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Principal feature list of PlanWizard
Advanced logics
Maximum assignment of workforce Workforce allocation plan
(Individual resource management)
Minimization of workforce
Time-dependent allocation of manufacturing operators Time-dependent allocation of changeover operators TOC auto-analyzing feature
Dyanamic dispatching feature Dynamic selection of process routings
Manufacturing management modules
Production plan/ Products stock control feature Intermediates stock control feature Raw materials stock constraints feature
MRP and Resource planning feature Actual manufacturing results feature Stock control (stock-in,shipping, issue, stocktaking)
Reply to inquiries on delivery dates feature Lot trace feature Area attributes setup feature
Logics unique to production plan and scheduling
Changeovers types: both setup and cleanup Changeover type & Pre/Post arrangement Changeover for specification change
Changeovers after long intervals Regular changeovers Limit to the number of changeovers
The longest idle time between C/O and MFG Maximum downtime during changeover Controlling connections between changeover and production at different steps
Pre/Post arrangement feature Multiple job assignment to limited operators One-by-one transfer feature
One-by-one transfer and lot grouping Delayed start of succeeding lots Lot start time setting feature
Concurrent production Co-products feature Process steps avoiding concurrent manufacturing feature
Restriction of the number of products feature Maximum downtime during manufacturing Machine assignment options at each step
Change of manufacturing quantity along with stretched bars JIT connection between process steps(Special assignment) Substitute process routings selection feature
Bi-directional scheduling feature Assignment to facilities according to loading limits Assignment control of machines by numeric specification
Overlap assignment to a single machine Restriction of concurrent use of machine groups Consistent line assignment feature
Assignment with weight factors Multiple machines assignment function Locking of assigned machines
Multi-purpose tank control Intermediate warehouse capacity constraint feature Resources proportionate to production quantity
Resource retention between process steps Resource retention through semi-product and final product Raw material substitution
Disallowing preservation of raw materials feature Rolled materials concurrent use forbidden feature Disallowing mixed usage of raw material lots
Variable machine capacity with time-course Production rate change to each step Productivity depending on operators skills
Lot number customization Data linkage feature A single product manufacturing feature
Order grouping feature Locking/Unlocking feature
Other logics
Forms creator Form customization and conversion into HTML feature Work order sheets customization feature
Direct output of table information to Excel feature Tracking connection of steps in the master and listing feature Setting unit measures to each step feature
Linkage with external data base External interface customization Conversion coefficient between PW and external systems
EntrySheet feature Navigation of masters registration feature Graphical editing tools
Macro function COM function Simulation feature
Equipment/Resource grouping feature Direct link feature Comments feature
Validation check feature Search/ Extraction feature Deleting master as a whole
Field name customization Field display/hiding customization Field arrangement customization
PlanWizard's GUI
Gantt chart window Order Gantt chart window Product Gantt chart window
Individual Resource Gantt chart window Chart windows Calendar windows
Table windows Registering display layouts Master consolidation editor
Order editor
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Summary of functions
Advanced logics
Feature name Outline
Maximum assignment of workforce PW can assign jobs to operators as much as possible by changing necessary number during a single operation, which cuts excess manpower.
Workforce allocation plan
(Individual resource management)
PW can assign jobs to individuals takng their skills into account.
Their working conditions are visible on Individual resource Gantt chart.
Minimization of workforce PW makes a plan to minimize necessary workforce in consideration of due date. It also makes such plan that minimizes operators within a day by leveling .
Time-dependent allocation of manufacturing operators Even when a single manufacturing task ranges over several shifts, PW is able to assign different workers to the task in consideration of their shifts. This assignment is very practical.
Time-dependent allocation of changeover operators Even when a single changeover task ranges over several shifts, PW is able to assign different workers to the task in consideration of their shits. This assignment is very practical.
TOC auto-analyzing feature/JUst-in-connection (special assignment) PW automatically finds the bottle neck operation steps and carries out an assignment so that a total lead time becomes shorter.
