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OR Soft - Industry Solutions
Metal Production and Foundries

latest changes 2009/11/16
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Operative Planning in Primary and Secondary Smelter Industries

The production planning and scheduling in the metal production industry is characterized by a high grade of special specific requirements. A set of specialized Advanced Planning and Scheduling (APS) Systems, which supports the planner to resolve certain tasks, exists. For example, support can be provided to the production of secondary metal or the detailed production planning of foundries. A disadvantage of these software products is that they are stand -alone systems and this mean that these systems use a separate database and are not integrated in the ERP system of the company. Hence, there is redundant data management. 
OR Soft’s Manufacturing Workbench fills this gap. Based on the master and dynamic data of the SAP R/3, respectively SAP ECC, this solution proposes a set of specialized APS solution modules, which are of particular interest for those involved in the metal production industry. 
Manufacturing Workbench is a software solution for detailed production planning and is certified by SAP as an endorsed business solution. This software product offers the following functionalities:

 

  • Resource allocation planning for furnaces
    • Consider all related resources and their availability, including handling units and other tools used in production
    • Consideration of dynamic set up costs
  • Burden calculation on homogeneous raw materials
    • Calculation of Bill of Materials (BOM) to a certain finished product (or customer specification) by minimizing the raw material costs
    • Consideration of other constraints (thresholds, limitation of BOM items, etc.)
  • Support make-to-stock production and make-to-order production
  • Consideration of productions tools, such as molds, in foundries

deutsche Version

 Detailed Scheduling
To produce metals, the raw materials are fused together with a smelting furnace and after quality is checked with various parameters, the blend is forwarded to the foundry where the finished products are formed or the liquid metal is filled into a transportation container. It is then sent to be delivered to the customer. In both cases, the planner has to check the disposability of the production tools (molds, transport container, etc.). Furthermore, the planner has to consider set up costs for cleaning, cooling, or other costs which will appear once the original recipe for the finished product has been modified or changed.
Burden calculation
The central task of the burden calculator is to assign an optimal bill of material to a process order / production order by considering the quality constraints of the finished product. Here, a set of important constraints must be considered. One finished product can be produced by many different bills of material (different recipes) and the planner needs the capability to compare these variants; this calculation can be based on a linear optimization algorithm.
Cast Planning
When producing casting molds, there are requirements for optimal cast planning. When there are mold orders, whether the order is from one or multiple customers, it is essential to select the most optimal combination of casts in order to reduce over production and byproducts, while simultaneously considering the delivery dates.
SAP PartnerThis software was developed by the OR Soft GmbH, Germany. OR Soft is certified development and implementation partner of SAP AG for solutions in the area of production logistics, planning and optimisation. More tools for production planning, supply chain management and MS Excel user GUIs for SAP ERP can be found at www.orsoft.de.

SAP® ERP, SAP® SCM, SAP® xApps™, SAP NetWeaver®, and other SAP® products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world.
All other product and service names mentioned are the trademarks of their respective companies.

Additional information products offered by OR Soft Jaenicke GmbH: *

SAP Best Practices - Advanced Planning Board *
Planners Workbench for SAP ERP and SCM *
smartPlan - electronic whiteboard

Topics and Technology

Industry Solutions

Material stock reduction
Detailed Scheduling
Supply Chain Management
Simulation, Optimization, Analysis
Master Data Maintenance *
Automated System Testing for SCM & ERP
Shelf Life *
*also in English, others only in German

Repetitive Manufacturing, Automotive *
Made-to-order production, Assembly
Pharma, Packaging *
Oil and Refineries *
Chemicals
Utilities, Maintenance, Service
Food, Beverages *
Lab planning *
Metal Production and Foundries *

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