CAP Capacity Planning and Optimization
Table of Contents Content (3)
Module Flow (3)
Flow Diagram (4)
General Explanations (5)
Relation with other Modules (7)
Operations (8)
CAPT01 – Advanced Scheduling and Optimization (8)
Basics (8)
Operation Flow (8)
Schedule (9)
Scheduling Notation (10)
Production Status to be Scheduled (11)
Priority Rules (11)
Schedule Performance Measurements (14)
Scheduling Messages (15)
CAPT02 – Advanced Scheduling – Graphical (16)
Capacity Groups (27)
Sequence Dependent Set-up Time Reduction (32)
Parallel Operation (35)
Overlapping (36)
Exceptional Days of Production Days (36)
Manual Scheduling (38)
Reports (40)
CAPT05 – Capacity based on Work Center (40)
Missing Materials Control Button (40)
List Missing Materials (42)
CAPT06 – Capacity Based on Production Orders (44)
Check Tables (50)
IASCAP001 – Performance Criteria Formulas (50)
IASCAP002 – Set-up durations based on Sequence (53)
Active Schedule Performance Result Measurement (55)
Performance Measures Notation (56)
Content
Module Flow
Production orders recorded in the system are planned with determined simulation method by CANIAS Capacity Planning and Optimization, and a chart is acquired. This chart defines the works of each work center at a minute accuracy. It is designed to optimally reconcile the capacity limits of the enterprise and the work requirement of the system. The mainline specification of this module is that it assists for the
prompt programming of the work centers and company administrative operations. At the beginning of
every day the Capacity Planning and Optimization Module can be run and daily program can be created.
If a machine is out of order or the material is not applicable, module can be restarted and changes in the program can be traced. This shows that the system has a scheduling capacity. These results guide the
producer to finish up their work and determine the shortest delivery dates if the sources are available. This shows the “promising capacity” of the CANIAS Capacity Planning and Optimization Module.
Scheduling is a difficult problem. It can not be solved out by simple experience methods. As work volume increases, the problem increases non-polynomial. The complexity of the work gets larger when the
number of works in queue increases. To find the most optimal solutions Heuristic algorithms are used.
Priority rules are specified in accordance with the work and sales capacity of the enterprise. The recorded production orders in the system are scheduled in accordance with a priority rule, taking work orders and operation status in consideration and without breach of the product routes. Scheduling function prepared on the basis of Giffler and Thompson Algorithm (1960) produces active charts. One of the most optimal conclusions is accessed based on the performance measurement of the selected priority rule.
If there are changes in the quantity or time of the order or work orders, system makes the necessary
adjustments taking capacity position in consideration. Scheduled work orders can be applied in real time with outputs of “Machine Load Report”, “Production Load Report”, “Daily and Shift Planned Programs”
When number of works to be scheduled increases, to find the optimal becomes almost impossible. By intuitive methods (Heuristic Algorithms) solutions most probable to optimum is found.
When scheduling is done and result is taken, the performance should be measured in accordance with the priority rule chosen for this chart, and it should be optimum (the best).
Measurement can be based on work flow time:
◆Average flow time
◆Longest flow time
◆Average completion time
◆The longest completion time
Measurements can be based on delivery time:
◆Average termination deviation
◆The longest termination deviation
◆Average delay
◆The longest delay
Relation with other Modules
CANIAS Capacity Planning and Optimization Module gives the best productive results when used in
integration with other IAS modules as Product Design, Sales and Customer Relations, Material
Management, Production Management.
Product Design: Definitions of products, bill of materials, routes, work centers are done. The capacity of the Production Centers and capacity groups, the work centers which will be scheduled manually, the work calendar of work centers and out of work days are defined.
Sales and Customer Relations: At a new sales order record, scheduling is done with the real planning time mode for the sales units as a sample (simulation) and thus realistic delivery dates can be given during offer and order stage.
Material Management: Production plans created in the system is initiated to form work orders and charts.
Production Management: Production plans are transformed to production orders. New production orders are created manually.
Planned and targeted production beginning and production finishing dates are defined. Priority can be
given to work orders. After scheduling, when an operation is ranked, the target initiation and finishing
dates of the next operation, and all further operations targeted initiation and finishing dates which will be taken into queue in the production order now, are re-calculated. The work center information of an
operation is updated in the production order for that operation if the work center defined on the route due to the capacity group is changed to another work center mentioned in the capacity group.
Maintenance Management: Production orders/maintenance/repair plans are created for the production
work centers. The days where no work is done for the work work centers are updated.
Operations
CAPT01 – Advanced Scheduling and Optimization
Basics
Advanced scheduling and optimization methods are used at CANIAS Capacity Planning and Optimization Module. An active chart is derived in accordance with the operations in relation to the products
manufactured in the enterprise. These are ranked with various criteria and when necessary the ranking
order can be promptly changed. Priority rules to be applied in the charts are entered from the IASCAP001 check table.
