APS System Success: 6 Golden Rules for Seamless Implementation

The decision for an APS system is made, but the journey’s just begun. Don’t let ambition be your only plan. Before take-off, define your clear goals: What production roadblocks will the APS have to conquer? Which APS system best suits my needs and budget? And what internal steps will ensure a smooth rollout for my company? 

Choosing the right APS system isn’t a one-size-fits-all game. Providers offer specialised solutions with unique philosophies, often targeting to specific industries. This guide unveils the key considerations for decision-makers and planners navigating the diverse world of APS software. By understanding these factors, you’ll be well equipped to compare options and find the perfect fit for your company and its specific production needs.

What is an APS system and what are its benefits?

APS software, which stands for Advanced Planning and Scheduling, acts as your production planning mastermind. An APS system analyses data from across your production line, including materials, machines, and personnel, to optimise their use in the planning and scheduling process.

Here’s what APS software does:

• Identifies bottlenecks: By analysing all data relevant to production, it pinpoints areas where things could slow down, like overloaded machines or material shortages.
• Optimizes your schedule: It uses this information to create a more efficient production schedule, taking into account real-world constraints.
• Boosts transparency: With APS systems, you have clear visibility into your entire production process, allowing for better decision-making.
• Improves flexibility: When unexpected changes arise, APS software can quickly adjust the schedule to minimise disruptions.

Another major advantage of APS software is its modular use. It integrates with existing systems like ERP (Enterprise Resource Planning) and MES (Manufacturing Execution System) to give you a complete picture of your manufacturing process.

APS system success: Start strong with clear goals

Identify Bottlenecks: Analyse your current production data to pinpoint areas experiencing delays or resource congestion. Are specific machines overloaded? Do material shortages cause frequent disruptions? Clearly define these pain points to guide your APS implementation strategy.

Set SMART Objectives: Don’t settle for generic goals like “improve efficiency.” Establish Specific, Measurable, Achievable, Relevant, and Time-bound objectives. For instance, aim to “reduce production lead time by 15% within the next six months through optimised scheduling with APS.”

Align Department Goals: Break down silos between departments with a unified vision. Production may prioritize on-time delivery, while sales focus on meeting customer demands. Procurement might aim for lower inventory levels. APS ssystems can bridge these gaps by optimizing the entire process for everyone’s benefit.

Don’t settle for Clunky Software: Great business tools should be powerful and user-friendly. Beyond functionality, prioritise a sleek web interface, smooth connections to other systems, and seamless integration into your existing setup.

No effective APS software without creating an integrated planning model

The success of an APS system depends on how well it aligns with your company’s specific needs. Skip the generic RFPs (which may be useful for shortlisting vendors or testing their responsiveness and understanding of the topic of planning and scheduling) and invest time in a thorough evaluation phase. Focus on matching the system’s capabilities to your unique production processes and constraints.

Good providers go the extra mile. They’ll analyse your existing data, identifying any missing pieces crucial for your planning and scheduling goals. For example, a modern APS system accepts for built-in consistency checks.

The final step? A preliminary planning model built with your actual ERP/MES data. This can be done as part of a “proof of concept”, for example, allowing you to see the system in action, analyse specific use cases with your own data, and define implementation steps.

This approach benefits everyone. You gain a clear understanding of the power APS software offers, while recognising the irreplaceable expertise of your planners. At the same time, it shows the limits at which intelligent intervention and interaction by planners is required.

Don’t fly blind: Don’t settle for promises, seek proof

Selecting an APS system is a big decision. Don’t settle for generic promises! Invest time in thoroughly vetting potential providers.

Look for industry cred: Request references from companies in your sector and size. Does the provider have deep experience in your specific industry? Can they tailor a solution that seamlessly integrates with your existing systems and addresses your unique challenges?

Seek user insights: The best endorsement? Existing users! Look for providers who actively connect you with other user companies through reference visits or customer events. These interactions offer invaluable insights. Learn from their experiences, minimize potential pitfalls, discover new solutions, and clarify questions directly with fellow users.

