Factory Logic is the first and only lean operations solution integrated with the SAP NetWeaverT platform. It is also the only plant-centric, level scheduling solution available that is designed to accelerate your lean initiatives while building on your SAP investment.
With our solid background in lean manufacturing, Factory Logic can show you how to use SAP to your advantage in accelerating your lean initiatives and in sustaining the lean philosophy as a full-scale enterprise practice.
By adding Factory Logic's level scheduling (or Heijunka) and kanban management solutions to an existing SAP environment, you will be able to:
- Use real-time level scheduling alongside the SAP advanced enterprise planning and forecasting functions to make pacemaker processes more agile, more resilient to disruption and more efficient in their use of inventory, labor and time.
- Provide suppliers with leveled pull signals from Factory Logic, absent the bull-whip effect, transmitted through the SAP Suppliers Portal. These leveled signals are in addition to leveled demand forecasts from SAP, and the leveled production schedules produced by Factory Logic. Predictable pull signals, unlike forecasts, reduce the Supplier's costs and contribute directly to their performance improvements.
- Model the capacity of complex multiple-tool manufacturing processes for the most accurate kanban size recommendations available from any vendor. Factory Logic publishes its kanban recommendations to the SAP Manufacturing and Kanban Tracking module. Third-party MES and shop-floor solutions can also use the same information.
- Sustain the thousands of kanban loops within the enterprise with minimal user intervention through automatic monitoring of changes to the recommended loop sizes, target and alert levels. This data can be sent to any external kanban tracking system already in place.
A Close Partnership with SAP
Factory Logic is a member of the SAP Shop Floor Partner Program and its Lean Operations Suite (Factory Logic Pacemaker Scheduler, Factory Logic Production Synchronizer, and Factory Logic Supply Synchronizer) is a unique component of the SAP Manufacturing Ecosystem strategy.
Factory Logic solutions have earned the "Powered by NetWeaver" certification. Factory Logic deployments on the NetWeaver infrastructure benefit from seamless collaboration with SAP's ERP modules and the Manufacturing Execution Systems (MES) available as part of the Manufacturing Ecosystem.
A direct benefit of the partnership is accelerated deployment through pre-certified integration with SAP Item Masters, Bills-of-Materials, Routes, Customers, Suppliers and other data owned and managed by SAP.
The only Plant-Centric Level Scheduling Solution available for SAP
The level scheduling (or Heijunka) principle states that a production schedule for pacemaker operations using a stable takt time with as small lots as possible will smooth material flow throughout the factory.
A smooth material flow throughout the factory then enables synchronization across the entire supply chain, as production and consumption rates rise and fall in unison to meet changing demand.
The Factory Logic Pacemaker Scheduler contains the most advanced scheduling algorithm available for manufacturing operations that require level scheduling on a large scale:
- A production model for processes with variable run-rates, variable staffing levels, production splitting, sequence-based production and changeover constraints.
- Support for a mix of leveled production items and build-to-order items in the same schedule.
- In collaboration with a real-time production tracking system, Factory Logic detects disruptive events - shifts in customer demand or execution problems, assesses their impact on the manufacturing operations and responds rapidly in order to keep the supply-chain in line with customer demand. Decisions are made in minutes vs. hours.
Supply-chain Synchronization: Forecasts from SAP, Leveling from Factory Logic, Execution from SAP
In its role as the supply-chain synchronization layer between SAP's ERP and Manufacturing Execution Systems (MES) systems, Factory Logic provides real-time replenishment decisions (what to produce and what to pull from suppliers) to all constituents. SAP receives these real-time control signals from Factory Logic and manages the extended supply chain accordingly. Factory Logic's lean scheduling capabilities coupled with SAP's enterprise infrastructure enable more flexible manufacturing operations and leveled supply-chain synchronization.
There are of course many ways to deploy Factory Logic in an SAP environment; only a few aspects are touched on here. Contact us for case studies and to discuss how we can tailor a deployment plan for your lean initiatives.
Click here for more information on Factory Logic’s Lean Operations Suite »
