Production Planning and detailed scheduling with capacity constraint. this solution will tailer-made for discrete or process industry (PP-PI) with mix-up between MPS (Master Production Schedule), CRP (Capacity Requirement Planning) and Sequencing Matrix. To calculate and initial production planned in Planning Table each of work centers or resources group.
Simulation planned orders are represented trial the constrain calculation which calculated each day (daily planned) and integrated for call-off materials (RM/PK) each of day. The method of calculation able find the alternative work center / resource and distribute allocate if full capacity. The schedule run will reduce the setup time or change over for each sequencing.
Planning table able adjust planned if they would like to manage the proper planning by themself.
Finalize step will approve by production planner and do release to the active version for run next MPS or MRP so on.
Master recipe is importance of calculate the production scheduling in planned orders or production/process orders.
in Standard value is included activity type such as Setup Time, Machine Time, Labor Time or other activities. For machine time is ok following based on production quantity able convert to duration of planned (determine the start time to finished time) But for Setup time is static value because when create a planned order or production/process order always carry out the setup time. in case implement Setup Matrix in ECC will require perform only in production/process order only. The setup matrix compatible in PP/DS module. For this case will demonstration without PP/DS that how to realize this function on ERP.
The Capacity Evaluation report will show the available capacity (Hrs) each work center/resource as defined the shift pattern in capacity master.
The CIP Time or Change over require production stop when clean the line or operation change/setup transition from a product to a product. That may be increase setup time or require CIP break time that should reduce the capacity.
In sequencing matrix will define the CIP time each of sequence material which each product has setup time 30 MIN from recipe/routing and CIP time 60 MIN from matrix.
Program sequencing will calculate the planned order with constraint by deduction both setup time and CIP time in available capacity each of period.
- Program will merge planned order if it is same product in same period.
- Split planned order by period and determine the setup time each period.
- In during change over between product, program will calculate Setup time + Change over time (CIP).
- For example: Product-A defined recipe/routing rate is 80 CAR per 1 hrs.
- Resource has available capacity = 11 hrs/day.
- Deduct Setup Time 30 min remain capacity = 10.5 hrs/day.
- Planned orders suggestion from program is 10.5 x 80 = 840 CAR. per day.
- 20-21.03.23 planned 840 CAR.
- For 22.03 allocate 420 CAR that calculate capacity usage = 5.25+0.5 = 5.75 hrs. Resource 1F0001 remain Available Capacity = 11-5.75 = 5.25 hrs. To change over another product will produce rate 90 CAR/hrs and Setup time = 30 Min. and CIP = 60 Min total equal 90 Min.
- Remain available capacity 5.25 - 0.5 - 1 = 3.75hrs. Program will suggest planned = 3.75 x 90 = 337.5 and rounding to 338 CAR. for next product.