Implementation of a production planning software in a gearbox plant

Abstract

Consulta en la Biblioteca ETSI Industriales (Riunet)

[EN] Gearbox del Prat produces a total of 35 types of gearboxes. Each gearbox has 15 main components, which means there is a total of 120 variants of these components processed in 60 different lines. To be able to arrange the production of these components, each day, two qualified operators plan a rough demand and production of the assembly line for two weeks, keeping in mind parameters like the capacity assembly line, the transport limitations, the assembly stock, and the production mix1 . However, at present, the demand is adjusted for the current and next day. The problem with this way of planning is that, without the help of any software it is highly difficult to have all parts of the gearbox needed to assemble each type of them at the right time in the assembly line. If this happens and the demanded pieces are not delivered here, the necessary gearboxes would not be assembled ; another gearboxes with the available pieces would be assembled in their place, creating an increase of the gearboxes inventory. For this reason, a new MRP planning system has the intent to be implemented using a software called GESPRO. Through this software, it is possible to control most of the production parameters of a company, knowing at all times the needs of production on each line and workstation and being able to react quickly to any problem. In addition, to control the situation of the production, the interface of the program shows all planning towards the horizon of two weeks through tables and charts, the parameters as demand, the level of production, availability of machines, the stock level, etc. With the implementation of this software the company can acquire the following benefits: · A more efficient use of resources: The inventory -both on products that are in process and on products already finished- would be reduced. It is easier to localize the bottlenecks in the workplace and the maintaining of the machinery is easily scheduled. · Better planning of priorities: The time to start the preparation of a product is reduced and it is easy to change the schedule of production, keeping in mind the needs of the customers. · Better customer service: The Company enhances the ability to meet the delivery dates previously fixed with the costumers. This gives the Company an opportunity to improve quality and reduce prices.· Better information given to the managers: The management uses the outputs of the MRP to be clear about the physical system of production and be able to measure its efficiency. The more informed is a manager, the easier the long-term planning would be.