Повышение качества клиентского сервиса и производственной эффективности производителя спецсталей благодаря улучшению процессов планирования удовлетворения заказов
A scope of a new order fulfilment planning methodology is provided including order promising, material allocation, production planning and scheduling. An experience of successful implementation of the planning methodology at American special steel maker is provided.
The article analyzes a key order fulfilment process component of steelmaking companies –melt shop and caster scheduling. The main optimization objectives of melt shop and caster scheduling are defined as: minimization of earliness and lateness of orders, maximization of tundish utilization, minimization of steel grade changes and minimization of mold width changes, minimization of stock, minimization of over grading, management of iron inventory. Key problems of scheduling in the past are analyzed. The following key problems are defined: underdeveloped optimization algorithms for the problem and insufficient computer performance.
Based on this analysis the key provisions of a new method of melt shop and caster scheduling are proposed. This method significantly improves quality of planning. It includes the following three stages: production capacity allocation; heat building; sequencing. Several key requirements on program solution which is based on the proposed method are defined: high performance, manual changes, online visualization, prioritization of optimization objectives, scalability. An experience of successful development and implementation of specialized software solution based on the new method at Czech steel maker is provided.
In conclusion, the results of implementation of the specialized software solution at Czech steel maker and recommendations of improvement implementation are provided.
The article analyzes practical aspects of master planning process organization with the usage of linear programming methods at one of the largest Russian metallurgical companies.
Planning process analysis before improvements is provided. Its key disadvantages are defined which are simplification of model, absence of scalability, and absence of optimization capabilities. The conclusion is done about necessity of formalization of planning process, development of economic-mathematical model of company’s supply chain in specialized tool with optimization capabilities.
It is highlighted that the new master planning process was based on own company’s experience and elements of Supply Chain Management concept from Global Supply Chain Forum (GSCF). Particularly elements and principles of the demand management process of GSCF were used.
The key stages of planning system implementation were analyzed. Qualitative and comprehensive items design is highlighted as very important and resource consuming task.
The technologies for master planning are defined and reasons for their usage are proved. It is highlighted that integrated approach to tactical planning with the usage of linear programming methods allows a company to form comprehensive understanding of key factors which influence the final result, find out potential appearance of undesired situations and define best alternatives in company’s business.
In conclusion the description of achieved results at the metallurgical company is provided, also economic reasons for improvement implementation is defined.