Constraints Management has revolutionized manufacturing planning by providing an approachable strategy to focus available resources towards efforts that have the highest statistical likelihood of constraining dependent efforts. Sabe’s Adaptive Buffer Management takes these tools further, providing tool to define for buffer size and placement and signaling to the materials planner. However, small to mid-tier manufacturing companies, with their "lumpy" demands and more significant resource constraints, can struggle with planning tactics that emphasize maintaining statistically generated buffers over pending demand.
We've addressed the need for more pertinent signaling with Sabe's Constraint Status. Sabe's Constraint Status combines the visual signals of buffer management with the buffer penetration of stock on hand, showing the you the statistical likelihood of a material constraint, in conjunction with the pending consumption of current stock on hand. This allows you to prioritize resources more effectively than by judging the importance of an order by the buffer penetration alone. Constraint Statuses not only inform you as to what might happen but also what is about to happen with a highly approachable graphical representation.
An Itemsite's or Order's Constraint Status is composed of two regions: the Buffer Status and the Stock Status.
|Buffer Status||Stock Status|
|When the Item in question is buffer planned the green, yellow, and red zones of the Buffer Status portion of the Constraint Status graphic provides a visual representation of the current inventory level with respect to your planning inventory buffers.||The Stock Status portion of the Constraint Status graphic shows the amount of predicted penetration into the current inventory level of all of the pending demand over the Reaction Time. This provides a quick check into the near term replenishment plan and highlights any pending inventory constraints. Additionally, the penetration graph is color coded to offer additional guidance.|
|Blue||The AOH is not projected to drop below the Reorder Pointer during the RT.|
|Green||The AOH is projected to drop before the Reorder Pointer during the RT but orders have been placed to prevent a Stockout.|
|Yellow||The AOH is projected to drop below the Reorder Point during the RT and one or more replenishment orders placed are late.|
|Red||The AOH is projected to drop below the Reorder Point during the RT and orders have not been placed.|
|Dark Red||A Stockout is projected over the RT.|
Order Status: When a Constraint Status is determined for an Order, additional information regarding the inventory availability of the Order's components, i.e. Work Order materials or Sales Order Items, is provided:
|Itemsite||The current inventory level has penetrated into the Safety Stock. Of the inventory on hand, little will be used over the RT.|
|Itemsite||The Buffer Status is simular to the above, but there is greater consumption of the inventory on hand. There are replenishment orders to replace the consumed inventory.|
|Itemsite||The current inventory level has not penetrated into the Buffer Stock, but there is a large spike in consumption over the RT and no replenishment orders have been placed.|
|Itemsite||The current inventory level has penetrated into the Safety Stock and there is very little remaining, but there are no pending allocations over the RT.|
|Work Order||The current inventory level has penetrated into Buffer Stock and there is very little remaining and, even though components exists that will allow this Work Order to be released immediately, doing so will not prevent a Stockout condition over the RT.|
|Production Workbench: Quickly prioritize Work Orders by the Constraint Status and understand the availability of all components in an instant.||
|Inventory Availability by Work Order: View the Constraint Status of all of a Work Order's components to immediately identify those which will prevent a Work Order from being completed.|