Scheduling Shop Orders with CBS—Key Exercises

IMPORTANT
It is extremely important that you set up and work within the CBS training site. If you work within any other site, you will not be able to access a CBS server. To simplify data entry, select the CBS site as your default site on the System Data for Inventory and Distribution/Users tab. Also, to keep your data separate from that of other users, be sure to name all data using your initials as the prefix.

Basic Data Setup

Overview of Constraint Based Scheduling Data

Purpose: The purpose of this exercise is to create the required data used in the Constraint Based Scheduling (CBS) exercises. This sets up data for your site that needs to be done only once for all CBS exercises.

  1. If you have not done so already, set up your site so that it includes all the CBS required data.

General exercise for Overview of Constraint Based Scheduling Data

Main Exercises

Scheduling a Shop Order with Only Work Center Constraints

Purpose: The purpose of this exercise is to show you how to create a shop order for CBS to schedule.

Windows:
Shop Order

  1. Make sure that the program is set to create shop orders with a status of Planned.

Note: You can specify that shop orders be created with the Planned status on the Parameters for Distribution and Manufacturing .

  1. Create a new record.
  2. In the Order No field, enter XX–SO1 (where XX is your initials).
  3. In the Part No field, enter XX–250–G10.
  4. In the Site field, enter your site name, if it is not defined as the default site for your user.
  5. In the Sched Direction list, click Backwards Scheduling.
  6. In the Earliest Start Date field, enter next Monday's date in MM/DD/YY format.
  7. In the Need Date field, enter next Thursday's date in MM/DD/YY format.
  8. In the Lot Size field, enter 10.
  9. Click Save to save the shop order.

Expected Results: Once you save a shop order, CBS schedules it and updates the start and finish dates. CBS tries to fit the shop order into the current schedule. It checks the availability of both materials and resources to determine the earliest date and time the shop order may start. The need date is the date before which the order should be completed. With backward scheduling, CBS tries to adjust the schedule of the shop order so that it is as close to this date as possible. If the finish date is on or after the need date, a message appears indicating that the shop order did not meet its need date, and the order is designated as tardy in CBS.

Viewing Shop Orders in the Simulation Client

Purpose: The purpose of this exercise is to demonstrate how you can view results and perform schedule changes without affecting the Scheduling Server. An image of the Scheduling Server data is created for simulation purposes, which enables the server to continue processing transactions. All changes made in simulation are not applied to the Scheduling Server or the database. They must be manually applied in the database to take effect in the Scheduling Server.

Windows:
Simulation Client

Note: Once CBS opens, make sure that no plot settings have been selected by clicking Settings on the Tools menu.  

  1. In the Tree View/Activities window, double-click Activities, and then double-click Shop Orders to see a list of the shop orders that are now in the Scheduling Server.
    1. Select shop order XX-SO1. While holding down the left mouse button and the Shift key, drag the shop order to the object table area (the white space on the left side) of the Gantt Overview pane. The shop order is now plotted on the Gantt chart. In the object table, the shop order appears as three objects: the parent shop order, XX–SO1, and its children, the operations XX–SO1~10 and XX–SO1~20.
    2. If the shop order does not appear on the Gantt chart, click a few times on the scroll arrows adjoining the End Date field above the Gantt chart to expand the time schedule. Try the other buttons above the chart, and experiment with their functions.

Note: In the object table, the status or statuses of each object are presented. Also, each object (i.e., a shop order or shop order operation) has its own icon, which helps to identify the type of object. You can remove an object from the display by dragging it to the trash can icon. Alternatively, click Clear All to remove all objects.

To obtain a detailed view of an object such as a shop order, select it in the object table area of the Gantt Overview pane. The details of this object are displayed in the Gantt Detail pane. The Details tab displays the constituents of the selected object and zooms the timescale to the period in which the selected object has been scheduled. The Resources tab displays the work centers and work center resources associated with the selected object. The Materials tab displays any finitely available material that is associated with the selected object.

