Re: Cycle Time -- BPCS-L

Rory

BPCS handles this stuff quite handily, but if you are not experienced inmanufacturing engineering, it can seem like rocket science.

1. Within the Routings (FRT file) you provide the math for how long ittakes to make the parts, using the program SFC100, after having setupvarious other files in support of the Routings, such as the Work CenterMaster file (the guts of the <G> warp engine).


There is a TBC Time Basis Code
You make some # each hour
or in some time period you make 1,000 or 10,000 or whatever

Then when you release shop orders, that math is taken into consideration.
Operation 100 get done in 1 day
Operation 200 take 2 days
etc.

Need the whole part done on Friday, it gives date earlier in week to getdone with the earlier operations, based on quantity to make in the shoporder, vs. math in Routings how long it going to take.


2. There is also concept of move time between steps.

You can allow for a few hours between production steps, such as to allowfor inspection, getting enough staged to keep factory workers busy. You canfactor in setup time.

In our case we have overlap. I might not be using the correct terminologyfor overlap. What I mean by that ... we might have some part in which weneed to make several thousand, and this will take the better part of morethan a day at each operation. The first operation gets like 1,000 or sodone, and the people there continue to be busy with the machine churningout more, but without waiting the 2-3 days or however long it will take toget that operation completed, the folks at the next operation take the workthat has been done so far, and they start doing the next step. So when thefirst operation actually gets done, the last operation is perhaps 2-3 hoursaway from completion. Think like an assembly line with worker clumps atmultiple points on the line.

If you have zero move times between manufacturing steps, BPCS assumes 100%complete one step before the next one starts, but we have overlap, so wecan put in a negative number for the move time in between, and BPCScorrectly calculates the math for how long that will take. You have tounderstand the math in the Routings for this to work correctly, and youhave to put that math into your Routings.


3. There is also a concept of LEAD TIME.

When we order raw materials from our suppliers, we need to allow 30 days 60days whatever, because our suppliers cannot manufacture instantaneously forus, and deliver by Star Trek teleporter, through SGC worm hole, HG WellsTime Machine, matter transmission by e-mail, or whatever is your favoritefantasy. In the real world, we have to allow time for our vendors to getthe raw materials to us.

If you have more than one facility, you can have different lead time andother rules by combination of item and facility.


Locate the file BPCSDOC
Then locate the members within it that talk about BOM and SFC.
Those two explain how to setup the engineering with this data

Then when the team is making progress doing that

Locate the members on MRP and CAP which I think are the most importantplanning modules of BPCS

MRP for materials planning which is what you asked about

CAP for capacity ... your company might not have infinite capacity ...which means you might not be able to do millions of hours of work one dayand a few hundred another day ... you may need to even it out so you areusing about the same size work force each day continuously

There's also BPCS vendors that can teach you this stuff, help you setup theengineering files to work well for your industry.


Al Macintyre

Dan,

I was talking about cycle time (i.e - Lead time of production). I guess that
since this is not my primary area of expertise, I didn't use the right
words. The explanation about cycle counts was useful tough, since I'll talk
to our inventory guys and check out how they are doing this.

Do you have any ideas about calculating lead time of production ?

Thanks again,

Rony


On 3/29/06, Dan Sweeney <dsweeney@xxxxxxxxxxxxxxxx> wrote:
>
> Rony,
>
> As a rule whenever an item goes negative for any reason it is
> automatically selected for cycle count the next time that you generate
> the cycle count sheets.
>
> I have found that a good rule of thumb for cycle count frequency is to
> use ABC analysis for the timing.
>
> For example if 80% of the inventory value are classified as A, B and/or
> C item then they should be counted more frequently as that is where the
> inventory and usage value resides in your inventory system.
>
> Once you have calculated each category of an item then it is up to you
> and your users as to the frequency for counting the items.
>
> Hope that this helps!
>
> Dan Sweeney
>
> Senior Technical Consultant
>
> PHOENIX Business Consulting, Inc.
>
> Tel: 724.836.4446 x7, Cell:  860.490.6712,
>
> E-Fax: 832-550-5144
>
> www.phoenixbcinc.com
>
> SSA GLOBAL Recognized Services Provider
>
>
> -----Original Message-----
> From: bpcs-l-bounces+dsweeney=phoenixbcinc.com@xxxxxxxxxxxx
> [mailto:bpcs-l-bounces+dsweeney=phoenixbcinc.com@xxxxxxxxxxxx] On Behalf
> Of Rony Mayer
> Sent: Wednesday, March 29, 2006 1:00 PM
> To: SSA's BPCS ERP System
> Subject: [BPCS-L] Cycle Time
>
> Hi guys,
>
> We're having a bit of a problem trying to calculate cycle times for some
> of
> our product lines, since our team does not know if BPCS offer a
> standard,
> easy-to-use way to do that. They are trying to calculate it through some
> queries and manipulate the info in access, but from what I've seen, the
> information is not going to be very trustworthy. Do you guys know a
> standard
> way to get this ? I can't believe BPCS does not offer this, as I've been
> told.
>
> Thanks in advance,
>
> Rony