Dyanamic dispatching feature PW carries out near optimal assignment automatically at ultrahigh speed. Assignment orders for jobs are decided with unique built-in algorithm.
Dynamic selection of process routings If there are several processes for a product (e.g. 2 operation steps by a new machine and 3 steps by an old one), PW selects a near optimal flow.
Manufacturing management modules
Feature name Outline
Production plan/ Products stock control feature PW creates production plans based on current stock, time-phased safety stock ,sales information, rules to products ,etc. and controls product stock.
Intermediates stock control feature Orders for semiproducts are made in consideration of scheduling results of products to use them. Stock control of semi-products is also possible.
Raw materials stock constraints feature PW makes schedules with constraints to materials stock such as receiving date, quantity, and stock on hand..
MRP Purchase planning for materials is carried out based on the scheduling result. Each material has any time bucket length (day, half week, etc.) .
Actual manufacturing results feature The progress of manufacturing can be monitored through terminals on the shop floors and those outcomes are reflected on the next scheduling run.
Stock control (stock-in,shipping, issue, stocktaking) Transactions of stocks (products, semi-products, materials), such as stock-in, shipment, issuing, stocktaking can be carried out through monitors on the shop floor also.
Reply to inquiries on delivery dates Accurate date of delivery can be confirmed on the Gantt chart, order lists and sales order lists, which boosts your credibility from customers and supports sales divisions.
Lot trace fearture Irrespective of industrial sector, the lot trace is indispensable. PW tracks lots both down and up ways between sources and products.
Area attributes settup feature PW deals with time gaps between remote production sites which shares part of the whole process, and if necessary, customers locations as well.
Logics unique to production plan and scheduling
Feature name Outline
Changeovers types: both setups and cleanups Setup and cleanup operations can be independently or at the same time scheduled before or after manufacturing.
Changeover types & Pre/Post arrangement In order to adapt to diverse sectors, PW's changeover operations have several different patterns.
Changeover for specification change PW is able to generate changeovers taking into account spec.combination of products such as color, shape, length, etc. and reduce total lead time.
Changeover after long intervals When an inoperative interval between two orders is too long, PW optionally generates a changeover even between the same products.
Regular changeover Even with mfg. of same products at same machine, changeovers may be necessary after several lots or a certain time. PW deals with this problem.
Limit to the number of changeovers When the work load of changeover is too heavy, setting the limit of changeovers to some machine or machine group is enabled.
The longest idle time between C/O and MFG PW allows idle time between setup and mfg, and mfg. and cleanup separately, or on the both side of the manufacturing.
Maximum downtime during changeover This downtime setting is utilized so that a changeover period does not include nights or holidays during its time course.
Controlling connections between changeover and production at different steps This feature is used in order to control assignment of setups and mfg's, or clenaups and mfgs. at different steps having various preceeding /succeeding positions.
Pre/Post arrangement feature Extra but inherent work to each production such as charging, discharging, adjustment, etc. is considered to be arrangement work different from changeover work in PlanWizard
Multiple job assignment to limited operators PW solves multiple jobbing case where a few operators have to operate multiple machines .
PW succeeded in completely modeling this kind of job conditions
.
One-by-one transfer Shortening lead time can be achieved by passing products to the next step one by one . PW allows items to be sent in any packed number.
One-by-one transfer and lot grouping Grouping lots which are once split by one-by-one transfer function is enabled. Proper grouping brings about a very effective production plan.
Delayed start of succeeding lots PW is able to insert some idling time between lots when machines need cooling or something.
The number of lots to have each interval can be set freely.
Lot start time setting feature With the settings, each lot starts at the designated time in forward scheduling.
Concurrent production Multiple kinds of different products and orders can be simultaneously made in a batch like in a furnace.
Co-products feature In some processes like press operation, a set of products is produced. PW creates that kind of orders and controls each stock of both products separately.
