scheduling.pdf

Epicor ERP Scheduling Course 10.0.700.2

Disclaimer This document is for informational purposes only and is subject to change without notice. This document and its contents, including the viewpoints, dates and functional content expressed herein are believed to be accurate as of its date of publication. However, Epicor Software Corporation makes no guarantee, representations or warranties with regard to the enclosed information and specifically disclaims any applicable implied warranties, such as fitness for a particular purpose, merchantability, satisfactory quality or reasonable skill and care. As each user of Epicor software is likely to be unique requirements in of thethis usedocument of such software andEpicor their business of this document are always advisedintotheir discuss the content with their accountprocesses, manager. users All information contai ned herein is subject to change without notice and changes to this document since printing and other important information about the software product are made or published in release notes, and you are urged to obtain the current release notes for the software product. We welcome user comments and reserve the right to revise this publication and/or make improvements or changes to the products or programs described in this publication at any time, without notice. The usage of any Epicor software shall be pursuant to an Epicor end user license agreement and the performance of any consulting services by Epicor personnel shall be pursuant to Epicor's standard services terms and conditions. Usage of the solution(s) described in this document with other Epicor software or third party products may require the purchase of licenses for such other products. Where any software is expressed to be compliant with local laws or requirements in this document, such compliance is not a warranty and is based solely on Epicor's current understanding of such laws and requirements. All laws and requirements are subject to varying interpretations as well as to change and accordingly Epicor cannot guarantee that the software will be compliant and up to date with such changes. All statements of platform and product compatibility in this document shall be considered individually in relation to the products referred to in the relevant statement, i.e., where any Epicor software is stated to be compatible with one product and also stated to be with another product, should notsame be interpreted that such Epicor Additionally software is compatible with both of compatible the products running at the same ittime on the platform or environment. platform or product compatibility may require the application of Epicor or third-party updates, patches and/or service packs and Epicor has no responsibility for compatibility issues which may be caused by updates, patches and/or service packs released by third parties after the date of publication of this document. Epicor ® is a registered trademark and/or trademark of Epicor Software Corporation in the United States, certain other countries and/or the EU. All other trademarks mentioned are the property of their respective owners. Copyright © Epicor Software Corporation 2014. All rights reserved. No part of this publication may be reproduced in any form without the prior written consent of Epicor Software Corporation.

ED820905 90521-10-9286-58310702 10.0.700.2 Revision: July 25, 2014 2:45 a.m. Total pages: 70 course.ditaval

Scheduling Course

Contents

Contents Scheduling Course..................................................................................................................6 Before You Begin....................................................................................................................7 Audience.........................................................................................................................................................7 Prerequisites....................................................................................................................................................7 Environment Setup..........................................................................................................................................8 Workshop Constraints..............................................................................................................................8

Scheduling Overview.............................................................................................................9 Company Configuration.......................................................................................................12 Workshop - Review Company Configuration..................................................................................................12

Daily Scheduling Processes..................................................................................................14 The Role of the Scheduler..............................................................................................................................16 Resource Loading and Capacity......................................................................................................................17 Scheduling Tools............................................................................................................................................17 Workshop - Resource Group Scheduling Board.......................................................................................18 Access the Resource Group Scheduling Board..................................................................................18 Locate a Job....................................................................................................................................19 User Preferences..............................................................................................................................19 Tool Bar...........................................................................................................................................20 Change Grid Scale...........................................................................................................................20 Drag and Drop Scheduling...............................................................................................................20 Accept or Undo the Schedule..........................................................................................................21 Workshop - Overload Informer...............................................................................................................21 Workshop - Reschedule a Job.................................................................................................................22 Select the Overloaded Resource.......................................................................................................22 Move the Job..................................................................................................................................22 Capacity Management...................................................................................................................................23 Production Capacity................................................................................................................................25 Workshop - Define a Production Calendar.......................................................................................26 Workshop - Assign Calendar to Resource Group..............................................................................27 Scheduling Capacity...............................................................................................................................28 Workshop - Schedule Jobs with Multiple Resources.........................................................................29 Manufacturing Lead Time.......................................................................................................................30 Queue Time.....................................................................................................................................30 Workshop - Manage Queue Time....................................................................................................31 Change Queue Time................................................................................................................31 Verify/Undo Queue Time Change.............................................................................................31 Move Time......................................................................................................................................32 Overlap Scheduling.................................................................................................................................33 Workshop - Overlap Scheduling.......................................................................................................34 Finish-to-Finish Scheduling.......................................................................................................34

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Contents

Scheduling Course

Start-to-Start Scheduling..........................................................................................................36 Multi-level Scheduling / Branch Scheduling......................................................................................36 Workshop - Material Status and Move......................................................................................37 Global Scheduling..........................................................................................................................................38 Infinite Capacity......................................................................................................................................39 Workshop - Increase Capacity..........................................................................................................39 Workshop - Review the Resource Group Overload...........................................................................40 Workshop - Update Resource Capacity............................................................................................40 Finite Capacity........................................................................................................................................41 Finite and Infinite Scheduling..................................................................................................................42 Global Scheduling Process......................................................................................................................43 Workshop - Calculate Global Scheduling Order................................................................................45 Calculate Global Scheduling Order...........................................................................................45 View the Calculation Results.....................................................................................................46 Modify Scheduling Priority Codes.............................................................................................46 Recalculate Global Scheduling Order........................................................................................48 View the Recalculation Results..................................................................................................48 Override Global Scheduling Order.............................................................................................49 Workshop - Set Global Scheduling Options......................................................................................49 Set Finite Horizon.....................................................................................................................49 Lock a Job Schedule.................................................................................................................50 Workshop - Rough Cut Scheduling..................................................................................................50 Set the Rough Cut Horizon.......................................................................................................50 Review the Rough Cut Load.....................................................................................................50 Workshop - Process Global Scheduling............................................................................................51 Global Scheduling Process........................................................................................................51 View Resource Load.................................................................................................................52 Scheduling Reports.................................................................................................................................53 Workshop - Shop Load Report.........................................................................................................54 Workshop - Priority Dispatch Report................................................................................................54 Workshop - Schedule Impact Report................................................................................................55 Workshop - Job Status Report.........................................................................................................56

