Four Commonly Overlooked Aspects in APS Application

>>Overlooking Strategic Planning and Goal Setting:

Many companies introduce APS without thoroughly analyzing their specific needs and the unique nature of their business processes. This lack of a clear strategic plan and specific goals leads to system selection and customization that deviates from actual requirements, failing to meet the unique production scheduling demands. Additionally, the absence of scientific and comprehensive implementation planning and strategies leads to frequent issues and project delays.

>>Overlooking the Importance of Data:

The efficient operation of APS depends on accurate and complete data support. Many companies face data silos, with poor data flow between systems, making it difficult to obtain high-quality key data needed by APS. This weak data foundation and system integration barriers significantly impact the overall effectiveness of the APS system.

>>Overlooking POC Verification for APS:

Each manufacturing enterprise has unique production processes. Without scenario verification (POC), the APS system may not fully adapt to the specific business processes of a company, leading to discrepancies between production plans and actual production, and posing other potential risks.

>>Overlooking Organizational Change Management:

Without proper cognitive training and change management within the organization, front-line employees may resist new systems, perceiving APS as a disruption to work habits and an additional burden. Furthermore, APS implementation is typically a "top management" project. A lack of necessary support and key decisions from management can hinder system promotion.

The main reasons for the difficulty in APS application include insufficient demand understanding and implementation planning, weak data foundation and system integration barriers, personnel training and cognitive obstacles, and inadequate continuous optimization and adaptability adjustments.

Established in 2009 as a joint venture between Zhuhai Gree Electric Appliances and Japan's Daikin Industries, Gree Daikin is a large-scale precision mold company focused on precision injection molds, sheet metal stamping molds, research and development, manufacturing, sales, and after-sales service. With over 450 employees and more than 200 CNC machines, Gree Daikin operates in fields including home appliances, automotive parts, consumer electronics, and medical devices.

With continuous business expansion, Gree Daikin faces urgent needs for improved production management efficiency, shortened production cycles, and personnel efficiency. To address these challenges, Gree Daikin decided to introduce EMAN's APS to comprehensively optimize production processes.

>>Challenges Faced:

In the project's initial phase, with more than 200 CNC machines and complex scheduling scenarios involving numerous molds, workpieces, and processes, Gree Daikin demanded high speed and accuracy from the smart scheduling system:

Workshop Production: Efficiently schedule approximately 200 sets of molds, 10,000 workpieces, and 100,000 processes to ensure smooth production.

Capacity Simulation: In simulated scheduling, handle approximately 900 sets of molds, 50,000 workpieces, and 500,000 processes to evaluate production potential.

>>Objectives and Execution Rules:

Through multiple rounds of communication, discussions, and optimization of production processes, EMAN and Gree Daikin jointly established objectives and execution rules for APS application:

APS Objectives:

• Enhance production management efficiency by 30-50%
• Shorten the average production cycle in injection and sheet metal sectors by 10-30%
• Improve personnel efficiency by 20-40%

Optimization Rules:

Minimize Order T1 Delays: Prioritize timely delivery of important orders.

Maximize Equipment Utilization: Improve equipment usage efficiency through smart scheduling.

Non-interference of Primary and Backup Resources: Flexibly schedule resources to avoid idle time.

Fastest Completion of Parts and Priority for Urgent Parts: Shorten the parts processing cycle and enhance response speed.

Prioritize Complete Parts Processing: Accelerate assembly processes and reduce finished product delivery time.

Constraint Rules:

Allocate limited and unlimited resources based on process characteristics.

Synchronize production of electrodes and steel parts to optimize production processes and shorten cycles.

Reserve programming time for task modification.

Ensure precision and safety in production through process constraints with equipment size, accuracy, and human skills.

Besides system rules, Gree Daikin has established a set of APS implementation methodologies:

• Detailed Mapping of Existing Processes: Comprehensive understanding of all aspects of current production management.
• Role-Based Production Planning Process Analysis: Define roles and responsibilities in production planning for each position.
• Learn APS System: Master system functions and operational key points.
• Analyze Differences Between APS and Existing Processes: Identify discrepancies and formulate adjustment plans.
• Develop Standard APS Application New Processes: Ensure scientific and feasible new processes.
• Establish KPI Indicators for Production Planning: Quantitatively evaluate the implementation effect of the APS system.
• Continuous Improvement: Optimize based on implementation effects to ensure long-term stable system operation.

>>Value and Benefits:

By introducing EMAN's APS system and establishing scientific implementation methods, Gree Daikin has achieved significant improvements in production management efficiency, production cycles, and personnel efficiency, laying a solid foundation for sustainable development competitiveness.