日本語

1-1.Production schedule creation function (f-MRP/MRP calculations) 【Update】

■ Parameters for flexible production schedule development

 With parameters that can be set for each item, the system creates a detailed schedule that matches the actual operation of the site.

・Function of lead time and allowance (buffer)

Manufacturing lead-time：Sets the number of days required to complete an item from start to finish and back-calculates the scheduled start date from the scheduled completion date.

Unit manufacturing lead-time (standard time)：Sets the production time per item. By setting it together with the setup time, load is accurately calculated, allowing for developing a schedule according to the manufacturing quantity.

Allowance for manufacturing lead-time：In case that the required time is slightly advanced after the schedule is fixed, the parameters of the Item Master can be adjusted to avoid unreasonable express instructions to the site and maintain stable production.

Delivery lead-time：Manages the holding period after an item is are delivered or completed until they are used in the next process or shipped, as well as transportation periods.

Allowance for delivery lead-time：You can set the minimum buffer necessary to meet customer requirements and avoid causing confusion to suppliers, in the case that parts are not available on time.

・Lot-sizing functions (units of purchase order and manufacturing)

This function automatically calculates the optimal units of purchase order and manufacturing according to the actual business situation.

Basic lot-sizing：Specifies the minimum unit of manufacturing and purchase order, and rounds it up automatically.

Two-stage lot-sizing：Secures the minimum quantity with the first lot size and rounds it up by applying the second lot size (increment unit) to the extra quantity beyond it. For example, you can make a realistic arrangement by limiting the maximum quantity while totaling the required quantities over a certain period of time.

Lot-sizing within a period：Totals the required quantities within a specified period (e.g., days, weeks, months) to optimize the number of setups and purchase order placement.

Maximum lot-sizing：Sets a maximum value of manufacturing and purchase order for each lot-sizing. If the specified quantity is exceeded, the slip is automatically split to accommodate the capacity of the equipment and distribution restrictions.

 Calendar accumulation：This function allows you to schedule an arrangement on a specific day of the week according to the delivery destination or your company's date of reception.

■ Correction based on defect rate (item and bill of materials)

Assuming a certain yield in the manufacturing process, this function automatically develops a schedule for arranging and producing an extra quantity in advance. In addition to setting the defect rate for the entire item, you can individually specify the defect rate of a particular child item for a particular parent item based on the Bill of Materials to calculate a more realistic net withdrawal scheduled quantity.

■ Various buckets and dynamic schedule operations

・Operations with up to 365 buckets

The number of scheduled days (buckets) in the Production Schedule table can be defined in units of day, week, month, and even shift, up to 365 buckets. By using calendars with different units in a single schedule, you can respond to longer material delivery times and give the latest detailed instructions to the site.

・Management of multi-level structures with up to 128 levels

You can build a multi-level hierarchical structure of up to 128 levels for a product, achieving the simulation and arrangement of even complex products in batch.

■ Monitoring calculated inventory that reflects the actual situation

・Developing schedules based on calculated inventory

Starting from the current inventory, the system develops a schedule based on a calculated inventory that accurately reflects purchase orders already made and delays in delivery and work. By simulating inventory transitions over time at all hierarchical levels, and replenishing only the necessary quantity exactly upon a shortage, it can both reduce inventory and prevent stockout.

Base stock (Buffer inventory)：A buffer to respond to sudden demand fluctuations and shortened delivery times within the period for which the schedule details have already been created. Even for parts with long procurement lead time, setting the base stock achieves stable production while avoiding making unreasonable express requests to suppliers.

Minimum inventory：When a minimum inventory is set, a replenishment schedule is created to ensure that the inventory does not fall below it, reducing the risk of stockout.

Maximum inventory：It is the upper limit of inventory for avoiding excess inventory during auto-replenishment, ensuring an appropriate inventory level.

■  Load aggregation and visualization 【5.0】

・Showing load distribution over a production period

After MRP calculations are performed, the load of each department and equipment is automatically aggregated based on the standard setup time of the item. In addition to the conventional method that piles up only on the scheduled completion date, TPiCS-X Ver. 5.0 and later are implemented with a function to distribute the load over the entire manufacturing lead time for aggregation. This prevents unreasonable schedule interruptions, allowing you to monitor the realistic status of the load.

