Advanced planning and scheduling systems in aluminium conversion industry

Standard software packages, known as advanced planning and scheduling systems (APS), are often implemented to compute feasible production plans that can take into account several constraints (such as resources capacity), at different decision levels. In this research, emphasis is put on studying the relevance of APS principles in the specific area of the aluminium conversion industry (ACI). In this particular case, the characteristics of the processes involved (e.g. casting and rolling) are such that certain principles used by APS (e.g. finite capacity scheduling, constraint-based planning, bills of materials) may cause problems. This article extends a previous study related to the relevance of enterprise resource planning (ERP) systems for ACI in the direction of APS. It aims at identifying benefits, but also limitations and problems, which may arise when implementing this type of system. In this respect, the main features of APS systems are recalled. Specific features of ACI that are likely to cause problems are identified. It is shown that, if APS are indeed attractive, in certain cases important limitations exist, which can significantly affect the performances (e.g. increasing the lateness of product delivery, overproducing or increasing scrap and inventories). Several results presented in the current article can be relevant for other types of process industries.