JDA Factory Planner (i2 Factory Planner)

JDA Factory Planner (i2 Factory Planner) is support system of production planning, materials and resources.

I2 Factory Planner components

i2 Factory Planner mentions the fields of planning:

• formation of requests for materials for all components of production

• the report of problem areas of the plan (the postponed orders, missing materials, the delayed produced parts, problems of capacities and resources), including the final requirements of customers which are under the threat because of these problems

• redistribution of stocks and permission of exceptions

• the analysis of the different modeling scenarios "what‐if" at the problem resolution with planning

• determination of limited resources and distribution of loading to a production equipment

• formation of an optimal priority of transactions on resources (in particular, at considerable setup time)

• check of terms of implementation of requirements of the customer taking into account restrictions in materials and resources

Formation of requirements to materials

The technique of reservation of stocks used in the solution i2 Factory Planner consists in opportunities:

• The plan performing optimal reservation of materials for the purpose of minimization of number of back orders is created.

• The algorithm of placement of stocks executes "assembly coordination" on the basis of availability of an important component. It creates interrelation between all components mentioned in one electronic edit.

• Placement of materials is performed by the just‐in‐time method thanks to what it is optimum used directly available excesses of materials and not placed developed positions.

• Allows the user to make placement of stocks on the basis of the chosen criteria (for example, the term of the order, an order priority, etc.).

Possibilities of modeling

i2 Factory Planner allows to include in planning model a number of elements which can be significant for this environment and have an impact on result of planning, for example:

• Make or buy: at first we make a certain goods item, and at some point we begin to buy it from outside.

• Safety stock of the purchased components: at a position it is possible to set a certain inventory level by means of which we will be insured from the fluctuations in demand.

• Insurance time for any component: the safety stock structured on time changing depending on requirements for this position.

• Order point, the minimum ordered quantity: at some point an additional order the strong quantity (dozakazyvayemy quantity) is ordered always.

• Ordered quantity/consolidation: it is possible to set the minimum ordered quantity or to make temporary consolidation of requirements of the purchased and made positions and to evenly distribute deliveries on statutory rules.

• Alternative materials: possibilities of material substitution by the predeterminated alternatives are integrated into i2 Factory Planner. In case of a lack of initial material alternative material can be used.

• Input/output of components: the new component as replacement for available which thereby will pass into unnecessary stocks will be entered into certain time (change term).

• Exhaustion of a stock of components: input of a new position is correlated on time by the time of exhaustion of stocks of an initial position (there is no unnecessary stock of an initial position)

Report on production problems and permission of exceptions

i2 makes the report on problem situations by means of data:

• all back orders and positions which caused a delay

• all made and purchased positions bringing problems and all orders which are affected by these positions (are delayed)

• all restrictions of resources and peaks of use of the overloaded working sections

For each of the described opportunities the tolerance range which depending on a situation allows to make the selective statement of positions, orders or working sections according to certain admissions is established.

Detailed analysis of problems, 2011

As this information contains detailed data for "basting" of a way forward, it is possible to carry out very effective planning of material taking into account exceptions and to independently make decisions on the selected critical positions affecting a large number of client orders. It gives the chance to the user - to detect bottlenecks in production and to adapt for them the plan.

Model scenarios ("WHAT‐IF")

i2 Factory Planner supports a number of opportunities for modeling of dummy situations. The analysis of impact of changes on the production plan belongs to standard scenarios:

• scope change or delivery date of orders at the available clients

• adding of new orders for final positions or cancellation of others, now irrelevant

• adding of new purchase orders or cancellation of the available orders

• change of delivery date of material (from the supplier)

• increase or reduction of power of crucial working sections

• clarification of the next possible delivery date by again taken order on the basis of the relevant material plan and capacities

• the analysis of financial influences on the production plan using one or several of the above described dummy scenarios

On each of these scenarios in i2 Factory Planner it is possible to set the complex or partial redistribution of stocks limited only to the mentioned positions. At change of resources, in this way it is possible to configure i2 Factory Planner that a system carried out alignment of load on capacities of konkrteny working section or all production.

Optimization of load of resources within current limitations (Constraint anchored optimizationtm, CAO)

i2 Factory Planner uses the CAO technology aimed at resource optimization taking into account the specified restrictions. The CAO method can be applied to a large number of various questions of production planning. The method includes determination of conditions for production and strategy adaptation so that influence of these limiting factors was minimum.

Main objectives of a balancing algorithm i2 Factory Planner:

• decrease in number of the delayed deliveries, i.e. the maximum adherence to deadlines

• work in progress minimization

• minimization of intermediate-term production cycles

• reduction of quantity of technology breaks at limited resources

General properties of a product

• Algorithm of floor planning of materials for timely deliveries from stocks and coordination of assembly.

• Fast data processing in OZU. Formation of plans happens in minutes, unlike the normal MRP systems using databases.

• Ample opportunities of modeling of strategy of the order of materials, alternative parts, material specifications, high efficiency at the minimum requirements to data.

• The short consolidated report of problems with materials and resources with separation into levels of all mentioned orders, problem spare parts and limited working sections.

• The accurate, very fast algorithm of balancing of resources defining the global and optimized solutions for load distribution.

• Installation of obligatory delivery time in real time with parallel accounting of material and resource restrictions.

• Wide scale of the tools of analytics reflecting effects of the changes entered by the employee of department of planning. Highly effective simultaneous support of a large number of clients.

• Ability to integrate with the operating ERP system for consolidation of data in production applications.