  1. Another way to adjust the time schedule is to drag an object, i.e., a shop order, upward from the object table onto the Drag & Drop Auto Timescale (ruler) button to adjust the time scale and make this object's schedule completely visible.
  2. In the Tree View/Master Data window, double-click Master Data, and then double-click Work Centers. For Work Center XX400, hold down the left mouse button and Shift key, and drag the work center into the object table area of the Gantt Overview pane. The work center and its resources appear as objects in the Gantt Chart window. Also plot Work Center XX500.
  3. Make sure that the shop orders and the work centers are visible in the Gantt chart. Click Plot Settings in the Gantt Chart window and then click Plot Settings on the menu that appears. The Settings window appears.
  4. In the Settings/Plot Settings/General tab, select the Resource Availability check box. The gray color for work center resources represents the time (according to the work center's calendar) during which the resource is unavailable.
  5. In the Show area of the Settings/Plot Settings/Operations tab, select the Names check box in the Operations Show area to plot the operation names on the operation and work center resource objects.
  6. Select the Splitted check box. Now the operations are plotted as connected segments of time during the available time rather than as a block of time covering both available and unavailable time.
  7. Select the Planned Line check box. Now the status of the operations in the Gantt chart is shown with color codes (Planned = light green).
  8. Select the Setup Times check box. Now the operation time is broken into its setup portion (white with blue diagonal lines) and run-time portion (gray with a light green stripe to indicate the status).
  9. Select the Tardy Line check box.
    1. Find your shop order, XX–SO1, in the Gantt chart.
    2. Right-click Operation 20.
    3. Hold down the right mouse button, and drag the operation to the right, into in the next available time slot. The shop order operation becomes tardy, and a red stripe appears in the operation. Remember that you are in simulation mode, so no changes can be saved to the database.
  10. Select the Show Status in Tree View check box. The status of each object in the Tree View is displayed on the screen.

Using the Scheduling Client to Change the Shop Order Schedule

Purpose: The purpose of this exercise is to show how to adjust the schedule, view results, and save changes to both the Scheduling Server and the database. An image of the Scheduling Server is made to perform schedule adjustments. However, the server is locked to prevent users from processing transactions. All changes made in the Scheduling Client can be applied automatically to the Scheduling Server and database. Unlike the Simulation Client, a limited number of options for schedule changes is available, i.e., only schedule prioritization, not capacity adjustments.

Windows:
Scheduling Client

Note: The Scheduling Client locks the Scheduling Server so that you cannot make changes affecting the schedule. If other users try to make schedule updates on the same site (e.g., updating shop order dates, updating shop order operations, or making capacity adjustments), a message appears indicating who is locking the Scheduling Server. The default time limit for the lock is 10 minutes. Once this limit is reached, the Scheduling Client automatically releases the lock on the Scheduling Server. You can change this time limit.

  1. Plot Shop Order XX–SO1.
    1. Right-click Operation 20, and drag it to the right so that it finishes the next day. The operation becomes tardy, as indicated by the red stripe.
    2. Depending on the number of shop order operations, you can do the following, as applicable:
      1. First Operation—Move back to the earliest date with available materials and resources or move forward to finish no later than the start of the second operation (except if operations are parallel).
      2. Middle Operations—Move an operation to an earlier start time (it cannot start before the finish time of the prior operation), or move forward to finish no later than the start of the next operation (except if operations are parallel).
      3. Last Operation—Move an operation to finish at a later time.

Note: An operation can be moved only to a point in time where all its required resources are available. CBS checks this condition as you move the mouse.

  1. Save the new schedule to the database, and release the server. Exit the Scheduling Client.
  2. Query Shop Order XX–SO1 to verify that the finish date has changed.
  3. Open the Shop Order/Operation tab, and check the start and finish date/time of Operation 20.
  4. Optionally, reset the shop order to the previous schedule.
    1. Right-click the Shop Order header, and then click Schedule Shop Order.
    2. CBS reschedules the shop order based on the original criteria (e.g., the finish date returns back to its original value, 2/14/01).

