Raytstep SPM - Schedule system and Monitoring of Lean SCMo ERP

The SPM system (Schedule system and Monitoring, Lean SCMo ERP) is intended to Raytstep company for management of production logistics chains (internal and external) industrial enterprises.

SPM is developed with use of both the western, and domestic methodical practices and supports both the western, and Russian industrial model, including the distributed productions and cooperation interaction.

Allows to build PS (Production systems) on the basis of concepts: MRP-II (structure of plans and objects), SCM (planning methods, optimization and managements of chains), Lean (pulling, a kanban, visualization), TOC (planning and prioritization), APS (the synchronous optimized planning of a production and logistic chain), the updated "Novocherkassk system of Rodov" (modifed planning through "a proportionality card file", monitoring through "the diagram of proportionality"), etc.

Includes specifics of modern space productions (long cycles, cooperation), productions of special automobiles (configuring, pulling under assembly), difficult instrument making (multinomenclature and multiconversion production), shipbuilding (long cycles, parallel design-production-assembly, a huge number of component parts), machine-tool construction and production of a promoborudovaniye. It is also surely implemented and applied on rather small (dozens/hundred of people) the growing enterprises, allowing to develop surely without change of the platform.

For October, 2018 SPM covers the following fields and features of management:

• Management of release (long-term planning)
  • Modelling of release on a release clock period, a bottleneck (restriction) of a production chain.
  • Automatic/manual formation of the Release schedule, on the basis of orders, the forecast, on different algorithms. Including on assemblies "inside" and in "depth" of structure of a product (fair implementation Sborka-pod-zakaz).
  • C manual/automatic balancing of capacities, according to cyclic assembly schedules, on loading of key repartitions.

• Synchronized planning разработки-производства-поставок-кооперации:
  • Planning on the basis of SI both in parallel developed, and existing (the specification + shop-to-shop routing).
  • Calculation of both dates, and start/release priorities.
  • Different models and algorithms of planning for different types of productions/repartitions (final assembly, modular assembly / welding, machining and mechanoassembly, procurement/stamping).
  • Fast and permanent (nightly) synchronization the plan/fact (planning "back and forth" on all production logistics chain: transfer to the customer<-испытания и доработка<-финальная сборка … <- межзаводская кооперация <- снабжение).
  • Possibility of permanent recalculation of plans and accounting of changes: release schedule, structures of products, production fact.
  • Fast (hours/minute) the general planning of large volumes of data (tens of the nesting levels, hundreds of thousands of products completing in structures)
  • Planning and monitoring of all cooperation chain of any depth, geography and complexity.

• The difficult distributed production and interfactory cooperation
  • Modelling of the plan for all to the CPU (supply chain), taking into account loading, cycles of production and delivery on nodes.
  • the Opportunity for work of "suppliers"/co-operators in the system of "consumer" (information input about the status/fact of stages of deliveries")
  • Technology and Deliverable sets and complexes

• Production management
  • Clear visual and (automatic) digital prioritizing of starts/works.
  • Simplification of objects of production and accounting via Phantoms, A-phantoms and Avtofantoma. Autowrite-offs "forward" and "back".
  • Different "levels" of management: intershop / interlocal, intra shop - step-by-step.
  • Different control objects – Production Lots of type: Mashkomplekt / Group registration certificate, Route Chart, Assembly registration certificate, Kanban. Inline assembly.
  • Intra shop planning and management: the manual / automated job sharing on equipments/crews; manual/automatic control of queues, accounting of course of production about use of technology of barcoding / tablet input.

• Management of MTS and interfactory cooperation
  • Management of MTS "as production" (MTS = "workshop", process = "route"), with planning and purchase management on all stages of delivery.
  • Planning and purchase under the order (under head products with the serial numbers).
  • the Prioritized payment schedule under a priority of a complete set and start of production.
  • Inventory management with analytics the contract/order / a finished product / assembly / serial No. with different degree of rigidity: reservation / a possibility of automatic redistribution.
  • Integration with the automated warehouse complexes.

