MPDV: Clearly arranged shop floor and optimized detailed scheduling with HYDRA by MPDV

Detailed Planning using HYDRA Shop Floor Scheduling (HLS)

Application & benefits
Optimum production control without bottlenecks or missed deadlines!
In order to remain competitive in the long term, production companies must plan effectively, utilize their resources efficiently and react quickly to customer demands. This also includes reliable scheduling for sales and customers.
HYDRA HLS supports planning your production processes by providing a 360° view of all of the required resources. The shop floor scheduling tool enables realistic detailed planning based on actual capacities and a proactive, responsive production control, which is faster and more effective than a centrally organized PPS or ERP system. To this end, HYDRA HLS accesses machine and shop floor data that is recorded in real time.
The central element of HYDRA HLS is the graphic planning board in the form of a Gantt chart. Scheduling your production orders and work steps, according to the individual production stages, directly onto the available machines (machine allocation) will remove the need for manually operated pegboards or confusing Excel spreadsheets. Instead, you’ll be able to respond in real time to changes in delivery quantities and deadlines, as well as critical situations at the machine or workstation.
Not only does HLS have the aforementioned benefits, but you can even integrate your planned material requirements, maintenance and tool setup control, and your personnel scheduling! These topics are constantly gaining importance for modern manufacturing companies.
Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.
Highlights
Responsive production planning and control
HYDRA HLS takes on the assignment of production orders to machines and takes into account other resources such as tools, test equipment, NC programs, materials and energy. Not only that, this HYDRA module compares actual personnel capacities (personnel scheduling) with the personnel requirements, which is the result of planning. Alternatively, HYDRA HLS determines the personnel requirements using a personnel scheduling function. The comparison of the resource requirements with the available resources takes place during the scheduling of operations, so that a possible resource shortage can be immediately spotted.
Highlights of the HYDRA HLS solution are:
Graphical planning board (Gantt chart) operated with user friendly drag and drop
Clearly arranged multi resource planning
Automatic planning based on assignment rules, KPIs and profiles (e. g. setup optimization)
Splitting and pooling of operations
Order networks spanning multiple hierarchy levels
Simulation, evaluation and optimization of planning scenarios
Intelligent and highly flexible planning algorithms
Support of evaluations like conflict lists, capacity utilization and utilization profile
Additionally, HYDRA HLS can be integrated with other HYDRA applications as required. Examples include:
Shop floor data collection
Machine data collection
Material management
Energy management
Tool and resource management
Personnel scheduling
Quality management
As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to integrate your requirements into the system conveniently.
Functions
Monitor the complete value chain
To ensure that everything runs smoothly in production, and to be certain tasks can be clearly distributed, your information must be available in the proper format. To accomplish this, the HYDRA shop floor scheduling tool offers numerous evaluations and functions. In order to avoid unexpected bottlenecks, detailed planning with HYDRA HLS is based on actual data and is measured against available capacities.
Detailed planning and production control
HYDRA HLS allows you to plan production orders and operations on machines and other resources. Possible resource conflicts are automatically checked and visualized. The result of the planning process is distributed to all departments involved at the push of a button.
Example functions
Flexible, configurable planning board containing a broad range of functions
Manual, semi- and fully automated assignments
Parallel planning of several resources (machine, tool, material, energy, personnel)
Posting of supporting order information (notes)
Split, fix and targeted release of operations
Mobile app for decentralized production control (Touch2Plan)
Graphic presentation of relationships between orders and work steps in the order network
Planning support
HYDRA HLS supports the production planner with the daily tasks using a multitude of information and functions that only an integrated MES can provide.
Example functions
Display and consideration of machine-related shift calendars and current performance levels
Scheduling of single-level and multi-level production orders (order networks)
Special functions for campaign management and to split orders
Flexible forward and backward scheduling
Strategies to cope with capacity bottlenecks
Automatic closing of assignment gaps
Adjustment of machine capacity in case of technical interruptions or maintenance
Evaluations
In addition to the specific lists for machines, planning with HYDRA HLS results in other useful reports and evaluations that support production-related departments in the processing of pending orders. Many of these reports would otherwise have to be maintained manually.
Example functions
Display an up-to-date shop floor plan, designed not to be edited, but to be viewable by users
Setup change list for work preparation
Material requirement list for intralogistics planning
Capacity peaks and utilization charts
Automatic calculation of personnel requirements
Print functions for assignment graphics and tables
Communication between ERP systems and the shop floor
HYDRA HLS is an important data hub which acts as a link between the higher-level ERP system and the shop floor applications. Information is processed in real time and distributed to all relevant departments.
Example functions
Processing of orders and operational steps from the ERP system
Displaying order backlog for machines and machine groups
Presenting a production list (sequence planning) on the shop floor terminal at the machine
HYDRA shop floor scheduling as an Advanced Planning & Scheduling System
In addition to the central functions for detailed planning and production control, HYDRA HLS offers similar functions normally attributed to so-called Advanced Planning & Scheduling Systems (APS). However, if you are looking to use an APS, you should check whether HYDRA HLS is suitable for your individual requirements on the basis of your desired functions.
Display of specific requirements
Because every production company has unique requirements, HYDRA offers a large array of versatile configuration options, while the advantages of a standard software can still be maintained.
Further details
Using master data and flexible configuration options, HYDRA HLS can be set up without interfering with coding:
Configurable planning scenarios
Variably adjustable planning and approval horizons
Individual shift calendar for each machine to compare true capacities
Consideration of consecutive tools and materials to optimize setup times (setup change matrix)
Functions to temporarily change resources (machine and workplaces)
Defining individually weighted planning algorithms
Incorporating a preexisting set of rules and planning profiles to divide the production into units that are easier to manage and schedules
Configuring the graphic display of operations
Modern development tools are available to customize HYDRA HLS according to your needs.
HYDRA HLS networked with many other MES applications
Unlike many ERP or PPS systems, the HYDRA HLS planning is based on real time data. Thanks to the seamless horizontal integration, HYDRA HLS accesses relevant production data collected via other MES applications.
Further details
Integration into shop floor and machine data collection
Transfer of progress messages from recorded shop floor data for permanent calculation of the remaining run time of operations
Transfer of sequence planning available at the shop floor terminal
Display and consideration of machine conditions and maintenance activities from recorded machine data
Integration into material management
Availability check for required raw material and semifinished products
List of material requirements
Preview on development of WIP levels
Integration into tool and resource management
Availability check for tools and other devices
Consideration of planned maintenance activities
Assignment of tools and devices based on planning data
Providing setup change list
Integration into energy management
Consideration of defined energy quotas
Energy efficient production planning based on collected energy consumption data
Integration into personnel scheduling
Consideration of available or scheduled personnel
Calculation and visualization of orderrelated personnel requirements
Display of planned personnel on the graphic planning board
Integration into quality management
Consideration of available test equipment
Assignment of test equipment
Confirmation to CAQ applications (e. g. production inspection) to make inspection plans available in time for the production start