Adjusting Shop Orders

Purpose: The purpose of this exercise is to make changes on a shop order and understand the impact on the schedule. All changes that may affect the schedule are sent to the Scheduling Server and result in the rescheduling of the shop order.

Windows:
Shop Order

  1. Query for Shop Order XX–SO1.
  2. Change the need date as follows:
    1. Enter next Friday's date in the Need Date field.
    2. Save your changes. The start and finish dates change according to the new schedule.
    3. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by clicking Open and then Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    4. Plot Shop Order XX–SO1, and look at the changes. The Gantt chart shows the first operation starting one day later and the last operation completing one day later.
  3. Return to the Shop Order window. Change the schedule direction as follows:
    1. In the Schedule Direction list, click Forward Scheduling.
    2. Save your changes. The start and finish dates change according to the new schedule.
    3. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by pointing to Open and then clicking Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    4. Plot Shop Order XX–SO1, and look at the changes. The Gantt chart shows the first operation starting at the current time and the last operation completing two days later.
  4. Return to the Shop Order window. Change the lot size and schedule direction as follows:
    1. In the Lot Size field, enter 5.
    2. In the Schedule Direction list, click Backwards Scheduling.
    3. Save your changes. The start and finish dates change according to the new schedule.
    4. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by pointing to Open and then clicking Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    5. Plot the Shop Order XX–SO1, and look at the changes. The Gantt chart shows the first operation starting one day later. The last operation still finishes the same day as before.
  5. Return to the Shop Order window. Reset the shop order to the initial values as follows:
    1. In the Need Date field, enter next Thursday's date.
    2. In the Lot Size field, enter 10.
    3. Click Save. The start date and finish date are updated.
    4. Verify in the Simulation Client.

Adjusting Shop Order Operations

Purpose: The purpose of this exercise is to make changes on a shop order operation and to understand the impact on the schedule. All changes to shop order operations that may affect the schedule are sent to the Scheduling Server and cause a rescheduling of the shop order.

Windows:
Shop Order

  1. Query for Shop Order XX–SO1.
  2. Click the Operation tab.
  3. Change the manufacturing setup time, the manufacturing factor, and the factor unit as follows:
    1. For Operation 10, change the value in the Mfg Setup Time field to 2 (hours), the value in the Mfg Factor field to 0.25 (hours), and the value in the Factor Unit field to Hours/Unit.
    2. Save your changes. The date values in the Start and Finish fields remain the same. The values in the Op Start Date and Op Finish Date fields for operation 10 change. The values in the Op Start Date and Op Finish Date fields for operation 20 remain the same.
    3. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by pointing to Open and then clicking Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    4. Plot Shop Order XX–SO1, and look at the changes. In the Gantt chart display, double-click Operation 10, and click Show Contents. Verify that the values in the Setup Time, Scheduled Setup Time, Hours/Unit, and Units/Hour fields reflect the changes made to the operation.
  4. Return to the Shop Order window. Change the transport time as follows:
    1. For Operation 10, enter 2 (hours) in the Transport Time field.
    2. Save your changes. The date values in the Start and Finish fields remain the same. The values in the Op Start Date and Op Finish Date fields for Operation 10 change. The values in the Op Start Date and Op Finish Date fields for operation 20 remain the same.
    3. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by pointing to Open and then clicking Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    4. Plot Shop Order XX–SO1, and look at the changes. In the Gantt chart display, double-click Operation 10, and click Show Contents. Verify that the transport time reflects the change made to the operation
  5. Return to the Shop Order window. Change the work center and operation efficiency as follows:
    1. For operation 20, change the value in the Work Center No field to XX500, and value in the Efficiency field to 75.
    2. Save your changes. The date values in the Start and Finish fields remain the same. The values in the Op Start Date and Op Finish Date fields for Operation 10 change. The values in the Op Start Date and Op Finish Date fields for Operation 20 change.
    3. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by pointing to Open and then clicking Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    4. Plot Shop Order XX–SO1, and look at the changes. In the Gantt chart, double-click Operation 20, and click Show Contents. Verify that the operation efficiency reflects the change. Click Show Assignments to verify that the work center role reflects the change.
  6. Return to the Shop Order window. Add a new parallel operation as follows:
    1. Add Operation 30 with the following values: Operation Description = New Op, Work Center No = XX400, Mfg Setup Time = 1 (hour), Mfg Factor = 0.5 hours, Factor Unit = Hours/Unit, Parallel = Parallel, Op Start Date = today's date, and Op Finish Date = today's date.
    2. Save your changes. The date values in the Start and Finish fields remain the same. The values in the Op Start Date and Op Finish Date fields for Operation 10 remain the same. The values in the Op Start Date and Op Finish Date fields for Operation 20 remain the same. Operation 30 is scheduled with its operation start and finish dates.
    3. Reopen the Simulation Client. If you did not close it before making the changes, you need to manually retrieve the new information by pointing to Open and then clicking Database Open on the File menu. Alternatively, populate the window by clicking Database Open on the toolbar.
    4. Plot Shop Order XX–SO1, and look at the changes. In the Gantt chart display, double-click Operation 10, and click Show Relations. This window indicates the preceding (e.g., none) and succeeding activities (e.g., both operation 20 and 30) for Operation 10. Review the relations for Operations 20 and 30.
  7. Return to the Shop Order window. Reset the data for the operations to the original values:
    1. For Operation 10, enter 1 hour for both the manufacturing setup time and the manufacturing factor, Units/Hour as the factor unit, and 0 (zero) as the transport time.
    2. Save your changes.
    3. For Operation 20, enter XX400 as the work center number, and 100 as the efficiency.
    4. Save your changes.
    5. Delete Operation 30.
    6. Save your changes again. The date values in the Start and Finish fields remain the same. The values in the Op Start Date and Op Finish Date fields for Operation 10 change. The values in the Op Start Date and Op Finish Date fields for Operation 20 change.

