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Thanks for the info. As I have understood routings (my background was originally with Oracle Mfg and Rhythm Factory Planner), Set Up and Run Time put the 'load' on the workcenter, Queue is the amount of time wip should be in front of a workcenter, and Move Time is the amount of time it takes wip to move from one workcenter to another. I only removed the Move to from the last operation (this was to allow a day to move from our packaging operation out to the shipping area. Given that, with Bpcs, Queue and Move times are static, my expectation was all the workcenter's load would move a day out to correspond with the day of Move Time that was removed. Are quantities are relatively the same; they don't cause huge changes in Machine time. Based on the calculation of -- Order Start Date = (Order Due Date) - (Move Time Days) - (Calculated Operation Time) - (Queue Days), does Bpcs sum all the Move time, then the Op Time, and then the Queue time? Or, does it backward propagate based on how these elements occur in the routings? I've put an example of one of our routings: Operation Status W/C B Run Setup Machine Move Queue 20 PANEL LAYUP 1 1040 2 .28 .7 30 SAWING 1 1050 2 .25 .35 .7 37 EDGE PLG 1 1069 2 .42 40 PUTTYING 1 1071 2 .33 60 SANDING 1 1121 2 .12 .23 1.3 61 RESAND 2 1125 2 80 FINISH FACE 1 1130 2 .15 .15 81 FINISH BACK 1 1130 2 .15 1.3 83 REFINISH 1 1135 2 90 STALL GRADE 1 1150 2 .13 .99 100 PACKAGING 1 1160 2 .15 The was one day of Move at this operation I should add that, being as I am not a progammer, I am only looking at this from the functional aspect. I should also say that the goal is to get the routings, for most cases, to be less than or equal to the Item Lead Time Days as set in the Facility Planning Record. Anymore insight would be helpful, Thanks, Marc Graff Production Control Manager States Industries, Inc. (541) 688-7871 ext. 283 -----Original Message----- From: bpcs-l-bounces+mgraff=statesind.com@xxxxxxxxxxxx [mailto:bpcs-l-bounces+mgraff=statesind.com@xxxxxxxxxxxx] On Behalf Of Mike Sarro Sent: Wednesday, January 24, 2007 1:39 PM To: bpcs-l@xxxxxxxxxxxx Subject: [BPCS-L] Routing Question (Marc Graff) Hi Marc, Attempting to make your Shop Order scheduled time match the "static" MRP lead time can be tricky. It's fairly straight-forward if your order quantities are constant. However in many environments, the quantities from one instance to the next (for the same item) can vary significantly. In your example, you didn't reference if there were quantity swings between the shop orders. Also, I'll assume you are not running these Shop Orders as part of a campaign in API. The following information should prove helpful in your analysis. You correctly stated that BPCS schedules backward. On a shop order, regardless of quantity, the Queue, Setup and Move times will be constant. Therefore any variation in the operation Start/Complete times would come from multiplying the order quantity by the Run (or Machine) times. As a general rule for BPCS scheduling, Queue is time added before the Operation's Start Date. Move Time is added after the Operation's Complete Date. The calculated Operational Time (Setup + calculated Run/Machine time) is sandwiched in the middle. So the back-scheduling calculation for a one-step shop order is performed as follows: Order Start Date = (Order Due Date) - (Move Time Days) - (Calculated Operation Time) - (Queue Days) Note: Calculated Operation Time = (Setup Hrs) + (Run Hrs/Unit x Order Quantity). BPCS inserts the operation's Start and Complete dates at the beginning and end of this segment. Some additional thoughts that might help are: 1. Check the Run/Machine times and Time Basis Codes within the routing . Be sure the total Operation Times are being calculated consistent with your expected lead time. 2. Consider utilizing a combination of "Lead Time Days" (static) and "Daily Lead Time Rate" (variable) in MRP140. In essence, this allows MRP to calculate a "dynamic" lead time for planned orders. This could help if there are wide swings in order quantities. Marc, hopefully this information helps you solve the problem. Feel free to post a follow-up question if necessary. Sincerely, Michael J. Sarro II, CPIM, CSCP PHOENIX Business Consulting, Inc. Direct: 484-431-4260 msarro@xxxxxxxxxxxxxxxx message: 1 date: Wed, 24 Jan 2007 08:16:27 -0800 from: "Marc Graff" <mgraff@xxxxxxxxxxxxx> subject: [BPCS-L] Routing question I'm hoping someone can offer some insight into how manipulating routing Queue and Move times impacts capacity regarding how Bpcs plans orders at workcenters. We recently changed the lead time days for planned items to 4 days; we are using Bpcs 405cd. We discovered that some of our routings total time (Set Up, Run, Q, Move) was more than the lead time days. This caused the 'release date' to be later than the start date of the first operation; from a capacity standpoint the first operation start date was a day prior to when the system told us to open the shop order. In order to have the routing time be less than or equal to 4 days I removed 1 day worth of Move from the routing (example below). I was expecting the result to be that the first operation start date would be equal to the release date-the first operation start date would move to a day later. This did not happen. Of the 6 planned items that had the 1 day of Move removed, 4 planned items actually had the first operation start date move to a day earlier, and 2 didn't change. Since, I believe, Bpcs backward propagates to get operation start times, when removing Queue or Move times, should the operation start times move to a later date/time and not an earlier date/time? Any insight into how Bpcs manages this would be greatly appreciated. Marc Graff Production Control Manager States Industries, Inc. (541) 688-7871 ext. 283 ------------------------------ -- This is the SSA's BPCS ERP System (BPCS-L) digest list To post a message email: BPCS-L@xxxxxxxxxxxx To subscribe, unsubscribe, or change list options, visit: http://lists.midrange.com/mailman/listinfo/bpcs-l or email: BPCS-L-request@xxxxxxxxxxxx Before posting, please take a moment to review the archives at http://archive.midrange.com/bpcs-l. End of BPCS-L Digest, Vol 5, Issue 21 *************************************
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