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EGN 5623
EGN 5623
Topics
DS concepts 1. Finite and infinite loading 2. Scheduling directions 3. Sequencing rules 4. Criteria for evaluation of sequencing rules 5. Controlling changeover costs 6. Minimize total production time DS in SAP APO
Process-Focused Operations
Process-focused factories are often called job shops. A job shops work centers are organized around similar types of equipment or operations. Workers and machines are flexible and can be assigned to and reassigned to many different orders. Job shops are complex to schedule.
Pre-production Planning
Design the product in customer order Plan the operations the product must pass through ..... this is the routing plan Work moves between operations on a move ticket
The production control department controls and monitors order progress through the shop.
Assigns priority to orders Issues dispatching lists Tracks WIP and keeps systems updated Controls input-output between work centers Measures efficiency, utilization, and productivity of shop
Input-Output Control
Input-output control identifies problems such as insufficient or excessive capacity or any issues that prevents the order from being completed on time. Input-output control report compares planned and actual input, planned and actual output, and planned and actual WIP in each time period
Gantt Charts
Gantt charts are useful tools to coordinate jobs through shop; graphical summary of job status and loading of operations
Fabrication
Assembly Test
D
C C
E
D
F
E D
Scheduled
Progress
Setup, Maint.
Infinite loading
Assigns jobs to work centers without regard to capacity Unless excessive capacity exists, long queues occur Uses work center capacity to schedule orders Popular scheduling approach Integral part of CRP
Finite loading
Forward scheduling
Jobs are given earliest available time slot in operation excessive WIP usually results Start with promise date and work backward through operations reviewing lead times to determine when a job has to pass through each operation Less WIP but must have accurate lead times
Backward scheduling
Order-Sequencing Problems
Sequencing Rules Criteria for Evaluating
Rules Comparison of Sequencing Rules Controlling Changeover Costs Minimizing Total Production Time
Sequencing
Order-Sequencing Problems
We want to determine the sequence in which we will process a group of waiting orders at a work center. Many different sequencing rules can be followed in setting the priorities among orders. There are numerous criteria for evaluating the effectiveness of the sequencing rules.
First-come-first-served
Performs poorly on most evaluation criteria Does give customers a sense of fair play Performs well on most evaluation criteria But have to watch out for long-processing-time orders getting continuously pushed back Works well on average job lateness criterion May focus too much on jobs that cannot be completed on time, causing others to be late too.
Critical ratio
Changeover costs - costs of changing a processing step in a production system over from one job to another
Changing machine settings Getting job instructions Changing material Changing tools
DS in SAP APO
Tasks and activities of detailed scheduling
Controlling Detailed Scheduling Dates/Times and Planning Directions Resource Availability Selection of Resources Time Relationships Pegging Relationships Automatic Propagation of Changes Determining the Setup Time for Sequence-Dependent Setup Activities Synchronizing Activities on Multi-resources Block planning Scheduling Log Terminating Scheduling
1. Determine the resources and dates/times for carrying out operations, taking resource and product availability into consideration. 2. Support the scheduler in scheduling resources when creating an optimal operations sequence.
An operation in the SAP APO system is either scheduled(with no separate status), or de-allocated (in this case it has the status deallocated).
Adjusting is a detailed scheduling activity that is carried out automatically by the system for dependent objects (for example, if relationships or pegging relationships have to be adhered to). You cannot adjust de-allocated operations manually.
2. Through the fixing process, a scheduled or de-allocated operation is assigned the status fixed.
3. A fixed scheduled operation cannot be rescheduled or de-allocated, and a fixed de-allocated operation cannot be scheduled or adjusted.
Prerequisites of DS
The system can trigger detailed scheduling activities automatically. For example, it automatically schedules the order operations when an order is created. Three ways to start detailed scheduling activities: production planning run, detailed scheduling planning board, or resource planning table specifically for selected operations or orders.
SAP APO Production Planning Interactive Production Planning Detailed Scheduling Detailed Scheduling Planning Board/Variable view (APO/CDPS0)
SAP APO Production Planning Interactive Production Planning Detailed Scheduling Detailed Scheduling Planning Board/Variable view (APO/CDPS0)
SAP APO Production Planning Interactive Production Planning Detailed Scheduling Detailed Scheduling Planning Board/Variable view (APO/CDPS0)
Homework for DS
1. 2. 3. 4. 5. 6. 7. Change demands for Distribution centers Run network plan with multilevel heuristic Review planning board Define SNP deployment profile Define transport load builder profile (TLB) Assign TLB profile to the transportation lanes Run deployment heuristics