Scheduling a Shop Order With Labor Constraints

Purpose: The purpose of this exercise is to schedule and view a shop order with a work center and labor constraint.

Windows:
Shop Order
Simulation Client

  1. Create a new shop order as follows:
    1. Create a new record.
    2. Enter XX–SO2 (where XX is your initials) as the shop order number.
    3. Enter XX–250–G30 as the part number.
    4. Enter your site name (if it is not defined as the default site for your user).
    5. In the Sched Direction field, choose Backwards Scheduling.
    6. Enter next Monday's date as the earliest start date.
    7. Enter next Wednesday's date as the need date.
    8. Enter 10 as the lot size.
    9. Save the shop order. CBS schedules it and updates the start and finish dates. Note that the start date of the shop order becomes earlier than the earliest start date. The reason for this is explained in the last step of exercise, Scheduling a Shop Order with Material Constraints.
  2. Reopen or refresh the Simulation Client, and review the constraints and assignments for an operation as follows:
    1. Select Shop Order XX–SO2, and plot it on the Gantt chart.
    2. From the object table, right-click Operation 10 and then click Show.
    3. Click Show Assignment. This opens a window that shows the constraints and assigned resources for each role of the operation. Click the arrow next to the role list to see one role for the work center and the role for set up labor class and run labor class.
    4. Notice that assigned work center resources and employees are shown.
    5. Close the window.
  3. Plot the constraints and assigned resources for an operation as follows:
    1. From the object table, right-click Operation 10 and then click Expand. The work center and labor class constraints for the operation are plotted.
    2. Right-click the work center and then click Expand. The work center resources for this work center are plotted.
    3. Right-click the labor class and then click Expand. The employees of  the labor class are plotted. The available labor slots (the white spaces) are between the hours of 8 and 16 for a workday for each employee. The work center is always available (24 hours x 7 days), so the line for the work center resource is all white. The schedule for the work center resource is limited by the availability of the employee time.
    4. In the case of labor setup time is less than machine setup time the labor setup time will be evenly distributed along the machine setup time span. If labor setup time is more than that of machine setup time, then also the labor setup time is equally distributed along machine setup time. In this situation the employees could be overbooked and that overbooked information is shown on Gantt Chart as text info ( available capacity , maximum utilization) and also will show overbooking by drawing 100% utilization line. Gantt chart text info should be enabled in the current plot settings.
  4. Highlight the schedule for an operation on its constraints and assigned resources:
    1. Right-click Operation 10 and then click Highlight This. The schedule for this operation is highlighted on the work center and on the labor class constraints and employees. When multiple combinations of resources are available, CBS selects the combination of work center and employees that yields the earliest finish time and shortest operation time.