Operation Flow
From Users menu, Production Management → Capacity Planning and Optimization → CAPT01 –
Advanced Scheduling and Optimization route can be followed or on the field of Open Transaction,
CAPT01 is written and thus window CAPT01D001 is reached.
Schedule
Company and Plant data are entered. “New Schedule Initial Date” is defined. If there are works waiting to be scheduled, and if they were planned to initiate before this date, their planned initiation date are
evaluated as “New Schedule Initial Date”. “Schedule those before the Date” field, provides that the
production orders with prior planning initiation dates are also covered in this scheduling. “Priority Rule”
field is used to choose a priority rule defined in advance at IASCAP001 check table. With “Schedule”
button, advanced scheduling and optimization process is realized. During this realization some of the
scheduling algorithm points are defined below:
◆System programs “n unit work” ( i = 1,2,...n) “at m unit machines” ( j=1,2,...m )
◆Every work has a route. Schedule can not violate this route.
◆One production order can visit a machine more than once. . p ij, is the process time of i work at j
machine.
◆r i, time to initiate the i work.
◆d i, is the delivery time of i work.
◆If all the production order routes are same, the ranking of the passage from the machineries are the
same and if they stop at least once at a machine, this work system is called as “flowshop”. -“flowshop”. – Permutation Flow Type
◆If the routes of all the works are the same and can use one of the same type of the machinery than it is
called “flexible flowshop” . – Flexible Flow Type Production Scheduling
◆If the routes of all the production orders are the same, the passage ranking from the machinery is the
same and if it stops more than once at one machine than this work system is called as “re-entrant
flowshop”.
◆If the routes of the works are different than each other, the production system is called “jobshop”. –
Productionshop Type Production Scheduling.
◆At some production styles, the preparation time at some work centers can change by the production
types of works coming one after another. The time spent for preparation of a work can change according to the type of the work done just before than that one. - Rank-Dependant Preparatory Time Production Scheduling
CANIAS – Capacity Planning and Optimization module supports all the above mentioned work systems.
Scheduling Notation
?r i = ready time of i. production order
?s i = setup time of i. production order
?p ij = process time of i. production order
?d i = due time of i. production order
?W ik = waiting time of k. operation with k-1 operation at i. production order
?W i = total waiting time of i. production order
?C i = completion time of of i. production order. C i = r i + ∑( s ik + p ik + W ik)
?F i = flow time of i. production order. F i = C i - r i
?L i = lateness of i. production order. L i = C i - d i
?T i = tardiness of i. production order. T i = max(0, L i)
?E i = earliness of i. production order. E i = max(0, -L i)
Production Status to be Scheduled
For the work orders to be charted they have to be; created (STATUS1), started (STATUS2), not
completely approved (STATUS3), partially not approved (STATUS4), not delayed (STATUS9), not
deleted (ISDELETE). When production orders are in parallel with these conditions, for their operations to be scheduled they have to be, created (STATUS1), not unsuccessful, (STATUS2), not completely
approved (STATUS3), not partially approved (STATUS4). At each work center information as, maximum end date of the current work and information like the preparation type of the last processed product are kept separately as they affect algorithm works when appointing the work centers.
Priority Rules
A brief summary of scheduling behavior structure in accordance with the chosen priority rules on the
CAPT01D001 window is as; The most known priority rules:
SPT(Shortest Processing Time ): Its target is to shorten the stay period of the work in the workshop to its minimum and keep the machine productivity at its maximum. As it does not consider the termination dates sometimes it can cause early or delayed terminations. This is the best rule for the bottleneck
problems.
◆Minimizes the flow time
◆Minimizes the Termination time.
◆Minimizes the delay
◆Minimizes the waiting period
◆Minimizes the number of the work orders waiting at queue.
◆Makes the average work period shorter.
◆Decreases the WIP stocks
At this sample, 3 work is scheduled with processing periods of 1, 2 and 3 units. At the first chart above, priority is given to the work with the longest processing time. As a result total waiting time will be 8 units.
In the second chart priority is given to the work with the shortest processing time and total waiting period decreases by half and becomes 4 units.
PRDT01 application and on the PRDT01D003 window its priority is increased.
The measurements written for SPT and EDD are exactly current. More details will be given under“2.2 CAPT02” application (page 22.)
Tie-Breaking : One of the priority rules as SPT, EDD, LSETUP, WSPT, WEDD is taken as the original criteria and the other is accepted as a secondary criteria at a tie-breaking position.
The measurements written for SPT and EDD are exactly current.
