APS - Advanced Planning & Scheduling
Overview
What is APS
APS (Advanced Planning & Scheduling) is a system that optimizes the entire production planning process from demand forecasting to production scheduling. While ERP plans "what to produce and how much," APS determines "at which work center, in what sequence, and by when" to produce -- reflecting real-world constraints such as equipment capacity, material availability, and worker skills to create optimal schedules.
For example, when a customer order is received, APS automatically calculates whether delivery is possible from current inventory (ATP -- Available to Promise), and if production is needed, when it can be completed (CTP -- Capable to Promise). Based on demand, it establishes MPS (Master Production Schedule), calculates raw material requirements through MRP (Material Requirements Planning), and assigns optimal work sequences to each work center through finite capacity scheduling.
VEXPLOR APS Positioning
VEXPLOR APS is an enterprise-grade solution that integrates the entire planning process from demand forecasting to delivery confirmation. It includes finite capacity scheduling, a multi-constraint engine, What-If scenario analysis, Monte Carlo simulation, S&OP process management, and ATP/CTP delivery confirmation, with real-time MES integration for plan-versus-actual monitoring.
Key Figures
| Item | Count | Description |
|---|---|---|
| Business Tables | 69 | Complete data structures for demand, production planning, resources, scheduling, constraints, and optimization |
| Management Screens | 55+ | Demand forecasting, MRP, Gantt charts, scenarios, optimization, and more |
| Automated Workflows | 7 | Core process automation from demand planning to ATP/CTP delivery confirmation |
| Shop Floor POP Screens | 6 | Touch-optimized screens for production plan status, schedule board, capacity load, and delivery progress |
| Dashboard Widgets | 8 | Real-time monitoring of utilization, on-time delivery, bottleneck trends, and forecast accuracy |
Why VEXPLOR APS
1. Realistic Finite Capacity Scheduling
Scheduling is performed reflecting all real-world constraints including equipment capacity, worker availability, mold/tool constraints, and setup times. Multiple scheduling rules (SPT, LPT, EDD, FIFO) are supported, with drag-and-drop manual adjustment available on the Gantt chart.
2. ATP/CTP Delivery Confirmation
When customer orders are received, inventory availability (ATP) is immediately checked. If inventory is insufficient, the production feasibility date (CTP) is automatically simulated. Multi-site alternative supply is also evaluated, enabling sales teams to confirm delivery dates to customers on the spot.
3. What-If Scenarios and Monte Carlo Simulation
Various situations such as demand fluctuations, equipment failures, and rush orders can be pre-simulated as scenarios. Monte Carlo simulation quantitatively analyzes probabilistic risks, and scenario comparison helps adopt the optimal plan.
4. Integrated S&OP Process
The monthly S&OP (Sales and Operations Planning) process is systematically managed. The entire process -- from demand review, supply review, supply-demand gap analysis, parallel financial/operational scenario review, to executive meeting -- is automated through workflows.
Core Technical Elements
Finite Capacity Scheduling
Unlike infinite capacity MRP, scheduling considers actual work center available time and equipment capacity. Work center calendars, shift schedules, and planned maintenance are all reflected to create feasible schedules.
MRP (Material Requirements Planning)
Based on BOM (Bill of Materials), all raw materials and sub-materials required for finished goods production are calculated. Current inventory, safety stock, lead times, and lot sizing rules are applied to determine precise procurement timing and quantities.
SMED (Single-Minute Exchange of Die)
Systematic analysis for setup time reduction is supported. Internal and external setup tasks are distinguished, and setup matrices determine optimal work sequences during product changeovers.
Planning Nervousness Index
The frequency and scope of plan changes are quantitatively measured. Frozen Zone, Slushy Zone, and Free Zone settings manage plan stability.
End-to-End Production Planning Process Flow
VEXPLOR APS manages the entire planning process from demand forecasting to work order generation.
