Capital Stress
Major contributing factor for working capital stress is, cash blocked in unusually high inventory. Uncontrolled demand variation, inaccurate Bills of Material, wrong SKU codes, wrong lead times for procured parts, uncontrolled demand variation causing incoming pipeline breakdown, collapse of basic ERP system, production planning being done manually using excel spreadsheets; are the causes of excess inventory with high obsolescence. Low or delayed recovery of receivables also causes working capital stress. Continuous monitoring of inventory turns and benchmarking to industry data, is the best way to keep this under check.  

But there is a very silent and therefore serious factor. And that is "eroding margins".  If input costs are spiralling and customers keep pushing for price reductions, it will create a creep load on working capital. This stress builds up silently in the system. And working capital requirements grow disproportionate to revenue growth. If business is seeing revenue growth then it is even more risky, as this stress remains hidden till a breaking point. Monitoring of EBITDA margins and material costs as % of revenue (being more than 70% of total costs) will  create a timely alert.   

Over or Under Capacity
Both over or under capacity is highly risky. Definition of capacity includes installed capacity and manned capacity. In loose terms installed capacity is the capacity of machines installed. And installed capacity can be productive only when it is adequately manned. Beyond these loose terms however, capacity is a very dynamic phenomenon, because of multitude of variables. The product mix, demand variations, equipment uptime, material availability, quality yield, absenteeism. 

Installed capacity is a sunk cost. It can not be reduced. And addition to installed capacity has substantial lead time. However manned capacity can be adjusted to cyclical variations in demand, with much lesser lead time. While reduction in manned capacity can be achieved in relatively shorter lead time by reducing contract manpower, adding manpower can be a lengthy process due to learning curve of newly added headcount. And till the new hires achieve certain degree of expertise, they tend to imbalance entire line. Based on the product mix changes month over month, bottlenecks also keep moving. Capacity is a vast subject and I will dwell on it in a separate blog. However the point is, not knowing the existing capacity or when and how to reduce or increase the capacity, can be detrimental to survival.   

Recalibration

As discussed above, several of these internal factors affect business health and require transformation or recalibration. Any business transformation involves five key initiatives, namely  “listen to customer”, have a  “winning strategy”, implement the strategy using  “balanced score card”,  to eliminate waste “reengineer” critical workflow and strengthen “corporate governance”.  


But only that is not enough. Because all these initiatives have to be consistently sustained over long term. Need to ensure adherence to all reengineered processes and constant monitoring of balanced score card. Otherwise such initiatives have a tendency to fade off over a period of time. I also realised, from my past experience, that ERP Systems, especially for manufacturing workflows, have GAPs and do not cover several critical workflows, or if they do, implementation of these add-on modules is costly and tedious.  

 

We firmly believe sustainability is achieved thru digitisation. Digitization helps brings transparency, adherence and hence accountability. Another main purpose of digitisation is also to build a knowledge repository – a central knowledge gateway to freely draw upon by the organisation, rather than knowledge becoming proprietary to an individual.  Decintell Falco Knowledge Platform is a "single sign-on" seamless cloud platform, which hosts Knowledge Repository (KRè), KPI Measurement Dashboards, Digitised Workflows. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform) 


Other relevant topics decintellfalco.blogspot.com



Shantanu Joshi
Co-Founder
Decintell Tech Pvt. Ltd.

 

www.decintell.com 

Sep 7, 2020

Decintell Falco Constraint based Capacity Planning & Control (CPC)



                    

Decintell Falco Constraint based Capacity Planning & Control (CPC)

Decintell Falco Knowledge Platform is a complete enterprise suite consisting an array of modules to cover enterprise wide transactions and workflows. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity. Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre)



The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customised workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), 
TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform). 

For the scope of this blog we will discuss CPC module in detail. CPC is a customized module to plan capacity loading, levelling the production load and tracking actual production against plan. It is designed to suite specific needs of an organisation. Many ERP systems normally assume infinite capacity model and therefore there is no visibility of available capacity.  

