i2 Introduces New Planning Solution
10 May 2000
i2 Introduces New Planning Solution to Increase Lean Manufacturing Benefits
DALLAS--May 10, 2000--i2 Technologies, Inc. , the leading provider of intelligent eBusiness solutions, is extending its manufacturing offering to include a new solution, Lean Planning. Available today, this solution increases the benefits of lean manufacturing by reducing inventories and improving throughput in complex, constrained environments that lean manufacturing techniques alone do not efficiently address."Implementing Advanced Planning and Scheduling (APS) to support lean manufacturing principles creates a powerful solution," said John Beakes, president of RWD Technologies, the world's leading lean manufacturing consulting company. "We are finding powerful synergies between lean manufacturing and i2's solutions in areas such as process stability, continuous flow, synchronized production, pull systems and level production."
Thousands of plants worldwide are applying lean manufacturing, but cannot fully satisfy the conditions necessary to accommodate a 100 percent lean manufacturing operation. Many plants cannot fully implement smooth material flow, consistent run rates, or reduced set-up times. Also, many companies cannot control their incoming orders enough to accommodate stable, fine-tuned production. These companies include automotive suppliers, aerospace assemblers and parts suppliers, build-to-order manufacturers, and other discrete operations.
i2's New Solution Enables Companies to Employ Full Lean Techniques
i2's new Lean Planning solution combines lean manufacturing systems with APS technology and Theory of Constraint planning. The APS solution eliminates or reduces problems such as "wandering bottlenecks," overtime planning, and serious demand fluctuations. The model also creates advanced heijunka (a level production schedule) and kanban quantities that consider real-time production constraints. This approach makes lean manufacturing techniques more effective by reducing inventories, increasing throughput, and reducing premium freight.
"Lean manufacturing has enjoyed great success, but often has not achieved its full potential. It is a demanding discipline and does not always fit perfectly with real-world conditions," said Kelly Thomas, vice president of i2's Automotive and Industrial Business Unit. "Tremendous value remains trapped in supply chains, even in the midst of aggressive lean initiatives. With this tool, companies can amplify the impact of lean manufacturing on their operations and profitability."
Visteon Implements i2's Lean Planning Solution to Increase Efficiencies
Visteon's North Penn facility in Landsdale, Pa. has implemented i2's Lean Planning solution. As a result, Visteon's premium freight has been practically eliminated, in-process inventories have been considerably reduced, and finished goods are proportioned to demand. Overtime planning is much more consistent and reliable, and weekly production is more stable, giving the company further insight into continuous improvement initiatives. The ability to plan and level the production schedules over a longer horizon also has improved supplier releases and reduced part shortages in the plant.
"The automotive industry continues to face the challenge of implementing advanced planning solutions in lean manufacturing environments," said John Cunningham, Andersen Consulting Automotive, Industrial and Transportation (AIT) partner. "With this announcement, i2 has taken a leadership role in helping companies realize the benefits of marrying the latest planning technologies with the value generated from lean manufacturing environments."