    Reset the objects displayed in the Gantt chart as follows:

    1. Right-click Operation 10 and then click Collapse. The work center and labor class lines are removed from the Gantt chart.
  5. On the toolbar, click Clear Highlights.

Adjusting Shop Order Labor

Purpose: The purpose of this exercise is to make changes to the labor requirements on a shop order and to understand the impact on the schedule. All labor changes to shop orders are sent to the Scheduling Server and cause the shop order to be rescheduled.

Windows:
Shop Order
Simulation Client

  1. Query for Shop Order XX–SO2.
  2. Click the Operation tab.
  3. Change the crew size as follows:
    1. For Operation 10, change the setup  crew size to 2 and crew size to 3.
    2. Save your changes. The start and finish dates remain the same.
    3. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 10 (as in the previous exercise).
  4. Return to the Shop Order window. Change the labor class as follows:
    1. For Operation 20, change the run labor class to XX–LC2.
    2. Save your changes. The start and finish dates remain the same.
    3. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 20.
  5. Return to the Shop Order window. Remove the labor class as follows:
    1. For Operation 30, remove Labor Class XX–LC1.
    2. Save your changes. The start and finish dates are updated.
    3. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 30 (as in the previous exercises).
  6. Return to the Shop Order window. Change the crew size to an unavailable quantity as follows:
    1. For Operation 10, change the setup crew size to 4.
    2. Press Save. Save your changes. The start and finish dates remain the same. A message appears indicating that one or more operations are unscheduled.
    3. Check the CBS Scheduled column to see which operations are unscheduled.
    4. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 20 (as in the previous exercises).
  7. Return to the Shop Order window. Reset the labor requirements for the shop order operations as follows:
    1. For Operation 10, setup  crew size to 2 and crew size to 3.
    2. Save your changes.
    3. For Operation 20, enter a labor class of XX–LC1 and a crew size of 1.
    4. Save your changes.
    5. For Operation 30, enter a labor class of XX–LC1 and a crew size of 1.
    6. Save your changes.
    7. Verify that the start and finish dates are updated.

Scheduling a Shop Order with Tool Constraints

Purpose: The purpose of this exercise is to schedule and view a shop order with a work center and tool constraint.

Windows:
Shop Order
Simulation Client

  1. Create a new shop order as follows:
    1. Create a new record.
    2. Enter XX–SO3 (where XX is your initials) as the shop order number.
    3. Enter XX–250–G1 as the part number.
    4. Enter your site name (if it is not defined as the default site for your user).
    5. In the Sched Direction list, click Backward Scheduling.
    6. Set the earliest start date to next Monday's date.
    7. Set the need date to next Thursday's date.
    8. Enter 10 as the lot size.
    9. Save your changes. The start and finish dates are updated.
  2. Reopen or refresh the Simulation Client. Review the assignments and schedule for Shop Order XX–SO3, Operation 10.

Note: The gaps between the operations allowed for the transport times after Operations 10 and 20.

Adjusting Shop Order Tools

Purpose: The purpose of this exercise is to make changes to the tool requirements on a shop order and analyze the impact on the schedule. All tool changes to shop orders are sent to the Scheduling Server and cause the shop order to be rescheduled.

