APS Scheduling Module

In the modern steel and roll-manufacturing industry, products often come in multiple specifications, small batches and bespoke orders, with complex workflows and tight production rhythms. Our MES platform’s built-in APS (Advanced Planning & Scheduling) module, driven by multi-dimensional constraints and multi-objective optimisation algorithms, uses a Rolling Programme, automatically generated cutting-line lists and loading instructions to achieve dynamic synchronisation of planning and execution, maximising manufacturing accuracy and resource efficiency.

1. Core Features

1.1 Rolling Programme Synchronisation

• Unified Week-and-Section Management
  Auto-generates a rolling schedule from the plant calendar, marking each Week Number and Section against available equipment and shifts.

• Real-Time Adjustments
  On order changes or shop-floor exceptions, the schedule updates instantly—respecting customer due-dates, inter-operation buffers and maintenance windows.

• Mandatory Constraint Modelling
  Ensures the plan is executable by enforcing:

  • Process routing: Adherence to product-specific workflows (rolling → annealing → cutting → inspection).
  • Resource capacity: Equipment, line and personnel availability & throughput (including shift plans and downtime).
  • Material supply: Raw and semi stock pulled from live inventories.
  • Auxiliary tools: Tooling, dies and fixtures allocated without conflicts.
  • Quality requirements: Material grades, hardness and tolerance specifications upheld.

1.2 Automated Cutting Saw Line Summary

• Order-Driven Cutting Strategy
  The system reads both Sales Orders and Planned Orders, distinguishing between "customer dispatch" and "inventory transfer" demands, then intelligently splits or merges orders to match roller specifications and batch requirements.
• Auto-Generated Saw Line Cutting Lists
  A detailed saw-cut list is produced automatically - specifying each roller’s cut lengths, quantities and priorities—to help the workshop organise production swiftly.

1.3 Intelligent Loading-Instruction Scheduling

• Automated Load-Demand Matching
  Before rolling, the system assesses order type and production progress to calculate required loads of finished goods, trim allowances and inspection reserves.
• Auto-Issued Loading Instructions
  Through the MES execution layer, loading instructions are generated and dispatched automatically, clearly indicating to the Pilier operator (shop-floor scheduler) the quantities and storage locations for:
  • Semi items to be cut
  • Material to be rolled
  • Finished products to be tied, loaded and dispatched

2. Constraint-Based Fine Scheduling

• Process-Route & Operation Constraints
  Strict adherence to sequences—rolling, annealing, cutting, inspection—and support for complex steps such as re-winding and on-line re-profiling.
• Equipment & Capacity Constraints
  Considers availability, throughput and shift patterns for roll mills, saws and cranes, including maintenance windows and downtime allowances.
• Material & Inventory Constraints
  Live ERP integration ensures billets, strip and semi rollers are available, driving dynamic MRP adjustments.
• Time & Delivery Constraints
  Rigid control of customer due-dates and internal buffers, with both backward- and forward-scheduling modes.
• Quality & Compatibility Constraints
  Accounts for roller material grades, hardness and die compatibility to safeguard product integrity and equipment safety.

3. Multi-Objective Optimisation & Intelligent Decision-Making

• Maximised On-Time Delivery
  Prioritises urgent orders and key customers to uphold delivery commitments.
• Balanced Equipment Utilisation
  Load-balancing algorithms minimise changeovers, boosting OEE (Overall Equipment Effectiveness).
• Minimised Production Cost
  Optimises cut sequences and loading batches to reduce energy consumption, tooling wear and WIP inventory.
• WIP & Inventory Control
  Dynamic WIP monitoring shortens material lead-times and lowers storage costs.
• Flexible Priority Rules
  Customisable rules—by product value, contractual terms or batch—support FIFO, batch-homogeneous runs and other modes.

4. Advanced Algorithms & Real-Time Rolling Optimisation

• Hybrid Optimisation Solver
  Combines heuristics and operations-research techniques (genetic algorithms, integer/linear programming) to converge rapidly on near-optimal solutions.
• Dynamic Feedback Closed-Loop
  Live shop-floor data (machine status, yield feedback, quality metrics) triggers rolling-window re-optimisation or full rescheduling.
• Configurable Rule Engine
  Scheduling rules (batch splitting/merging, priority shifts, downtime compensation) can be updated on-the-fly without system restarts.

5. Deep Integration & Data-Driven Insights

APS typically integrates deeply with upstream and downstream systems—MES, ERP, LIMS—via multi-layer interfaces and data models to achieve end-to-end production, material and quality data exchange:

5.1 Key Data Flows & Scenarios

Source	Data Type	Use Case
ERP	Customer orders, planned orders, material master data	• Fetch order due-dates/quantities • Retrieve stock availability & procurement parameters
MES	Equipment status, real-time yield, consumable usage	• Sense roll-mill & saw states for dynamic cadence adjustment • Track WIP progress
LIMS	Chemical-composition reports, mechanical-property tests	• Enforce quality constraints (hardness, alloy content) • Fit optimal process parameters

• ERP → APS
  1. Master Production Schedule (MPS): Pulls daily MPS data to drive rolling-schedule demand.
  2. BOM & Routing: Imports latest BOM and standard process routes to map APS resource models.
• APS → MES
  1. Dispatch Instructions: APS issues detailed work packages (order numbers, operation sequences, equipment assignments).
  2. Shop-Floor Feedback: MES pushes machine start/stop, OEE and alarm data back to APS to trigger rolling updates or alerts.
• LIMS → APS
  1. Quality Parameters: LIMS writes back material batch’s chemical and physical attributes after test approvals.
  2. Online Quality Monitoring: Deviations trigger APS to adjust subsequent schedules or launch compensatory plans.

5.2 Integration Benefits

• End-to-End Traceability: Data from order to material issuance, rolling, cutting and loading is logged in APS—meeting ISO/TS and IATF 16949 requirements.
• Closed-Loop Planning & Execution: Real-time production and quality data drive rolling optimisations—automating “plan → execute → feedback → re-plan” with minimal human intervention.
• Transparent Decision-Making: A unified data platform with Gantt charts, dashboards and KPIs supports cross-functional collaboration.
• Scalable Architecture: Modular interfaces and a configurable rule engine make it easy to integrate WMS, TMS and other systems—building a smart-manufacturing ecosystem.

6. Realised Benefits

1. Improved On-Time Delivery: > 95 % punctuality, rapid market response
2. Enhanced Equipment Efficiency: + 10 % OEE, – 20 % changeover frequency
3. Cost Reductions: – 5 % to 8 % in tooling and WIP costs
4. Operational Efficiency Gains: – 50 % manual scheduling time, greater transparency and collaboration
5. Agile Supply-Chain Support: Handles multi-variety, small-batch, rapid-change demands—empowering lean, intelligent manufacture

By harnessing these APS scheduling capabilities, your MES achieves a true closed-loop from planning to execution to feedback—“schedule on demand, dispatch intelligently, optimise continuously”—laying the foundation for an agile, high-performance steel and roll manufacturing ecosystem.