Both, over and under capacity is highly risky. Definition of capacity includes installed capacity and manned capacity. In loose terms Installed capacity is the capacity of machines installed. And installed capacity can be productive only when it is adequately manned. Beyond these loose terms however, capacity is a very dynamic phenomenon, because of multitude of variables. The product mix, demand variations, equipment uptime, material availability, quality yield, absenteeism, to name a few. 

Installed capacity is a sunk cost. It cannot be reduced. And addition to installed capacity has substantial cost and lead time. However manned capacity can be adjusted to cyclical variations in demand, with much lesser lead time. Even adding manpower can be a lengthy process due to learning curve of newly added headcount. And till the new hires achieve a certain degree of expertise, they tend to imbalance entire line.  

 

Bottleneck neither is a fixed point, nor it is static. Bottleneck in a value stream is a completely dynamic phenomenon. For a given installed capacity, bottleneck keeps shifting due to multiple variables such as demand variation, product mix variation, manpower, equipment breakdown, input material quality. There are two types of bottlenecks. Short term and long term. Short term bottlenecks tend to be impacted more by near term reasons like, product mix variations, sudden demand fluctuations, equipment breakdowns, material shortages, poor quality of inputs. However, long term bottlenecks are governed by installed capacity, line balancing, pacemaker operation, process routing, product cycle time and two to five-year demand cycle.      

 

Knowing the existing capacity or when and how to reduce or increase the capacity, is very critical to survival. It is like knowing where your off stump is. Capacity management is therefore a very complex subject, may be too complex to be handled manually. It is therefore highly desirable to digitise Capacity Planning. 

 

Neither can one depend on standardised capacity planning, that is generally available as basic module in ERP systems. This workflow is a typical example of requiring a customised flow and therefore it is essential that this handled by domain experts.  

 

At Decintell, we have deep domain knowledge to comprehend complexities of capacity planning and production tracking. 



CPC brings instant visibility to existing as well as future capacity, based on the demand. If one were to load 12 months demand for viewing impact, CPC will show the stress areas and bottlenecks, both short and long term. 

 

CPC considers all variables creating constraints on capacity, such as machine availability, manpower availability, material downtime, number of workdays, process routing, process cycle time.

 

Monthly demand, finished good stock and backlog is considered to arrive at net production load for the month. Net demand is uploaded to CPC Capacity module. Capacity module considers all near term constraints as explained above to arrive at loading. The capacity loading will show the under loading or overloading of various operations across all value streams. CPC Capacity module allows multiple iterations to arrive at best possible level loading of capacity to achieve max possible order fulfilment. Once the capacity loading is confirmed, CPC generates production tickets. Actual production can be filled against each operation. While production is in progress, Production Tickets allow change of route if there is any down time due to "man", "machine" or "material". Once the requisite production quantity is achieved production ticket can be closed. Production Tickets can be also short closed allowing back log to be transferred to next ticket or next production cycle. 

 

CPC allows two methods of demand loading. "Regenerative" demand loading. New demand for monthly cycle is uploaded. Finished Goods stock is allocated against demand. This feature closes all open tickets. Transfers backlog to new demand.

 

New production tickets are generated. "Regenerative" run is normally taken once a month. The second method is "Net Change". Net Change method is used to accommodate small number of orders received during the month. Then instead running "Regenerative" cycle, it is better to run "Net Change". This method creates only net additional demand and generates additional tickets or adds to existing ticket, if same SKU ticket is already live. Existing production tickets are not affected.  

 

CPC is a fully functional module of Decintell Falco. However, we appreciate that each organisation has its own specific needs and constraints. Leveraging our domain knowledge, we work closely with your team to map existing flow. Reengineer the same to remove non-value add activities. Optimise the flow to suite organisation specific requirements. 

 

Decintell Falco Knowledge Platform helps your organisation to be a data driven, digitised enterprise.


Other relevant topics. decintellfalco.blogspot.com



Shantanu Joshi
Co-Founder
Decintell Tech Pvt. Ltd.

 

www.decintell.com