Windows:
Shop Order
Simulation Client

  1. Query for Shop Order XX–SO3.
  2. Click the Operation Tools tab.
  3. Increase the tool quantity as follows:
    1. For Operation 10, change the tool quantity to 2 for Tool XX–100H.
    2. Save your changes. The start and finish dates remain the same.
    3. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 10.
  4. Return to the Shop Order window. Add more tools for an operation as follows:
    1. For Operation 10, add another tool, XX–100D, with a quantity of 1.
    2. Save your changes. The start and finish dates remain the same.
    3. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 10.
  5. Return to the Shop Order window. Remove tools for an operation as follows:
    1. For Operation 10, delete the tool records.
    2. Save your changes. The start and finish dates remain the same.
    3. Reopen or refresh the Simulation Client. Review the assignments and schedule for Operation 10.
  6. Return to the Shop Order window. Reset the tool requirements for the shop order as follows:
    1. For Operation 10, enter a tool ID of XX–100H, with a quantity of 1.
    2. Save your changes.
    3. Verify that the start and finish dates are updated to the initial condition.

Scheduling a Shop Order with Material Constraints

Purpose: The purpose of this exercise is to schedule and view a shop order with material constraints.

Windows:
Inventory Part
Shop Order
Simulation Client
Receive Inventory Part
Issue Inventory Part
Supplier for Purchase Part
Purchase Order

Note: This exercise assumes that you have no inventory available for the part XX-250-G400.

  1. Open the Inventory Part window and query for the inventory part XX-250-G400. Click the Manufacturing tab. Set the Sched Capacity to Finite Capacity.
  2. Query for the inventory part XX-250-G30. Click the Manufacturing tab. Set the sched capacity to Always Finite.
  3. Create a new shop order as follows:
    1. Create a new record.
    2. Enter XX–SO4 (where XX are your initials) as the shop order number.        
    3. Enter XX–250–G30 as the part number.
    4. Enter your site name (if it is not defined as the default site for your user).
    5. In the Sched Direction list, click Forward Scheduling.
    6. In the Earliest Start Date field, enter next Monday's date.
    7. In the Need Date field, enter next Thursday's date. 
    8. Enter 10 as the Lot Size.
    9. Save your changes. The start and finish dates will be updated. A message appears indicating that the shop order did not meet its need date.
  4. Reopen or refresh the Simulation Client window. Plot shop order XX-SO4, and review its schedule. In the Gantt chart, double-click operation 10, and click Show Materials. The shop order operation has one material role that needs to consume 10 pieces of part XX-250-G400.
  5. Double-click on the Material field to open a window for part XX-250-G400. Click the Show Contents tab. This window shows part XX-250-G400, has a lead time of 10 days and has finite availability within this time. The table lists the date, time, and quantity of available supply for this part. The table also lists the date, time, and quantity for the shop order operations that consume this part. Since part XX-250-G400 has no on hand supply and no other available supply, CBS needs to wait the lead time before it can schedule a shop order operation that requires this part. After the lead time elapses, CBS considers the part to have infinite available supply.
  6. You can plot this material on the Gantt Chart by dragging the material to the object table area. When a material displays in the Gantt Chart window, its lead time shows as a solid black line from the current time until the time when the lead time elapses. Red bars show the quantity, date, and time when the shop order operations require supply of the part. Yellow bars show the quantity, date, and time when the shop order operations produce supply of the part. A green line shows the net available supply quantity of the part.
  7. In the Gantt chart, double-click operation 30 and click Show Materials. The shop order operation has one material role to produce 10 pieces of the part XX-250-G30.
  8. Double-click on the Material field to open a window for part XX-250-G30. Click the Show Contents tab. This window shows the part XX-250-G30, has a lead time of 0 (zero) and always has finite availability. The table includes a record with a date, time, and quantity when the material supply for the part XX-250-G30 is produced from the shop order XX-SO4. This material supply becomes available for other shop order operations to consume. 
  9. Use a non-order receipt transaction to receive an on hand supply of 50 for the part XX-250-G400.
  10. Return to the Shop Order window. Right-click in the header part of the window, and then click Schedule Shop Order. The start and finish dates of the shop order, change according to the new schedule.
  11. Reopen or refresh the Simulation Client window. Plot the shop order and review its schedule. The first operation of the shop order starts based on the availability of the employee and is not prohibited by the available on hand supply or part XX-250-G400.
  12. Use a non-order issue transaction to issue 40 of the on hand supply for part XX-250-G400.
  13. Reopen or refresh the Simulation Client window. Plot the shop order and review its schedule. The first operation of the shop order starts based on the planned receipt date from the purchase order.
  14. Use the Supplier for Purchase Part window to define supplier 5000, as the supplier for part XX-250-G400.
  15. Use the Purchase Order window to create a purchase order. Enter 5000, for the supplier and next Tuesday as the receipt date. Enter a purchase order line for the part XX-250-G400, with a quantity of 50.
  16. Return to the Shop Order window. Right-click in the header part of the window, and then click Schedule Shop Order. The start and finish dates of the shop order, change according to the new schedule.
  17. Double-click on the shop order and then click the Show Contents tab. Note that the EPST has no value. This allows CBS to schedule the shop order at any point of time, when there is available material and available resources. The earliest start date of the shop order does not serve as a constraint for CBS. 

