Scheduling and Rescheduling Shop Orders Using the
Infinite Scheduler - Key Exercises
IMPORTANT |
It is extremely important that you set up and work
within your own site to maintain your data integrity. If you work
within any other site, you will compromise your own exercise data as
well as the data of other students. Predictable exercise results require
that your data be isolated in your own site. |
Basic Data Setup
Discrete Manufacturing overview Racing Engine
Purpose: The purpose of this exercise is to create the
required data that will be used in the Discrete Manufacturing exercises. This
sets up data for your site that only needs to be done once for Discrete
Manufacturing course exercises
- If you haven't done so already, set up your site for discrete
manufacturing of racing engines.
General
exercise for Overview of Discrete Manufacturing Data
Required Data
Make sure that your site is not CBS enabled. If your site is
CBS enabled, the results of the scheduling could be completely different.
Main Exercise
Purpose: The purpose of this lesson is to study the
changes in Shop Order/Operations when changing the scheduling
direction and changing work center parameters.
Windows:
Shop Order
Shop Order/Operation
Work centers
Reschedule Shop Order By Work Centers
Reschedule Shop Order By Site
Background Jobs
Shop Orders with Parallel Operations
Study the
parallel operations in Shop Order / Operations and check the operation
scheduling when changing the scheduling direction.
- Open the
Shop Order window and create a new record.,
- If the value for the Site field is not your site, change it to your
site.
- In the Part No. field, enter 21-410 as the part to be manufactured.
- In the Need date field, enter a date of one week ahead.
- In the Lot Size field, enter 50 for the quantity to be
manufactured. Make sure that the Sched Direction field is set to Backwards
Scheduling and Earliest Start Date field is set to current date.
- Save the information.
Note: The Start and Finish fields are calculated based
on the manufacturing lead time for the piston assembly. The Finish field
should contain the previous working day before the date in the Need Date
field.
- Click the Operation tab and see the four lines of operations.
Verify the operation 20 is set as parallel. Go to Op Start Date and Op
Finish Date columns and see the starting and ending time of each
operation is stated. Note the operation 10 and 20 have same starting and
ending time. Note operation 40 has finished at the end of the day stated in Finish
field on
Shop Order Header.
- Go to the Mfg Factor column. Change the value for operation 20 to 0.05. Save the change.
- Go to Op Start Date and Op Finish Date columns. Verify the operations 10
and 20 have different starting times but same ending time.
- Go to
Shop Order header and change Sched Direction
field to Forward Scheduling. Save the changes.
- Click the Operation tab and go to Op start Date and Op
Finish Date columns.
- Note the operation 10 and 20 have same starting time but different ending
times. Also note the operation 10 and 20 have started in the beginning of
the date stated in the Start field in the
Shop Order
Header
Schedule Shop Orders
- Open the
Shop Order window and query for the shop order for
this exercise. If you did not record the shop order number, query for your
site, the 21-410 part number, and a quantity of 50.
- Change the Sched Direction to Backward Scheduling. Save the
information.
- Go to
Operation tab and verify the operation 20 is set to
parallel. Verify the Work Center No for that operation is 200. Note
the starting time of operation 20 is later than the starting time of
operation 10.
- Open the
Work Center window. Query for the work center 200. Change
the Utilization Field to 20. Now the work center is working in 20%
utilization.
- Go to Shop Order again. Right click anywhere in the header and click Schedule
Shop Order.
- Go to Op Start Date and Op Finish Date columns in Operation
tab. Note the starting time of operation 20 is earlier than the starting
time of operation 10.
- Go back to
Work Center window. Click the Resources tab.
Change the value in the column Efficiency to 60. Save the change.
- Go to the shop order again. Right click anywhere in the header and click Schedule
Shop Order.
- Go to Op Start Date and Op Finish Date columns in Operation
tab. Note the starting time of operation 20 has become earlier than the
previous value. It means the total shop order operation time has increased
again.
- Go back to
Work Center window. Change the values in Utilization
and Efficiency fields back into 100. Save the changes.
Reschedule by Work Center
- Open the
Shop Order window. Create a new shop order for the
part 21-410 for a quantity of 5 pcs.
- Make sure the field Site displays your site, Sched Direction
is Backwards Scheduling, and Need Date is one week ahead. Save
the information.
- Click the Operation tab. Record the operation starting time for operation 10 and the operation ending time for
operation 40.
- Create new shop orders for quantities 10, 15, 20 with same need date and
record operation starting and ending time for each shop orders.
- Fill the below table with those details.
Shop Order Number |
Manufactured Qty. |
Op Starting Time for Operation 10 |
Op Ending Time for Operation 40 |
|
5 |
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10 |
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15 |
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20 |
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- Open the
Work Center window. Query for the work center 300
in your site.
- Change the field Utilization to 50. Click the
Resource
tab and change the field Efficiency to 50. Save the changes.
- Open the
Reschedule Shop Orders By Work Center window.
- Enter your site to the field Site and 300 to the field Work
Center. You can use the List button also to fill those fields.
- Press OK to execute rescheduling process.
- Go back to the four shop orders you created. If you have closed those shop
orders, query
Shop Order window for the shop order numbers you
have noted in the table above.
- Check the starting and ending time of each shop order. Note that the total
operation time has been increased in all shop orders as the utilization and
efficiency dropped in a work center
- If you want, you may analyze how much of the time for each operation has
been delayed. Determine how much additional time allocated for the
operations 10, 30 and 40 after rescheduling.
- Go back to
Work Center window. Query for work center 300.
Change Utilization and Efficiency fields back into 100. Save
your changes.
Reschedule by Site
- Open
Shop Order window. Create a new shop order for the part
21-110, quantity 5 and need date one week ahead. Save the information.
- Click
Operation tab. Note the values in Op Start Date and Op
Finish Date columns. Fill the 2nd and 3rd columns in the table below with
details.
Operation |
Op Start Date Before Rescheduling |
Op Finish Date Before Rescheduling |
Op Start Date After Rescheduling |
Op Finish Date After Rescheduling |
10 |
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20 |
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30 |
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40 |
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50 |
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60 |
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- Open the
Work Center window. Query for the work centers 100,
300 and 810 in your site. Change the field Utilization for every work
center to 75. Now work centers 100, 300 and 810 in your site are working
at 75% utilization. Save the changes.
- Open the
Reschedule Shop Orders By Site window.
- Enter your site into the field Site. You may use List of Values for
that.
- Click OK to execute rescheduling process
- Open Background Jobs window and verify background job is
completed.
- Refresh the shop order. Go to the
Operation tab. Check the
values in Op Start Date and Op Finish Date column and fill the
4th and 5th columns in the above table
- Compare the values. You may see that allocated time for all operations
have been increased after rescheduling as work centers 100, 300 and 810 are
under utilized in your site.
- Go back to
Work Center window. Query for the work centers
100, 300 and 810 in your site. Change the field Utilization back into
100. Save the changes.
Note: The Discrete Manufacturing course will not use these shop orders
after this exercise, so you may further process this shop order if you desire.