Application & benefits

Optimum production control without bottlenecks or missed deadlines!

In order to remain competitive in the long term, production companies must plan effectively, utilize their resources efficiently and react quickly to customer demands. This also includes reliable scheduling for sales and customers.

HYDRA HLS supports planning your production processes by providing a 360° view of all of the required resources. The shop floor scheduling tool enables realistic detailed planning based on actual capacities and a proactive, responsive production control, which is faster and more effective than a centrally organized PPS or ERP system. To this end, HYDRA HLS accesses machine and shop floor data that is recorded in real time.

The central element of HYDRA HLS is the graphic planning board in the form of a Gantt chart. Scheduling your production orders and work steps, according to the individual production stages, directly onto the available machines (machine allocation) will remove the need for manually operated pegboards or confusing Excel spreadsheets. Instead, you’ll be able to respond in real time to changes in delivery quantities and deadlines, as well as critical situations at the machine or workstation.

Not only does HLS have the aforementioned benefits, but you can even integrate your planned material requirements, maintenance and tool setup control, and your personnel scheduling! These topics are constantly gaining importance for modern manufacturing companies.

Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.

Highlights

Responsive production planning and control

HYDRA HLS takes on the assignment of production orders to machines and takes into account other resources such as tools, test equipment, NC programs, materials and energy. Not only that, this HYDRA module compares actual personnel capacities (personnel scheduling) with the personnel requirements, which is the result of planning. Alternatively, HYDRA HLS determines the personnel requirements using a personnel scheduling function. The comparison of the resource requirements with the available resources takes place during the scheduling of operations, so that a possible resource shortage can be immediately spotted.

Highlights of the HYDRA HLS solution are:

Graphical planning board (Gantt chart) operated with user friendly drag and drop
Clearly arranged multi resource planning
Automatic planning based on assignment rules, KPIs and profiles (e. g. setup optimization)
Splitting and pooling of operations
Order networks spanning multiple hierarchy levels
Simulation, evaluation and optimization of planning scenarios
Intelligent and highly flexible planning algorithms
Support of evaluations like conflict lists, capacity utilization and utilization profile

Additionally, HYDRA HLS can be integrated with other HYDRA applications as required. Examples include:

As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to integrate your requirements into the system conveniently.