• Monitoring and KPI
  • Online monitoring of productions/deliveries on all chain. By заказа/контракта/поставщика/кооператора/цеха/участка.
  • From detailed (for the master) to summary (for the CEO), with a possibility of drill-down to parts and transactions.
  • Control of the general synchronism of work of plants/supply chain, visualization of economy and efficiency in a cut of synchronism and timeliness of accomplishment of plans.
  • Support of transition to a time and bonus system.

For October, 2018 in composition of SPM:

• MRP-II (the management concept production with a feedback, with different levels and methodologies of planning and management, including:
  • MRP (an algorithm of calculation of requirements through explosion, taking into account stocks and the WIP),
  • CRP (planning taking into account capacities for the level of work centers),
  • MPS (formation of the Release schedule, with prohibition of autoplanning (MRP/APS) "below"),
  • SFC

• APS (job order synchronous planning and optimization taking into account resource model, distribution and determination of a priority of execution of works by resources),
• SCM (modeling and planning of release, planning and management of the CPU: productions, supply, interfactory deliveries),
• MES (see APS + the automated and step-by-step accounting of production, electronic document management),
• VMI (online access to the system of suppliers and cooperators),
• SCMo (planning and monitoring of a supply chain, work in the system of suppliers and cooperators)

Practice of application of SPM

Application of SPM requires non-standard approach to creation both methodology, and the supporting IT system, under requirements and possibilities of the specific plants.

Approach Raytstep following:

• 1. the company initially defines and puts the "correct" methods of management, it is obligatory taking into account opportunities of the company, features of the market / an external environment, internal specifics of productions/deliveries.
• 2. Covers (automates and synchronizes) at once all supply chain, since a development process exit, further constantly recalculates plans of productions/deliveries for all nodes of a chain, including supply, suppliers, subcontractors. At the same time considers ("buffers") nonoptimality and/or the uncertainty of technology processes taking place owing to features of difficult productions: features of an output of new products, pilot production, etc.; with modeling of a possibility of product output and calculation of bottlenecks.
• 3. Constantly calculates the deviation plan/fact ("directive" vs "settlement" plans), visualizing online for all participants of a chain critical problems and/or positions of productions/deliveries.
• 4. Further the company "goes to depth", on "bottlenecks", optimizing production schedules, executing integration into the equipment, warehouses, the tool, etc., where it is necessary and justified.

Development History

2017: SPM 3.x

In 2017 Raytstep released the version of SPM 3.x which a number of improvements of functionality and ergonomics and also support of the alternative technology platform which is completely based on import-substituting technologies entered.

Version 3.x of the SPM system (Lean ERP SCMo) is developed using the advanced and open information technologies (Open Source):

• Under control of the highly reliable and protected open OS Linux.
• Productive DBMS PostgreSQL (with a possibility of use and other relational DBMS).
• Web servers of parallel processing Akka-http on the basis of Scala.
• Economic stream data processing using Java 8 Stream API.
• The standardized (HTTPS) REST API, both the user interface, and integration solutions of the reactive user interface HTML5 unified for work on the basis of Vue.js.

2013

With 2013 the international intellectual property rights to Lean ERP SCMo, including all source codes and development tools, passed the company Raytstep which patented it in RUSSIAN FEDERATION under the names "SPM — Schedule System and Monitoring of Production and Deliveries" and "Lean ERP SCMo" (state The registration certificate COMPUTER of program N 2014616615 of 6/30/2014). Further development and system development is completely executed Raytstep, with attraction, if necessary, the German and the French experts in the field of planning and management of production and logistics systems.

2009

Since 2009 Lean ERP SCMo was developed by SCM Solutions and Raytstep companies jointly, including changes and development of a program core and business logic of a system and also expansion of an arsenal of methods: "Rodov's system", etc.

2008

In 2008 as a result of cooperation Raytstep and SCM Solutions on promotion of SCMo on the Russian market, the industry version of Lean ERP SCMo, with expanded control functions by stocks, supply, sales, production cost value, i.e. management of all of "an operational circuit" of large engineering enterprise was released.

2000

A predecessor of SPM is the SCMo system (Supply Chain Management and Monitoring) developed in 2000 by SCM Solutions GmbH company (Germany, Dortmund), from the 1990th specializing in development and deployment of solutions for modeling, planning and management of production companies and cooperation supply chains.