Process steps avoiding concurrent manufacturing This prevents multiple processes at the joint or branch steps from running simultaneously, irrespective of their sequences.
Restriction of the number of products If necessary, the number of products and of product groups or kinds of specs. manufactured per day or hour can be restricted to machines.
Maximum downtime during manufacturing This setting is utilized so that manufacturing is not interrupted on the half way. Production orders are made so that they do not include nights or holidays within their time courses.
Machine assignment options at each step Preference of assignment order to machines can be defined at each operation step if necessary.
Change of manufacturing quantity along with stretched bars Products quantity or yield changes proportionately to the length of a stretched bar in the Gantt chart.
Just-in-time connection between process steps(TOC auto-analyzing) PW regulates intervals between two operation stpes, which is essential for planning just-in-time mfg. This function is necessary for those processes paying attention to continuity.
Substitute process routing selection If there are several routings (e.g. 2 operation steps in a new plant, 3 in an old one), users can select substitute steps on Gantt chart or the list.
Bi-directional scheduling Cross execution of backward and forward scheduling results in a forward scheduling result close to the backward one. It is very parctical.
Assignment to facilities according to loading limits When containers have maximum or minimum volume limit, PW judges which container is available for the production, by allowance range for loading.
Assignment control of machines by numeric specification PW assigns orders so that numberic specs. of products (lenght, weight, width etc.) may meet the machine's allowance. The allowance has both upper and lower limit.
Overlap assignment to a single machine Mounting multiple tasks within a duration is enabled by a simple flag setting. An image of mounted tasks on a machine can be seen in a histogram.
Restriction of concurrent use of machine groups To such problems as a shared stock room is too small, PW deals with it by preventing particular machine groups from running. at the same time.
Consistent line assignment PW optionally assigns lots to the consistent lines out of several candidates. This is essential for chemical, and assembly industries.
Assignment with weight factors The scheduler tries several temporary assignments using more than 30 sorts of weight factor. and decides the best one .
Multiple machines assignment An order can be assigned to multiple machines, for example, in bottle neck steps. Numbers of machines are defined to each step and each product.
Locking of assigned machines PW is able to insert an urgent order among currently assigned orders without changing currently assigned machines.
Multi-purpose tank control When semiproduct is made in a tank and discharged to product steps, the next batch waits until the tank becomes empty. PW deals with this mfg.
Intermediate warehouse capacity constraint feature PW makes a schedule to avoid situations that the warehouse lacks space for work-in-process goods if they are temporarily stored.
Resources proportionate to production quantity feature Resources used for orders can be proportional to the amount of the ordered products.
Resource retention between process steps PW is able to optionally retain the same resources even when there exists a idle timep or time lag between operation steps.
Resource retention through semi-product and final product Even betweem products and semiproducts steps, it is possible to retain the same resources., e.g., trays used throughout the process can be retained.
Raw material substitution Substitute raw materials are allowed to use for the regular one. If registered in the products master, those materials are conditionally used in stead of default ones .
Disallowing preservation of raw materials feature If a material is classified as non-preservable, PW automatically generates an exhaustion order which uses all the rest of the material.
Rolled materials concurrent use forbidden feature At processes where rolled materials are made in use, several machines cannot share the same reel material simultaneously. PW deals with this sort of manufacturing line.
Disallowing mixed usage of raw material lots This function works when for example, materials such as fabric are not allowed mixed usage with others.
Variable machine capacity with time-course It is possible to vary machine capacity along with series of certain intervals.
Production rate change to each step The productivity originally defined in the master can be altered on each order and each operation step.
Productivity depending on operators skills When productivity depends on operators skills, PW is able to make a production schedule taking their skills into consideration.
Lot number customization PW is able to provide lots with special numbers which users originally define. Serial numbers per product or group of products can be given, depending on necessity.
Data linkage feature Data exchange among several PW is possible. Each PW has its own position within the stream of whole production; upstream side or downstream side.