Functions

Monitor the complete value chain

To ensure that everything runs smoothly in production, and to be certain tasks can be clearly distributed, your information must be available in the proper format. To accomplish this, the HYDRA shop floor scheduling tool offers numerous evaluations and functions. In order to avoid unexpected bottlenecks, detailed planning with HYDRA HLS is based on actual data and is measured against available capacities.

Detailed planning and production control

HYDRA HLS allows you to plan production orders and operations on machines and other resources. Possible resource conflicts are automatically checked and visualized. The result of the planning process is distributed to all departments involved at the push of a button.

Example functions
Flexible, configurable planning board containing a broad range of functions
Manual, semi- and fully automated assignments
Parallel planning of several resources (machine, tool, material, energy, personnel)
Posting of supporting order information (notes)
Split, fix and targeted release of operations
Mobile app for decentralized production control (Touch2Plan)
Graphic presentation of relationships between orders and work steps in the order network

Planning support

HYDRA HLS supports the production planner with the daily tasks using a multitude of information and functions that only an integrated MES can provide.

Example functions
Display and consideration of machine-related shift calendars and current performance levels
Scheduling of single-level and multi-level production orders (order networks)
Special functions for campaign management and to split orders
Flexible forward and backward scheduling
Strategies to cope with capacity bottlenecks
Automatic closing of assignment gaps
Adjustment of machine capacity in case of technical interruptions or maintenance

Evaluations

In addition to the specific lists for machines, planning with HYDRA HLS results in other useful reports and evaluations that support production-related departments in the processing of pending orders. Many of these reports would otherwise have to be maintained manually.

Example functions
Display an up-to-date shop floor plan, designed not to be edited, but to be viewable by users
Setup change list for work preparation
Material requirement list for intralogistics planning
Capacity peaks and utilization charts
Automatic calculation of personnel requirements
Print functions for assignment graphics and tables

Communication between ERP systems and the shop floor

HYDRA HLS is an important data hub which acts as a link between the higher-level ERP system and the shop floor applications. Information is processed in real time and distributed to all relevant departments.

Example functions
Processing of orders and operational steps from the ERP system
Displaying order backlog for machines and machine groups
Presenting a production list (sequence planning) on the shop floor terminal at the machine

HYDRA shop floor scheduling as an Advanced Planning & Scheduling System

In addition to the central functions for detailed planning and production control, HYDRA HLS offers similar functions normally attributed to so-called Advanced Planning & Scheduling Systems (APS). However, if you are looking to use an APS, you should check whether HYDRA HLS is suitable for your individual requirements on the basis of your desired functions.

Display of specific requirements

Because every production company has unique requirements, HYDRA offers a large array of versatile configuration options, while the advantages of a standard software can still be maintained.

Further details
Using master data and flexible configuration options, HYDRA HLS can be set up without interfering with coding:
Configurable planning scenarios
Variably adjustable planning and approval horizons
Individual shift calendar for each machine to compare true capacities
Consideration of consecutive tools and materials to optimize setup times (setup change matrix)
Functions to temporarily change resources (machine and workplaces)
Defining individually weighted planning algorithms
Incorporating a preexisting set of rules and planning profiles to divide the production into units that are easier to manage and schedules
Configuring the graphic display of operations
Modern development tools are available to customize HYDRA HLS according to your needs.

HYDRA HLS networked with many other MES applications

Unlike many ERP or PPS systems, the HYDRA HLS planning is based on real time data. Thanks to the seamless horizontal integration, HYDRA HLS accesses relevant production data collected via other MES applications.

Further details
Integration into shop floor and machine data collection
Transfer of progress messages from recorded shop floor data for permanent calculation of the remaining run time of operations
Transfer of sequence planning available at the shop floor terminal
Display and consideration of machine conditions and maintenance activities from recorded machine data
Integration into material management
Availability check for required raw material and semifinished products
List of material requirements
Preview on development of WIP levels
Integration into tool and resource management
Availability check for tools and other devices
Consideration of planned maintenance activities
Assignment of tools and devices based on planning data
Providing setup change list
Integration into energy management
Consideration of defined energy quotas
Energy efficient production planning based on collected energy consumption data
Integration into personnel scheduling
Consideration of available or scheduled personnel
Calculation and visualization of orderrelated personnel requirements
Display of planned personnel on the graphic planning board
Integration into quality management
Consideration of available test equipment
Assignment of test equipment
Confirmation to CAQ applications (e. g. production inspection) to make inspection plans available in time for the production start