Note:  For purchased parts with finite availability, any open non-shop order demand within the purchase lead time reduces the amount of inventory, and the open purchase order supplies available for CBS. CBS does not get any manually pegged purchase order supplies. For manufactured parts with finite availability, all open, non-shop order demands reduce the amount of inventory, and the open supplies available for CBS.  

Adjust Shop Order Materials

Purpose: The purpose of this exercise is to make changes to the material requirements on a shop order, and analyze the impact on the schedule. All material changes to the shop orders are sent to the Scheduling Server, and cause the shop order to be rescheduled.

Windows:
Shop Order
Simulation Client

  1. Open the Shop Order window and query for the shop order XX-SO4.
  2. Click the Material tab. Add a new material allocation line for the part XX-250-G300, with 10 as the quantity required.
  3. Save your changes. The start and finish dates change according to the new schedule.
  4. Reopen or refresh the Simulation Client window. Plot shop order XX-SO4. Double-click on operation 10 and click the Show Materials tab. There is a new material role to consume 10 pieces of the part XX-250-G300. Double-click on the Material field to open a window for the part XX-250-G300. This part has infinite availability. When CBS has a requirement for this part, it assumes that there is always an available supply. In the table, a record exists with the date, time, and quantity when this shop order operation requires this part.
  5. Return to the Shop Order window and click the Material tab.
  6. For the part XX-250-G400, set the quantity required to 20, and set the operation number to 20.
  7. Save your changes. The start and finish dates change according to the new schedule.
  8. Reopen or refresh the Simulation Client window. Plot shop order XX-SO4. Double-click on operation 10 and click the Show Materials tab. The material role for the part XX-250-G400 no longer exists. Double-click on operation 20, and click the Shop Materials tab. There is a material role to consume 20 pieces of the part XX-250-G400.
  9. Return to the Shop Order window and click the Material tab.
  10. Remove the material allocation record for the part XX-250-G300.
  11. Save your changes. The start and finish dates change according to the new schedule.
  12. Reopen or refresh the Simulation Client window. Plot shop order XX-SO4. Double-click on operation 10 and click the Show Materials tab. The material role for the part XX-250-G300 no longer exists.
  13. Return to the Shop Order window. In the Lot Size field, enter 20.
  14. Save your changes. The start and finish dates change according to the new schedule.
  15. Reopen or refresh the Simulation Client window. Review the schedule for the shop order XX-SO4. Review the material roles at operations 10 and 20, to see the changes for the material role quantities.
  16. Return to the Shop Order window. Click the Byproduct tab. Enter a new record for the part XX-250-G10. In the Qty Per Unit field, enter 1. Save your changes.
  17. Reopen or refresh the Simulation Client window. Review the schedule for the shop order XX-SO4. Review the new material role for part XX-250-G10 at operation 30, and open its material window to see that CBS creates a material supply record from this shop order.