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Prod. Order Capacity Need

  • 1.  Prod. Order Capacity Need

    Posted Aug 07, 2019 02:19 PM
    Hello,

    I have an annoyance that I am wondering if the community can help me solve.  :)

    As we schedule our production orders it is often necessary to review the load at our work centers to make sure we are not over committing any resources. When I drill into the allocated qty I see a bunch of production orders with zero allocated time mixed in with orders that actually have time. 

    It is messy and causes confusion with my planners.  The zeros do not go away when we change operations on the orders to "finished" but they do go away when the production orders are changed to "compete" status.  This shows up in all of our work centers and machine centers.  Has anyone else seen/dealt with this?

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    William Green
    Planning Manager
    Phoenix Mecano USA Inc.
    Frederick
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    Conference-BCNAVUG_200x200


  • 2.  RE: Prod. Order Capacity Need

    Posted Aug 08, 2019 01:15 PM
    Right off the bat the easy solution would be to filter out the lines that have 0 allocated time.

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    Fred Holst
    Sign Zone LLC
    Brooklyn Center, MN
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    Conference-BCNAVUG_200x200


  • 3.  RE: Prod. Order Capacity Need

    Posted Aug 14, 2019 12:11 PM
    LOL

    Thanks Fred.

    Sometimes the simplest solutions are the easiest to implement!  Filtering will help for now, but I would still like to understand why some production orders show up with a zero allocated quantity and others do not.  I am hoping by understanding the cause we can possibly do something different as we plan or output that will eliminate the need for filtering each time the planners need to review load.  It will also reduce the amount of data cleanup (filtering the zeros) needed for some KPI related charting we do when exporting the data to excel.

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    William Green
    Phoenix Mecano USA Inc.
    Frederick
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    Conference-BCNAVUG_200x200


  • 4.  RE: Prod. Order Capacity Need

    Posted Aug 14, 2019 12:15 PM
    I didn't mean to sound so coy when I suggested that, sorry.

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    Fred Holst
    Sign Zone LLC
    Brooklyn Center, MN
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    Conference-BCNAVUG_200x200


  • 5.  RE: Prod. Order Capacity Need

    Posted Aug 24, 2019 07:59 AM
    No worries Fred.  I really laughed at myself for overlooking the option to filter :)

    ------------------------------
    William Green
    Planning Manager
    Phoenix Mecano USA Inc.
    Frederick
    ------------------------------

    Conference-BCNAVUG_200x200


  • 6.  RE: Prod. Order Capacity Need

    TOP CONTRIBUTOR
    Posted Aug 14, 2019 12:16 PM
    One thing to look at is whether the routing assigned to the production order has any Run or Start time assigned for that particular work center.  It is possible to add a work center to a routing with no time assigned.  Then when that routing is used on a production order, the work center will show as zero time since nothing was established on the routing.  Could that be what's happening in your case?

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    David Wiser
    Project Manager
    Tigunia
    Seattle WA
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    Conference-BCNAVUG_200x200


  • 7.  RE: Prod. Order Capacity Need

    Posted Aug 26, 2019 01:23 PM
    Thanks for your suggestion David!

    I think you pointed me in the right direction.

    I have been tracking and reviewing the orders that are showing the zeros.  They all have time (either run or setup or both) on the routers.  However, while reviewing the routers I found that all of the production orders in question are set up as parallel routers.  it seems that when the routers hit the parallel operations the first operation shows its scheduled time but the other operations show as 0.  If one of the parallel operations still has time remaining after the first is complete then the time shows back up for the second operation with only the remaining time.

    This opens a new can of worms because in our production we may have two machines running in tandem (using the parallel routing) but performing distinctly different operations and with separate operators.  If NAV is only showing time(load) for one of the two operations then we see available capacity that the operation where it shows zero time(load) and we are double booking the machine.

    I will now be researching if it is it possible to have NAV account for all time in parallel operations or if we need to reconsider how we structure out routers.

    ------------------------------
    William Green
    Planning Manager
    Phoenix Mecano USA Inc.
    Frederick
    ------------------------------

    Conference-BCNAVUG_200x200


  • 8.  RE: Prod. Order Capacity Need

    TOP CONTRIBUTOR
    Posted Aug 27, 2019 07:00 AM
    Consider increasing the capacity to 2 to recognize that you have two machines. 



    Sent from my Verizon, Samsung Galaxy smartphone



    Conference-BCNAVUG_200x200


  • 9.  RE: Prod. Order Capacity Need

    Posted Aug 28, 2019 12:35 PM

    Hi William,

    Consider a couple basic tests to best mitigate the issue for your schedulers and planners.  My opinion if I understand the issue correctly, I believe this falls on posted output and/or posting of the times, likely the ladder.

    When you post output, does the order update the allocated time?  Easy test here is pick a job, identify the total hours, post half of the output and see if the time reduces in half.  If it does, you are likely on the right path on changing setups between serial and parallel, there might be further setup or change to needing to be required.

    If they do not, then same test with posting of run time.  This should reduce the allocated hours respectively, however, you must do this for all routing lines!

    I hope this helps you out additionally with this issue.

    Warm Regards.



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    Steven Filipiak
    Business Consultant
    Columbus Global
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    Conference-BCNAVUG_200x200


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