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BellHawk Online Dynamic Production Scheduling and Materials Planning Solutions

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BellHawk Online provides better way to do production scheduling and materials requirment planning for manufacturers that make products in small batches to customer order on a quick-turnaround basis.

Traditional Materials Requirement Planning (MRP) algorithms found in ERP systems or shop-floor control systems start with a plan for the products to be made over the next few weeks or months and then the MRP system determines what materials need to be purchased and what need to be made and when. This planning may or may not take into account the people and machines that are expected to be available in future.

Because things never go as planned (orders get changed, machines break down, employees are out sick, materials are not available in time) the MRP schedule has to be adjusted, typically at a meeting of production supervisors, at the begining of each shift.  Often further deviations from this new schedule, during a shift, have to be spotted and compensated for by supervisors "walking-the-floor".

All of which wastes a lot of time and valuable and expensive people resources. It also often results in poor scheduling with machines and people waiting for work they were scheduled to do or for materials they were supposed to work on.

We observe many organizations that are wasting the valuable time of managers and supervisors by using these antiquated planning and scheduling methods. The time wasted often amounts to the time of between one to three people at a loaded labor rate of over $100,000 per year each, which could be saved by using a BellHawk Online system.

BellHawk Online takes a different approach, by dynamically scheduling work to be done based on the current status of operations and promised delivery dates. This makes optimum use of available resources to get orders out on time and does not require periodic total rescheduling, as in an MRP system, as all the rescheduling is done dynamically, with minimal time required from production managers and supervisors. Not only does this take account of all the things that tend to go wrong but it allows for the introduction of priority jobs in the middle of a shift.

As a companion to this, the BellHawk Online dynamically predicts available inventory based on physical inventory less materials needed for work orders or to be shipped plus materials on order on Purchase Orders (POs) and materials to be made on work orders. This information can then be used by a production manager, with the aid of the BellHawk DRP (Dynamic Resource Planning) module, to determine what materials need to be ordered and made and when in response to each new customer order, as it is received.

The difference from classic MRP is that in a BellHawk Online system, planning and scheduling is adjusted dynamically as orders arrive or change. There is no need to disrupt production by rescheduling everything. New jobs are automatically slipped into the production schedule, as needed, without any disruption to the flow of materials through work centers.

Best of all theBellHawk Online solution is available for around $1,000/month, including complete production and inventory tracking, warehouse management, and dynamic scheuling and planning.