Bucket-Oriented Planning vs. Sequencing with APS Software

Bucket-oriented planning and sequencing with APS software represent two distinct approaches in production planning and scheduling systems. While bucket-oriented planning may be suitable for simpler environments, it no longer meets the demands of today’s complex production processes. Sequencing with APS software offers clear advantages for companies aiming to stay competitive.

Various providers of planning and scheduling solutions rely on the principle of bucket-oriented planning when it comes to production scheduling. In this approach, tasks are assigned to resources or resource groups for a specific period—such as a day or a weekThese tasks are grouped into so-called “buckets,” and supervisors or machine operators decide on the priorities or sequence of execution based on their experience or individual preferences. Tasks that remain unfinished within the given time frame are simply carried over to the next bucket. However, this approach has significant drawbacks:

1. Sequential Processes: If three processes each have ten tasks in a bucket and process owners set their own priorities, lead times can increase exponentially.
2. Parallel Processes: In scenarios where three parallel processes, each with multiple steps, converge for final assembly, poor timing can cause substantial delays.
3. Progress Monitoring: Tracking progress and adjusting plans when necessary is nearly impossible.
4. Delivery Deadlines: Accurately determining completion dates is unfeasible, making it difficult to provide reliable delivery commitments to customers.
5. Synchronization and Lead Times: Synchronizing processes and completing orders within the shortest possible lead times is not achievable.
6. Idle Times and Semi-Finished Goods: Extended idle times and excessive inventories of semi-finished goods between processes are inevitable.
7. Standardization: Because production sequencing is determined by individual employees, the planning process lacks standardization, leading to inconsistent production outcomes.
8. Efficiency: While each process owner may aim for local efficiency, the lack of an overarching view means these efforts have minimal impact on overall efficiency.
9. Process Integration: Products are often produced through multiple parallel processes, yet linking sales orders to production orders is rarely possible, making the factory operate like a “black box.”

The result: bucket-oriented planning leads to long lead times, high inventory levels, and poor delivery performance. While this method might work for simple production environments—such as manufacturers with only one process or small workshops—it is no longer practical in today’s increasingly complex manufacturing landscape.

In APS systems, tasks are scheduled in a defined sequence and within a specific time frame, with each task assigned a precise start and end time. This approach often uses Gantt charts to visually represent schedules, providing a clear overview of task sequences. The advantages include:

• Sequential Processes: Sequencing automatically determines the optimal order for resources, ensuring that orders are completed on time and with the shortest possible lead times.
• Parallel Processes: APS software generates a sequence schedule for each resource, minimizing idle times between processes and optimizing the timing for process convergence.
• Progress Monitoring: Production progress can be tracked visually and in near real-time.
• Delivery Deadlines: Completion and delivery dates are calculated precisely down to the day, hour, and minute.
• Synchronization and Lead Times: Processes are reliably synchronized, enabling orders to be completed in the shortest possible lead times.
• Idle Times and Semi-Finished Goods: Idle times and inventories of semi-finished goods between processes are significantly reduced.
• Standardization: The processes of scheduling and control are highly standardized, ensuring consistency across operations and reducing variability in production outcomes.
• Efficiency: APS focuses on overall efficiency, allowing users to define and prioritize goals, such as on-time delivery, high factory output, or cost reduction. Additionally, process and resource productivity is optimized, for example, through reduced setup times.
• Process Integration: APS seamlessly links sales orders with production orders, whether for one-piece flow or batch production.

Say goodbye to buckets and switch to state-of-the-art sequencing. Asprova APS makes it possible—efficiently, precisely, and trusted by over 3,600 customers worldwide. Be one of them.