Meaning of Each Stage
| Stage | Description | Related Menu |
|---|---|---|
| Demand Forecast | Forecast future demand based on sales history and market trends | Demand Planning |
| MPS Creation | Establish master production schedule (weekly production quantities) based on forecasts | Production Planning |
| MRP Explosion | Calculate raw material requirements based on BOM and create procurement plans | Production Planning |
| Finite Capacity Scheduling | Assign optimal work sequences reflecting equipment capacity and constraints | Scheduling |
| Resource Allocation | Allocate work centers, workers, and molds/tools to the schedule | Resource/Capacity |
| Work Order Generation | Convert confirmed schedules into MES work orders for shop floor execution | Scheduling |
APS Overall Data Flow
Shows how the 9 menu areas are interconnected.
Menu Guide
Demand Planning Area
| Menu | Description | Detail Guide |
|---|---|---|
| Demand Planning | Demand forecasting, demand orders, ATP/CTP delivery confirmation, demand sensing, ATP allocation rules | From demand analysis to delivery confirmation |
Production Planning Area
| Menu | Description | Detail Guide |
|---|---|---|
| Production Planning | Production plan management, MRP execution, material requirements, safety stock, lot sizing, multi-plant transfers | MPS through MRP planning |
Resource/Scheduling Area
| Menu | Description | Detail Guide |
|---|---|---|
| Resource/Capacity | Work centers, calendars, capacity constraints, resource allocation, skill matrix, setup groups, tools/molds | Resource master and capacity management |
| Scheduling | Gantt charts, scheduling rules, setup sequences, SMED analysis | Finite capacity scheduling execution |
Analysis/Optimization Area
| Menu | Description | Detail Guide |
|---|---|---|
| Analysis/KPI | Bottleneck analysis, What-If scenarios, scenario comparison, S&OP, KPI, Monte Carlo, planning nervousness | Analysis and decision-making |
| Constraints | Constraint definitions, constraint violation history | Multi-constraint management |
| Optimization | Optimization algorithms, objective function weights, execution history, network optimization | Schedule and network optimization |
Shop Floor Area
| Menu | Description | Detail Guide |
|---|---|---|
| Shop Floor POP | Production plan status board, schedule board, capacity load, material availability, delivery progress, tool status | Shop floor touch terminal guide |
7 Automated Workflows
VEXPLOR APS automates core production planning and management processes through 7 workflows.
Planning Workflows
| Workflow | Description |
|---|---|
| WF1: Demand Planning | Demand forecast collection - auto-calculation - demand order generation - MPS creation - review - approval |
| WF2: Production Scheduling | MRP explosion - material shortage handling - finite capacity scheduling - resource allocation - schedule confirmation - work order generation |
| WF3: Capacity Planning | Load analysis - bottleneck identification - improvement recommendation - capacity adjustment review - rescheduling - KPI recording |
Analysis/Change Workflows
| Workflow | Description |
|---|---|
| WF4: What-If Analysis | Scenario creation - simulation execution - comparison analysis - adoption/rejection |
| WF5: Plan Change/Rush Order | Change request registration - impact analysis - approval - rescheduling - Frozen Zone check - MES synchronization |
| WF6: S&OP Process | Data collection - demand review - supply review - supply-demand gap analysis - financial/operational scenarios - executive meeting - plan update |
| WF7: ATP/CTP Delivery Confirmation | Inventory availability check - CTP production feasibility - multi-site alternative query - delivery confirmation/rejection |
APS and Other Solution Connections
| Linked Solution | Data Exchanged |
|---|---|
| ERP | Receive production orders/BOM, reflect MPS/MRP results, completion reporting |
| MES | Work order creation/modification, receive production results/delay information, plan vs. actual comparison |
| SCM | Receive material arrival schedules, urgent procurement requests, supplier lead time integration |
| WMS | Inventory availability query (ATP), material issue requests, finished goods receipt |