If you have problems with planning. Part one

Today there is hardly an IT ishnik whom the word "planning" comes to mind is not an acronym ERP, APS, MES. Although these systems have different features and are designed to meet the challenges of planning at different levels, they can not only get along fine, but complement each other. Sometimes we hear from the maximalist calls to increase the functionality of APS or MES to the level of ERP. Can this be done? In principle, it is possible. How can raskormit cat to the size of the Caucasian guard. But then who would catch mice and keep the house? Now, instead of outdated standards, class planning systems MRP (Material Requirements Planning) and MRP-II (Manufacturing Resource Planning), came a new generation of systems - ERP (Enterprise resource planning), APS (Advanced Planning & Scheduling Systems) and MES (Manufacturing Execution Systems). These system solutions, proven in the last 15-20 years in various engineering plants have a different purpose, function and can be used separately or together. Despite the existing controversy adherents of different platforms mentioned above, it should be noted that all of them, despite the fact that they have in their composition planning function at a given level of detail may be separate parts of the overall system - are used to. Remember how it all began The story planning systems ancient history. The idea of ​​planning activities in the undertaking, be it a factory, plant or process of construction of the pyramids, as old as the hills. As soon as people learned more or less tolerable to deal with numbers, just a desire to subdue with the help of these numbers in production processes. Also, long time people realized that the extreme value - not always the best, because in our world, he always opposed all sorts of restrictions. Combinatorics of the nature of things, events, and always has been. We always had the desire to remove the chaos and order of work in time and this order, even if it was found empirically to fix. Back in the early 20th century, a renowned expert on the organization of production, Henry Laurence Gantt was first formulated, in relation to the company, "Bancroft", which produces cotton, the following three simple rules for the organization of work: The order in which work must be carried out, is now defined in the office of the "white gate-prone "and not dyer. Accurate recording the best method of dyeing any shade kept in the office, respected master and no longer depends on a notebook or a dyer's memory. All painters and machinists are encouraged financially, when followed the instructions, or vice versa, shall be punished when they do not. And secured G. Gantt, this procedure works graphically in a certain diagram, which we now call his name. The foundation was laid. It remains only to find a way to calculate that the optimal sequence of operations that can not be broken. After implementing these principles of organization of production in a textile factory with a significant reduction of working hours has increased by 25-30% yield, while wages rose by 20-60%. [1]. A new story. "New" history of solving problems on the optimal planning of production calculated from the adopted 1939. It was then published by Leningrad State University published a small book in terms of a young professor, LV Kantorovich, "Mathematical methods of organizing and planning production." This monograph marked the beginning of scientific methods in planning and organization of production based on the emerging areas of economic mathematics then later took shape in mathematical programming. Not only the "iron curtain" in some way interfered with this work available to foreign scientists, in particular, JB Danzig, who in 1947 came to similar results the idea of ​​the numerical solution of optimization problems, later called the simplex method. Cause of the "irrelevance" was the absence of the feasibility of the proposed models and algorithms, as Computer was not yet before the first prototype of the programming language was still a long ten years. The appearance of the first computers greatly stimulated the development of research in mathematical economics, organization and production planning. Have been developed an effective method of solving integer problems (Gomory), branch and bound method (A. Land, W. Doig and John Little), a method of dynamic programming (Bellman), etc. All these methods of finding the optimum in the surrounding combinatorial world have found application in various fields of economy and production. One such application area of ​​mathematics called Scheduling theory is just "took" a large class of decision problems of planning work in the workplace. The problem of planning production operations on the machines, published by SM Johnson in 1954, which showed that the scheduling for the three machines already belongs to the class of problems intractable within a reasonable time (the so-called class of NP-hard problems) did not discourage the factory specialists first departments of ACS. If the first benefits of computerization