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In this video, we will talk about the basic differences between the HAL APS system and production planning and scheduling offered by ERP systems.

Let's start with the specifics.

First, ERP is based mainly on MRP calculations and focuses on materials, not on planning the optimal work of production resources.

Second, in ERP systems, the sequence to be scheduled is based mainly on dates. With a sequence built in this way, optimizing the changeover is difficult or most often impossible, and the possibility of manipulating the order of tasks to be scheduled is practically non-existent. Production workers very often simply produce in their own way.

Third, ERP does not balance all production resources involved in scheduling. It focuses on a single resource.

Such a schedule must be corrected on the production floor, because no one really knows which position to deliver the material to. There is no guarantee of availability, tools and people.

Fourth, ERP scheduling uses resources with infinite production capacity, creating overloads. Such a plan must be manually corrected. It is unrealistic.

Fifth, ERP does not understand primary, secondary, tertiary constraints, etc.

Sixth, ERP is based on a single scheduling scenario, with several parameters.

Seventh, ERP adds hundreds or thousands of exception messages to an overloaded schedule as a bonus, which in practice no one reads.

Eighth, ERP does not support changeover matrices and does not optimize changeovers, does not support scheduling of human resources, competences, splitting, resources with finite production capacity, batch resources, extended routes, multi-level BOMs, advanced calendars, extended scheduling rules, does not optimize batches, does not know how to select resources for operations, cannot create relationships between resources in technology. There are minor exceptions in some points, but the algorithms implemented by ERPs are trivial.

Ninth, ERP / MRP plans and balances everything down to the day, i.e. it doesn't matter whether the delivery is at 6:00 or 14:00. The level of detail is a production order, not a technological operation.

Tenth, in ERP, production on the customer's order is anonymous, so it is difficult to manage production variability. Once an order is released, it is better not to touch it, or to delete it and start all over again.

Only APS has a real chance to increase customer satisfaction and achieve measurable business goals in production. From ERP, you will upgrade to MS Excel sooner or later. Brutal, but that's how it looks.