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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





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