can only use state agencies, multi-dimensional balance model of grinding the Leontief or forming five-year plans, with cheaper computers and the advent of the first serial computer the opportunity to meet the challenges of planning at the enterprise level, and even shops and individual sites. The company is considered as good, if it develops its own manufacturing automation, if you try to build a schedule of work for a machine tool systems with operational scheduling of its own production of the same. The development of new application fields of mathematics and computer science classes available to IBM 360/370, UCS 1020 - 1060 took their toll in the 70-80s - they were the catalyst for onset of MIS and have allowed at least some approximation to solve the problem of getting rid of combinatorial chaos "in the world of machines and parts" [2]. Recent history. Whatever new treatment plots over time, not come up with science fiction writers, it is time to be running almost exponential dependence. For some twenty years mankind "has overtaken" Moore's law, and instead of mainframe and homegrown MIS, IT market is now wandering around the new "beasts" zoo, all of which are also called - enterprise management system and processes. The main types of these systems, which are now responsible for drawing up work plans at work - it's class system ERP, MRPII, APS and MES. If their ancestors - CAM system satisfied the possibility of a three-time schedules (at least - schedules of equipment), the rating for the financial prospects for the next five years with a steady demand and payroll, the new systems include more and more automation features of companies in this dynamic market products of modern consumer society. But the main function, as before, is the possibility of a work plan. It is this function that ultimately allows us to understand - who, when and what to do. As happens in these systems planning and some of them for some cases designed for? Planning for ERP. We will not dwell on the description of the functionality of ERP-systems, not only because of the fact that it is written quite a lot, how much due to the fact that the ERP-system, in fact, not a direct tool for planning work in the enterprise. After ten years, consultants and users finally believed that the ERP - this is primarily a corporate information system, enterprise management system, a kind of circulatory and nervous system of the industrial body, connecting the islands of the many logistics of performing certain functions (document management, procurement, supply, inventory, etc.). The nature of the work planning, manufacturing operations on machines and other technological unit in ERP-systems you can say in one sentence - planning in most systems is based on the old standard MRPII [3] without taking into account the current load of the equipment and the processing status of products . That is, in fact, any detailed ERP-plan will be virtually impossible. Figure 1. ERP: The formation of the plan of output (production program) Any planning at the level of ERP limited to the formation of bulk-month (decadic) plan. Adjust such plans can not be promptly and that's why their implementation requires a rigorous discipline in performing all those involved in the production chain units of the enterprise. That is, You can talk about the organization of production controlled by ERP, as the production of a certain stock of "sustainability" in relation to the emerging deviations from the plan drawn up by volume. The entire burden falls on it at the contestants: "as you like, but the planned target for the calculated time, to!" And, most importantly, ERP, issuing job to all units, when in need of updating the plans, unable to cope with it, that k. any recount would the same picture of the general tasks - tasks in the volume, but not in the detailed terms of products and operations that need to control the level shops. To be continued ... Published with the permission Frolov EB References: 1.Proizvodstvenny management. Ed. SD Ilyenkov .- M.: UNITY-DANA, 2000. - 583s. 2. Timkovskii VG Discrete Mathematics in the world of machine tools and parts. - Science, Moscow, 1002. - 144s. 3.Gavrilov DA Control of production based on the standard MRP II. - St. Petersburg. Peter, - 2003. - 352. 4.Bermudes J. systems optimized production planning: a new fad or a breakthrough in the field of production management and supply chain? The manufacturing survey. AMR Research. 5.Frolov EB, RR Zagidullin MES-systems as they are, or Evolution of manufacturing planning. / / The Director-General, № 4, 2008, sec. 84-91. 6.Zagidullin, RR Operative and scheduling in flexible manufacturing systems / under. Ed. V.TS. Zoriktueva. - Moscow: Publishing House of Moscow Aviation Institute, 2004. - 208s. About the Authors: Evgeniy Frolov © 2010, Professor, Moscow State Technological University "Stankin" Department "Information technologies and computer systems." Zagidullin Ravil Rustem-Bekovich © 2010, Professor, Ufa State Aviation Technical University (USATU), Department of "Automation of technological processes."