Application of Shangjian Intelligent Planning and Scheduling SPS in the auto parts industry

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Production planning and scheduling, as the core link in the supply chain management of automobile manufacturing enterprises, is a key factor affecting the cost reduction and efficiency increase of auto parts factories. The quality and efficiency of planning and scheduling play an important role in how companies manage inventory costs, production costs, operational efficiency, performance levels, and more. OEMs are always facing complex and changeable internal and external supply and demand environments, such as fluctuations in order demand and material supply, changes in human resources caused by internal personnel training and retention, demands for digital transformation and intelligent transformation of upstream and downstream supply chains, etc. . The traditional manual planning, production scheduling and material distribution methods relying on expert experience can no longer meet the overall needs of enterprises to improve the efficiency of supply chain management. Shangjian's intelligent planning and production scheduling based on deep learning and operational optimization technology provide enterprises with optimal untie.

For example, an auto parts factory has about 1,000 employees. Its main products are straight bevel gears, spiral bevel gears and cylindrical gears , which are widely used by OEMs in industries such as cars, buses, trucks, construction machinery, and wind power. 70% of the demand comes from the stock order based on the sales forecast, and 30% comes from the customer's direct order.

Before implementing APS, the company mainly had the following problems:

1. The accuracy of demand forecasting is not high, the inventory of finished products remains high, and it cannot flexibly respond to changes in market demand;
2. The production capacity of multiple workshops is unbalanced, and the inventory of intermediate products is too high;
3. The production cycle is too long, which affects the on-time delivery of orders;
4. Unreasonable scheduling of process changeovers, resulting in waste of production capacity;
5. When the production execution report data is collected to the MES system through the PLC, in the absence of the APS system, the data cannot be effectively used;
6. As the core link and necessary condition for the transformation of smart workshops, smart factories, and digital factories, APS can win a lot of policy awards and honors for enterprises. It is difficult for a supply chain management system lacking APS to be recognized by relevant institutions.

Suzhou Shangjian Intelligent Technology Co., Ltd. is committed to providing data-driven industrial intelligent decision-making solutions based on artificial intelligence and operations research algorithms for manufacturing enterprises, helping intelligent manufacturing enterprises optimize management processes, improve production efficiency, and reduce production costs.

The latest "Smart Planning and Scheduling System" (Smart Planning and Scheduling, SPS) independently developed by Shangjian Intelligence adopts technologies such as deep reinforcement learning and operational research optimization algorithms , which can independently improve decision-making capabilities, greatly improve various production indicators, and achieve minutes level planning and scheduling**.

Based on massive production data, the Shangjian SPS system uses deep learning algorithms to perform intelligent operations on the premise of satisfying multi-scenario business logic, and gives multi-weight and multi-dimensional pre-arrangement results, which can be made by the relevant person in charge of the enterprise to deal with the environment and The changeable operating objectives can improve the overall efficiency of the operation.

Shangjian SPS mainly includes two functional modules of production planning and production scheduling . The production planning module can respond quickly to the planned delivery date of the order based on the limited production capacity and materials, give the production weekly plan and monthly plan, and formulate a reasonable inventory for sales orders and forecast orders, taking into account the stock in stock and the stock in transit at the same time Water level, to solve the problems of material shortage and capacity shortage in the medium and long term; the production scheduling module answers the delivery date of the work order by generating a reasonable equipment-level process scheduling plan. Shangjian SPS can help enterprises to improve their business in the following aspects:

1. ** Improve the accuracy of demand forecasting. ** Support multiple algorithms (time series forecasting, machine learning, deep learning), through the establishment of accurate forecasting models, improve the accuracy of future demand forecasting, thereby improving the efficiency of supply chain management, reducing inventory costs, and improving delivery service levels.
2. **Reduce inventory cost. **Based on more accurate demand forecasting and a dynamic safety stock forecasting model, a dynamic inventory strategy that changes over time is generated to achieve the goal of lowering the inventory level, reducing capital occupation, and shortening the inventory cycle while ensuring the expected service level.
3. **ATP Quick Response. **Considering factors such as workshop capacity, production resources, and raw material supply, through system optimization calculations, we can respond quickly to the planned delivery date of the order.
4. **Material complete set optimization. **Considering the materials in stock, materials in transit, material substitution relationship and order dynamic priority, through second-level complete response, optimize multiple goals such as the number of complete orders, order revenue, inventory cost, etc., and output a complete set of complete orders Date, optimal BOM structure and material usage, and generate missing material analysis for uncompleted sets.

5. **Processing path optimization. **Find the optimal processing path in the complex production process network, make full use of equipment capacity, reduce resource conflicts, shorten production cycle, and reduce production costs.
6. ** Realize cost reduction and efficiency increase. **One-key intelligent calculation based on various constraints greatly improves the efficiency of the planning process, reduces cost waste caused by downtime for materials, downtime standby (mold), and frequent mold change, and greatly improves the utilization rate of the production line.
7. **Shorten the production cycle. **Automatically select the appropriate process route, find the shortest path, and use a series of intelligent strategies, such as work order merging and splitting, flow mode between processes (sequence, flow, smooth), process merging, process parallelism, etc., Shorten the manufacturing cycle.
8. ** Improve exception response speed. **When problems such as order changes, procurement delays, equipment failures, and process exceptions occur, the system can quickly assess the impact on existing plans and make real-time dynamic responses, generate new production plans and give accurate delivery dates, which is helpful To improve the response speed, service level and customer satisfaction of customer inquiries and customer progress control.

Landing value is mainly reflected in the following aspects:

1. In terms of orders: improve the accuracy of forecasts and the fulfillment rate of order delivery.
2. In terms of cost: effectively control the inventory level of raw materials, semi-finished products, and finished products through dynamic inventory strategies, and reduce inventory costs; through reasonable arrangement of processing sequences, reduce the number of changeovers and reduce the cost of changeovers.
3. In terms of efficiency: one-key intelligent calculation greatly shortens the response time of planning and scheduling; through intelligent optimization strategies, the utilization rate of equipment is greatly improved and the production cycle is shortened.
4. In terms of production capacity: automatic early warning when production capacity is insufficient, automatic generation of multi-workshop planning and production scheduling linkage, to achieve production capacity balance.
5. Demonstration effect: Provide support for enterprises to realize smart workshops, smart factories, digital factories, lighthouse factories, and industrial Internet benchmark factories.

After half a year of operation, quantitative statistics have been made on the value of Shangjian SPS system, and the value enhancement brought to the enterprise is as follows:

• Improve prediction accuracy by 20-30% ;
• Improve on-time delivery rate by 10% ;
• Reduce inventory cost by 15-30% ;
• Reduce production cost by 10% ;
• Reduced response time by 93.75% .