Schedule Performance Measurements
◆Total waiting period of the production orders
◆Waiting period of production order on a machine
◆Termination period of production
◆Delay period of production
◆Flow period of production
◆Total queue period
◆Total flow period
◆Total delay period
◆Total before deadline period
◆Average queue period
◆Average flow period
◆Average delay period
◆Average before deadline period
After scheduling from CAPT01 or CAPT02 applications, performance measurements on the basis of the chosen priority rule are made from CAPT06 application. Details will be given under “3.2 CAPT06”
headline.
For different priority rules scheduling can be repeated and the results seen on CAPT06 can be compared in order to decide for the scheduling in order to reach the performance targets of the enterprise.
Scheduling Messages
“Scheduling” process is realized by selecting the above mentioned specifications. Due to a problem
occurred during scheduling, after the scheduling process is finalized, if there are still some works which are not scheduled yet but had to be scheduled, the user is informed by numbers in the message box, if
requested they can be seen on the CAPT01D002 window which is opened by clicking on “Scheduling
Messages”. If bill of materials and route definitions are correctly done, the above shown list is expected to be empty after scheduling process. If the list is full, using the warning message, the main data has to be controlled by checking the related work order, than the route and the product tree information.
CAPT02 – Advanced Scheduling – Graphical
Scheduling process can be done from CAPT01 application and also from CAPT02 application. From user menu, Production Management → Capacity Planning and Optimization → CAPT02 – Advanced
Scheduling Graphical can be followed up or in the Open Transaction field CAPT02 is written and
CAPT02D001 window is reached. The work centers are listed according to the criteria entered in this
field. If work loads are to be watched than the related work centers are selected. Scheduling charts the production orders with the suitable status on all the work centers. The selected work centers on
CAPT02D001 window are graphically, the work centers where the work load is requested to be seen.
Work centers are listed according to the above mentioned criteria. For an advanced filtering, work center, upper work center, work center responsible fields are used. If “Show- Eye” button is clicked, the detailed information of the chosen work center is reached (ROUT02D002).
By clicking on the “Work Center Capacity” button, capacity information of the selected work center is reached.
The works on the work centers can be followed graphically by their detailed information and the existing capacity, used capacity and over loaded capacity information on the right side.
center’s work load chosen from the CAPT02D001 window can be view and the ‘Re-scheduling’ can be carried out. Ideal usage would be to monitor the real work load of the system before the CAPT02 application , to carry out the scheduling in the CAPT01 application and to use the CAPT02 application to use the results of the scheduling or to carry out the re-scheduling. Faster results for scheduling can be achieved by the CAPT01 application, because the CAPT02 application needs time for the drawing of diagrams as well as scheduling.
The work centers chosen in CAPT02D001window are viewed in the Gantt Chart shown above. The limited capacity of the plant will be charted according to the plants defined rules and the works will be directed to the work center which will provide the best closest result.
The targeted amount of productions and the confirmed amounts up to now are shown in the info boxes below the window.
Display Day is used to display the number of days up to that date in the Gantt diagram ,by going back for 60 days from the system date, by adding the value in the ‘Display Date’ to the value chosen by the earliest
start date of the works to be charted. Capacity Day shows for how many days the work center’s day capacity, Some information for a specific work center can be gathered in the detail fields shown below by choosing operations on that work center.
The followed operations of the production orders in the work centers are displayed by clicking on the “Link” button.
If all the work centers, the operations of a production order go through, are not shown in the window above, the connections in between can be viewed completely.
To display the connections one must choose one of the controls in the Gantt chart and then link single link
The arrows drawn to display the relations are taken off by pressing on the Clear Link button again.
Show PP (Show Production Plans); the work plans shown in yellow on the work centers are displayed by checking this control box and the relation with the capacity of a work center can be followed up.
Production plans are shown as production load in all of the work centers it is related to. In the ideal structure, MRP runs in the CANIAS ERP system and the created production plans are converted to production orders. The works plans shown in the Gantt Chart resulting from the scheduling in
CAPT02D002 are further in dates from the time interval the scheduling is set. These are production plans which are not certain to start and they are stuck in planning stage. Because of this situation, the existence of a production plan and a production order in between the same dates is clearly not expected. The production orders and the production plans are displayed for the same date, only if the system is changed by the user handling after the MRP results and the new production plans are created by the user.
The “New Schedule Start Date”, “Schedule Before The Date’, ‘’Priority Rules’’ fields are filled as it has been explained in CAPT01 and the ‘’Further Scheduling’’ button is pressed. The scheduling result must be the best of the chosen priority ruler. The active charts performance results are gathered from CANIAS- Capacity Planning and Optimization Module reports, which will be explained in the Reports section. The operations related to the manufactured products can be organized and quickly updated according to the priority rules. The capacity overrun (in red color) are not displayed after the Scheduling like it has been before the in the Gantt chart. The works are listed to provide the closest optimum result which will reflect the plants limited capacity.