■ Stable operation and change management of schedules

・Protecting instructed periods

Schedule details creation period：Even before an instruction is given, setting a schedule details creation period allows for fixing a schedule as if instructed. A change slip is issued for changes to the period to which an instruction has already been given, so careful adjustments can be made, taking into account the situation of the site and the supply sources.

Order issue period：An order issue period can be specified individually for each item, ensuring operation with a stable schedule over the appropriate period for each item. Purchase order lead times can be controlled according to the supplier and production department for each item. If it is expected that the product shipment or delivery time will not be made in time, instructions can be issued to handle it an express item to respond to it.

・Fixing schedules

Fixing schedules manually：You can explicitly fix a specific schedule by using the [Shift] and arrow keys on the Production Schedule table, even if the schedule is for that after a period for which schedule details have been created.

Fixed level：Fixed levels can be used to hierarchically fix schedules for processes where you want stricter control over schedule variations. Even if a shortage occurs within the fixed period, the system will not automatically make additional arrangements; instead, the values in the Inventory line will be negative, and the journal will warn you. It achieves a reliable operation that allows human operators to manually adjust production schedules, but because it requires more time and effort, focusing on the bottleneck process is more effective.

TPICS-X achieves data-driven management that identifies what to do now, without the need for detailed checks by human operators.

■ Journal function to prevent future problems

・Visualizing delays in and shortages of lead time

This function displays in a journal the schedule changes that require attention by human operators, such as exceeding purchase order lead times due to sales order changes or defects in intermediate processes. It clarifies when, what, how many shortages, and which shipments will be affected.

・Improved visibility of new Journals and jump to production schedule tables [5.1]

By simply clicking on a journal, you can instantly jump to the corresponding Production Schedule line and make adjustments. Besides, each record in the journal displays a warning icon, allowing you to identify the priority and urgency of the journal at a glance.

・Showing hints for detailed solutions 【5.1】

Instead of just displaying the error, a guide to action-taking (a hint button) is shown.

■ System optimization

・Separating journals and operation log tables【New】

Journals, which show the result of calculations, and tables, which record the operation history, are separated. This ensures a stable response even during large-scale operations.

■ Consistent workflow from sales order to production

・Automatic schedule calculation based on delivery dates

When a designated delivery date of sales order data is registered, it is automatically reflected in the shipping schedule and delivery date lines. The production planned date is automatically calculated based on the Bill of Materials and lead time starting from the shipping date.

・Automatic calculation of required quantities linked to inventory status

 Calculated inventory is verified in real time, and if there is a shortage in the inventory, a production schedule is automatically developed with no excess or shortage through MRP calculations (f-MRP).

■ Flexible made-to-order production based on sales orders by linking with schedule details

・Creating production schedules (schedule details) linked to sales orders

At the same time as sales order registration, a production schedule dedicated to the order can be created, allowing you to give manufacturing instructions and manage progress consistently, linked to a specific sales order.

・Responding to individual specifications using withdrawal details

Required units and parts can be individually added from manually entered withdrawal detail data, allowing you to flexibly respond to individual specifications.

・Automatic explosion to child items and arrangement

The added units and parts are recognized as component child items in the following MRP calculations, and an arrangement schedule is automatically created according to the start date.

■ Synchronizing and adjusting sales orders and production

・Production adjustment required (sales order adjustment) function【5.1】

When an express schedule occurs due to a sudden sales order and other reasons, the reception class of the sales order data is automatically changed to Production Adjustment Required (provisional reception) to support the decision-making of delivery date adjustment.

1-4.Running change function

■ Automating and optimizing part switchover

2-1.Production schedule creation function (Mfg. No. explosion)

The system assigns a unique Mfg. No. number to each sales order, linking items from the product to the end part, allowing for thorough identification of the progress. This enables precise control over costs and delivery dates for custom production, where specifications vary by customer.

■ Three Mfg. No. control methods of firmly linking orders and production

B-Seiban (Basic Mfg. No.)：All hierarchy levels can be connected using Mfg. Nos., and the structure can be tailored to each schedule. It is ideal for individual made-to-order production, which covers steps from design to manufacturing.

S-Seiban (preceding arrangement Mfg. No.)：Intermediate units are arranged using preceding Mfg. Nos., and confirmed Mfg. Nos. are allocated to them. Before a sales order is received, if forecast or sales order placement is highly promising, arrangements can be made for parts and unit production in advance.

F-Seiban (f-MRP Mfg. No.)： This control method uses Mfg. No. to link schedules developed through f-MRP. Mfg. Nos. can be allocated to schedules created in base stock or lot-sizing.

