The term "alternative resources / substitute resource planning" refers to the planning and management of alternative resources that can be used when the originally assigned resource is unavailable, overloaded, or unsuitable. These resources may include alternative machines, work centers, tools, employees, production lines, or other operational capacities. The objective is to increase planning flexibility, avoid capacity bottlenecks, and support timely and cost-efficient execution of production orders or other operational activities.
Definition of Alternative Resources: Assigning multiple suitable machines, work centers, employees, or other resources to an operation or order.
Substitute Resource Prioritization: Defining a preferred sequence in which alternative resources should be considered during planning.
Automatic Resource Selection: Selecting an appropriate substitute resource based on availability, capacity, cost, skills, or other planning criteria.
Capacity Checking: Verifying whether primary and alternative resources have sufficient capacity within the required time period.
Resource Capability Matching: Comparing technical capabilities, performance characteristics, qualifications, certifications, or approvals to ensure that a substitute resource is suitable for a specific operation.
Automatic Rescheduling: Reassigning orders to alternative resources in the event of machine failures, overloads, schedule changes, or other disruptions.
Evaluation of Planning Alternatives: Comparing different resource assignments based on lead time, due-date performance, utilization, costs, or setup requirements.
Resource Scenario Simulation: Analyzing the effects of different resource assignments and substitution strategies on production or operational schedules.
Integration with Detailed Scheduling and APS: Considering alternative resources within automated finite scheduling, sequencing, and optimization processes.
A production order is originally scheduled for Machine A. Because the machine is unavailable due to maintenance, the software automatically assigns the order to a technically suitable Machine B.
Three production lines are capable of performing the same operation. The planning system selects the most appropriate line based on available capacity, delivery dates, setup requirements, and cost.
A qualified employee becomes unexpectedly unavailable. The system identifies other employees with the required skills and proposes suitable substitutes for the assigned task.
When a work center becomes overloaded, an Advanced Planning and Scheduling (APS) system reallocates production orders to alternative work centers to help maintain delivery commitments.
A manufacturer simulates different resource assignments to determine which combination of machines and production lines results in the shortest lead time and best overall capacity utilization.