A single product manufacturing feature We call a certain group of functions as 'A Single product manufacturing function'. It facilitales registration and manintenance of masters for so-called 'a single product'.
Order grouping feature Certain orders can be dealt with as a group and assgined continuously. Other orders are not inserted within the grouped orders on automatic scheduling.
Locking/Unlocking feature Currently scheduled plans can be locked or unlocked with certain conditions about period, machine, and others.
Other logics
Feature name Outline
Forms creator With this tool, users are able to create original forms freely on Excel sheets.
Form customization and conversion into HTML function Users are able to design layouts of various forms on Excel and print them out or convert them into html.
Work order sheets customization function On the Excel sheet, users are able to make a layout of work order sheeets which include bar code or pictures. Management of W/O sheet is also possible.
Direct output of table information to Excel function All pieces of information in tables of PW are able to be directly exported on Excel sheets.
Tracking connection of steps in the master and listing function Connection of process steps can be tracked from the products final step to raw materials or semi-products, and listed, or inversely tracked and listed based on masters.
Setting unit measures to each step function Unit measures for products are designated at each process step. Therefore, scheduling results can be utilized as a work instructions without change.
Linkage with external data base PW provides database which is compatible with all the masters and lists of PW . Configuration of interface can be completed within this database.
External interface customization Customization of interface for the data exchange between PW and external systems is achievable at end-user level.
Conversion coefficient between PW and external systems By means of the interface coefficient, external quantity data in the host can be automatically converted into figures used at factories.
EntrySheet The EntrySheet enables communication between masters of PW and external computers to be established simply without programming.
Navigation of masters registration function Navigation movies facilitates registration of masters. (Now not available)
Graphical editing tools Master consolidation editor and order editor helps users confirm and modify masters and order information on the graphical screen.
Macro function Users are able to execute PW's commands according to macros described by users themselves. Customization by users is very simple.
COM function Through programs described in VisualBasic and others, direct access to PW's database, control,or customization is enabled.
Simulation feature Four runs of simulations are available on PW. Each simulation is carried out separately based on different orders, calendars, and others
Equipment/Resource grouping function Machines and resources can be registered and treated as a group. There is no limit to the number of hierarchy structures of groups .
Direct linkf feature All the data in PW are related with each other so consistently that one change in a master.
Comments feature Comments can be put to scheduling results. In addition, they can capture machines and resources to secure their space in the Gantt chart.
Validation check feature To keep consistency between each data, validation check is helpful for study of the error contents and for robust execution of the program.
Search/ Extraction feature This function is useful for looking for objective records in the tables by specifying diverse search conditions on the dialog box.
Deleting master as a whole feature Items in the masters of products, raw materials, resources, and other relevant masters can be deleted along with related information.
Field name customization Field names in the masters can be altered to familiar names by users. It facilitates introduction and implementation process of the scheduler.
Field display/hiding customization featureunction Users are able to hide or unhide any fields on the tables in the masters.
Field arrangement customization feature Arragement sequence of fields in all the masters and tables can be altered as you like.
PlanWizard's GUI
Feature name Outline
Gantt chart window Graphical display of Mfg schedule by each machine. Fonts and (other) properties can be customized.
Order Gantt chart window Graphical display of Mfg schedule by each order. Fonts and (other) properties can be customized.
Product Gantt chart window Graphical display of Mfg schedule by each product. Fonts and properties can be customized.
Individual Resource Gantt chart window Graphical display of work plan or usage plan by individual resources. Fonts and properties can be customized.
Chart windows Ten kinds of charts help users to confirm production schedules.
Calendar windows Working and non-working patterns of resources are defined here.
Table windows 'Copy & Paste' like Excel and such various functions
Registering display layouts All screen layouts can be registered or retrieved at any time.
Master consolidation editor A tool for editing masters. The editor window consisting of a graphical part and a form part is very helpful to generate various masters.
Order editor A tool for editing order information. Users can change order conditions easily with a graphical window and a form part.
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