A collaborative win-win: Engaging with existing users offers a treasure trove of insights. Learn from their experiences, minimize potential roadblocks, discover new solutions, and clarify questions directly. This valuable knowledge empowers you, while the provider receives feedback for ongoing development. It’s a win-win that ensures you choose the right partner for your APS journey.

Onboard your team: Planners are key to APS success

Embrace the future, together! Your production planners are the future users of the new APS system. That’s why involving them early in both selection and project planning is crucial. Early involvement fosters acceptance and quells doubts right out of the gate.

Understanding is Key: The realization that an APS system can actually mirror their existing procedures, making daily work easier, can encourage a positive shift in perspective for planners. However, patience on all sides is essential. We must value the planners’ viewpoint and their years of experience – this knowledge is vital! The APS system needs to be built around their expertise, not replace it. It’s about creating a meaningful partnership, a symbiosis that supports their increasingly complex daily tasks.

The goal of APS isn’t to eliminate planners, but to empower them. By capturing and systematizing their valuable knowledge within the system, the APS becomes an extension of their expertise, allowing them to focus on higher-level tasks and achieve new levels of production efficiency.

Success requires a team approach. Planners often work collaboratively, juggling limited resources like machines and production lines. This is where APS software shine!  Real-time visualization and other features dramatically reduce the coordination burden for your planners. Freed from these tasks, they can focus on achieving operational and strategic planning and scheduling goals.

Management support: Fuelling your APS journey

Planners on board? That’s a great sign! But to truly unlock the full potential of APS, you need the support of the people who holds the purse strings: your company’s senior management. They need to be firmly behind the idea of APS, recognising its need for growth and securing a competitive edge.

A half-hearted implementation of an APS system is a recipe for failure. It is a strategic decision that requires careful planning and a dedicated time investment. Project leaders must be given the necessary time to ensure a smooth implementation, and they must have the unwavering support of senior management.

Management buy-in is crucial. Implementing APS necessitates resources, both financial and human. Leadership support ensures that these resources are readily available. Additionally, such a project can often act as a catalyst for a cultural change within your organisation. Processes can be critically examined, and a mindset can be created for more digitalisation in the production environment. While challenges are inevitable during implementation, strong leadership provides the resolve and resources to persevere and overcome these hurdles.

Building your APS roadmap: Bitesize steps for big success

Internal buy-in secured? Now comes the exciting part: creating a realistic project plan for your APS software implementation. Forget about one giant leap! This plan thrives on achievable milestones, not aiming for the ultimate goal all at once. Realistic planning is key. Don’t overestimate your capabilities. Often, essential data is missing and needs to be analysed and systematised first. Focus on attainable steps.

What matters most? Defining initial goals with the biggest impact on your company. This is where experienced consultants from the system vendor shine. They’ll help break down the broad goal of “better, more efficient planning” into smaller, achievable targets.

Maximising your value: A good system provider prioritises your success. They’ll leverage their standard system first, minimising expensive customisations. However, if the APS system doesn’t fully meet your unique needs, the vendor should have the expertise and resources to develop modern, user-friendly further enhancements.

Conclusion: Efficient production planning starts with a well-planned APS software implementation

Production planning getting trickier? Complex order networks are the new normal. That’s where APS systems like GANTTPLAN come in! Many companies rely on them to achieve high planning accuracy, resulting in faster throughputs and on-time deliveries.

But a successful APS journey requires careful preparation. Everyone – from planners to senior management – needs to be involved. Remember, the APS system is meant to empower your production planners, not replace them. The more carefully you plan the introduction, the smoother the implementation.

Savvy vendors will involve all stakeholders in designing and modelling the solution right from the start. Why? Because only a system tailored to your company’s unique needs can deliver the maximum benefit. By embarking on a well-planned APS journey, you’ll unlock a new era of efficient production planning and scheduling that will drive your business forward.