The advantage of EFA Scheduling Software and Algorithm

Makespan - Production Planning & Scheduling Solutions Ltd.

Why EFA

The main advantage of EFA scheduling software is its ability to optimize production while maintaining your instructions and constraints (due dates, arrival dates of raw materials etc.). This is due to its unique and powerful sequencing and scheduling algorithm. EFA schedules the jobs according to their contribution to smooth and maximum material flow. In addition a simulation module which is included in the scheduling software enables the planner to make adjustments and sometimes to improve the production planning efficiency, actually the planner can intervene at almost every stage of the scheduling process. EFA doesn't use rules which are based on one parameter such as "select the shortest setup time" or "minimize work in process", although it considers setups and work in process in its calculations. It also doesn't use rule of thumbs like SPT, FCFS, EDD, FIFO etc. (It uses EDD - Earliest Due Date Planning as a reference to evaluate the efficiency planning of EFA).

The development of an optimal and applicable planning algorithm depends mainly on:
- An idea based on experience.
- Knowing and considering the users’ wishes.
- Patience and diligence, instead of “Time to Market”. Developing an efficient and effective algorithm is a long way process. Almost like in pregnancy the development time cannot be shortened even when the developing team is increased. For this reason "Time to market" as an essential business consideration will undoubtedly result in a poor algorithm and software.

The "EFA" algorithm was created and written by an Industrial Engineer with an experience of twenty years as a production manager and planner in Job Shops and Flow shops in several industries. Operating infinite and finite capacity systems (MRP, Bottleneck Based, and others) as well as manual planning using Common Sense was a part of his duties. Knowing the systems he used and the strong feeling, based on his experience, that he can do it better led to the development of the Evenly Feeding Algorithm. The algorithm together with the software was built step by step with no short cuts during a long period. The bottom line is that EFA is a very easily usable and efficient software which can reduce your total lead time and increase throughput. The extra throughput, almost with no additional cost (except raw materials) affects the plant’s profit considerably.

Many software producers are proud of their system contribution to the plant's efficiency and performance. This is true, but what is the reason?

Any new system which includes a production control element may improve the plant's efficiency, mainly in factories which have a low production level control. This is because the system forces the factory to work in an organized way based on reliable data. We are speaking about the efficiency that can be received beyond that: either increasing throughput up to 40% as compared to simple scheduling (based on rules like those mentioned above), or increasing throughput up to 20% as compared to more sophisticated scheduling (done by a planner who uses Common Sense and is assisted by a simulation software).

You may ask if there is any risk in buying a software package from a small software house. The answer depends on what sort of software you buy. Software like ERP incorporates all systems and organizational functions of the firm. Since a failure of ERP could severely affect the firm it is recommended to buy ERP from a well known software house with an efficient supporting system even if the software package is not the best one. Unlike ERP, EFA if fails will only temporarily reduce your performance and profit to the value that you have today until the fault is fixed. Therefore what counts in a scheduling software like EFA is mainly its ability to optimize production and increase shop floor performance. Actually once EFA functions correctly in your shop floor it will work without any problem. In any case just because we are a small software house we will try harder to support you on time.

Another question that might be raised by those who already have a system like ERP is, what is the point of buying our software ?. ERP systems usually use MRP-II or simple dispatching rules for planning. Therefore although their contribution to the plant is most significant, from the production point of view it is not sufficient. One can compare an ERP system without a sophisticated algorithm to a yacht or cruise ship without a GPS system. Although EFA can work as stand alone, the best way to use EFA is in conjunction with ERP (or any other system) so that ERP provides the relevant input data which enables EFA to optimize production.

But the main question is whether EFA suits your shop floor. How can you be sure that EFA will improve your performance and profit?
In order to assure you that EFA is the right scheduling software for you we suggest the following steps:
1. Getting a first impression about the ability of EFA .
Send us a simple description of your shop floor and an example of an order list with the necessary parameters for planning: layout of the shop floor, product structure, process parameters etc. (please look at the CAST and PCB examples). Once we get it, we will open a dialog in order to roughly model your shop floor. The planning results of this stage will enable you to get a first impression about the ability of EFA to improve your performance and profit. Note; if you already have a scheduling software you can also solve the CAST and PCB examples and compare the results to those obtained by EFA.
2. Detailed modeling of your shop floor.
Mapping your process and knowing the relevant parameters are essential for EFA to optimize production. Therefore we will continue our dialog in order to further model your shop floor. In addition we will define the input data needed for planning. In case you have ERP, MRP or any MES system, input data files could be derived from your data base; otherwise we will send you templates of input files in EXCEL or in text format.
3. Trying EFA in your shop floor.
We will send you a free copy of EFA scheduling software with operating instructions for a limited time.