Development of Decision Support System Using ATP-DSS Techniques to Reduce Delays and Efficiency Improvement in the Order Promising Process with Make-to-Order Manufacturing: Case Study of an Electronics Manufacturer
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Abstract
The case study company’s current situation, which is an electronic components manufacturer, who is facing a delay of an available-to-promise (ATP) response times from make-to-order (MTO) production, and the impact of customers service efficiency and competitiveness. This research addressed the development of decision support systems using ATP-DSS techniques which is a principle of applying the information system to manage the inventory for prolonged available-to-promise response times, exceeding 24 hours, within an electronics manufacturer's order promising process (OPP), aiming to reduce delay defects and variability. A Real-Time Decision Support System was developed, integrating ATP-DSS techniques, Six Sigma principles, Lean methodologies (ECRS), and Business Process Reengineering (BPR). This integration facilitated enhanced, real-time assessments of inventory levels, production capacity, and supplier part availability. Results demonstrated a significant OPP reduction average 22.23 minutes per order, or 84.62%, with OPP response times within 24 hours improving by an average of 69.71%. Defect rates were eliminated, achieving a 100% reduction or zero mistakes, and process variability stabilized, with the Process Capability Index (Cpk) increasing from 0.95 to 1.37. Moreover, the value-added (VA) activities increased by 7 steps (100%), and necessary but non-value-added (NNVA) activities decreased by 7 steps (87.50%).
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