■ Enhanced Mfg. No. explosion functions and flexible operations 【Update】

・Compensating for shortage in S-Seiban at the time of B-Seiban explosion 【5.1】

During B-Seiban explosion, if S-Seiban to allocate is short, schedule details for B-Seiban can be created to compensate for the shortage. This eliminates the need for creating a new S-Seiban to compensate for the shortage and then returning to B-Seiban to explode it again, which improves the work efficiency.

・Enhanced linkage between MRP calculations and F-Seiban

Mfg. No. can be exploded in MRP calculations, and it is now possible to give a Mfg. No. name in F-Seiban explosion following MRP calculations. Besides, for F-Seiban, Mfg. No. allocation to schedule details can be canceled in MRP calculations, and then allocate it again. This allows for accurate allocations without changing the order of Mfg. Nos., even if the schedule is advanced as a result of MRP calculations.

・Creating B-Seiban schedules based on production schedule table

Production Schedule table displays B-Seiban in a Mfg. No. line, allowing for creating a Mfg. No. schedule simply by entering quantities in the Mfg. No. line. An anticipated Mfg. No. schedule can be registered; in addition, Mfg. No. can be exploded at the same time as MRP calculations, allowing for seamless development of a schedule for generic parts.

・Optimizing the timing of issuing slips

Based on the order issue period (purchase order lead time) set for each item, the scheduled order issue date is automatically set in Mfg. No. explosion. This ensures that a slip is issued when arrangement is actually necessary.

・Supporting multi-level structures

The system supports multi-level structures up to 128 levels. It creates arrangement instructions for all hierarchy levels in a single explosion, managing them consistently with Mfg. Nos.

2-2.Journal function (Mfg. No.) 【Update】

The functions for early detection of unreasonable schedules in individual made-to-order production have been greatly enhanced.

■ Mfg. No. journal function 【New】

・Detecting abnormalities of Mfg. No. control items

This function warns of delay beyond delivery lead-times, manufacturing lead-times, and order issue periods (purchase order lead-times), as well as shortages of Mfg. No. to allocate found during Mfg. No. explosion. In addition, when checking Mfg. No. in Mfg. No. schedules and Mfg. No. Gantt charts, the system checks the entire Mfg. Nos., showing items that need addressing in a journal. This helps prevent delays beyond delivery dates early.

・Jump function for quick adjustment

By simply clicking on the journal, you can instantly jump to the corresponding schedule on the Mfg. No. Gantt chart, allowing for smooth delivery date adjustment.

■ Automatic reply of sales order reception class【New】

Based on the presence or absence of a Mfg. No. journal, the system automatically determines the reception class of sales order data so that on-site load status can be immediately shared with sales representatives.

2-3.Gantt chart display by Mfg. No. 【Update】

This function allows you to centrally manage and visually check the progress of processes linked to each Mfg. No. Detailed processes can also be displayed on a Gantt chart, allowing for the more precise identification of the progress.

■ Intuitive operation and visualization

2-4.Structure change function 【Update】

This function helps you flexibly respond to environments with frequent design changes.

■ Flexible structure editing

・Intuitive editing

By operating a Mfg. No. structure tree, you can easily make changes to individual specifications of each sales order.

・Specification selection by option code

By simply specifying specifications at the time of sales order, the system automatically makes arrangement to substitute specific parts for those in the standard specifications.

・Item removal function  【New】

You can remove an arranged item from a Mfg. No. and replace it with another item. This achieves rapid response to design changes and part diversions in the course of production.

2-5.Function to aggregate costs by Mfg. No.

This function visualizes the profitability of each order in real time.

■ Precise plan-to-actual management

・Real-time comparison between a plan and actual result

Even in the course of manufacturing, costs of incomplete items are calculated as planned costs, allowing you to project the final outcome early.

・Incorporating costs of f-MRP items

Costs for common parts can also be accurately aggregated by including them in the cost details for each Mfg. No.

・Distributing actual result amount to lots allocated to multiple Mfg. Nos. 【New】

If the same lot is allocated to multiple Mfg. Nos. and partially delivered, the actual result amount of that lot can be distributed in the order of issue planned dates to aggregate costs for each Mfg. No.

3.Supporting various sales order types using by-item management methods

The greatest feature of TPiCS-X is the ability to flexibly select from f-MRP- and Mfg. No.-based control and mix them.