Specialized Scheduling Processes........................................................................................57 Batch Scheduling...........................................................................................................................................57 Batch Jobs with Identical Methods..........................................................................................................58 Workshop - Batch Jobs with Identical Methods................................................................................58 Create Jobs..............................................................................................................................58 Batch Jobs................................................................................................................................59 Schedule the Batch Job............................................................................................................60 Review Jobs..............................................................................................................................60 Workshop - Save and Restore a Schedule.......................................................................................................62 Enter Scheduling Changes......................................................................................................................62 Generate Schedule Impact Report...........................................................................................................63 Undo the Changes..................................................................................................................................63 Workshop - Multi-Constraint Scheduling........................................................................................................63

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Contents

Add New Resource.................................................................................................................................63 Add Resource to Job Operation..............................................................................................................64 Reschedule the Job.................................................................................................................................65 View the Schedule Change.....................................................................................................................65 Workshop - Minimize WIP..............................................................................................................................66 Create Scheduling Priority Code..............................................................................................................66 Create a Job with Multiple Assemblies....................................................................................................67 Backward Schedule the Job....................................................................................................................67 Forward Schedule the Job.......................................................................................................................68 Re-schedule the Job................................................................................................................................68

Conclus ion.............................................................................................................................69

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Scheduling Course

Scheduling Course

Scheduling Course This course introduces the theory of scheduling and the use of the scheduling tools in the Epicor ERP application. The objective is to provide a foundation using the application to achieve realistic production schedules and load estimates that can be used to help control the shop floor and aid in delivery promises. The Scheduling Course focuses on creating job schedules, computing resource loads, and communicati ng this information to stakeholders. Upon successful completion of this course, you will be able to:

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Understand scheduling in a manufacturing environment.

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Apply scheduling features available in the Epicor ERP application.

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Understand scheduling options.

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Use the application to help create realistic production schedules and load estimates.

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Scheduling Course

Before You Begin

Before You Begin Read this topic for information you should know in order to successfully complete this course.

Audience Specific audiences will benefit from this course. •

Production Control

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Material Planning

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Operations

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Scheduling

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Engineering

Prerequisites To complete the workshops in this course, the necessary modules must be licensed and operating in your training environment. For more information on the modules available, contact your Epicor Customer Account Manager at [email protected]. It is also important you understand the prerequisite knowledge contained in other valuable courses. •

Navigation Course - This course introduces navigational aspects of the Epicor application's user interface. Designed for a hands-on environment, general navigation principles and techniques available in two user interface modes - Classic Menu and Modern Shell Menu. Workshops focus on each of these modes and guide you through each navigational principle introduced.

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Engineering Course- This course outlines the creation of a new part, engineering foa method of manufacture (MOM), approval of a method, and creation of a method available for use. Methods can be used in the quoting process, job entry, or as the basis for a new method.

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Industry Knowledge - A working knowledge of job scheduling capacity planning concepts.

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Before You Begin

Scheduling Course

Environment Setup The environment setup steps and potential workshop constraints must be reviewed in order to successfully complete the workshops in this course. Your Epicor training environment, in which the Epicor demonstration database is found, enables you to experience Epicor functionality in action but does not affect data in your live, production environment. The following steps must be taken to successfully complete the workshops in this course. 1.

Verify the following or ask your system administrator to verify for you: •

Your Epicor training icon (or web address if you are using Epicor Web Access) points to your Epicor training environment with the Epicor demonstration database installed. Do not complete the course workshops in your live, production environment. Note It is recommended that multiple Epi cor demonstration databases are installed. Contact Support or Systems Consulting for billable assistance.

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The Epicor demonstration database is at the same service pack and patch as the Epicor application. Epicor's education team updates the Epicor demonstration database for each service pack and patch. If your system administrator upgrades your Epicor application to a new service pack or patch, he or she must also download the corresponding Epicor demonstration database from EPICweb > Support > Epicor > Downloads and install ti . If this is not performed, unexpected results can occur when completing the course workshops.

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Your system administrator restored (refreshed) the Epicor demonstration database prior to starting this course. The Epicor demonstration database comes standard with parts, customers, sales orders, and so on, already defined. If the Epicor demonstration database is shared with multiple users (that is, the database is located on a server and users access the same data, much like your live, production environment) and is not periodically refreshed, unexpected results can occur. For example, if a course workshop requires you to ship a sales order that came standard in the Epicor demonstration database, but a different user already completed this workshop and the Epicor demonstration database was not restored (refreshed), then you will not be able to ship the sales order. Epicor's education team has written the course workshops to minimize situations like this from occurring, but Epicor cannot prevent users from manipulating the data in your installation of the Epicor demonstration database.

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Log in to the training environment using the credentials manager/manager. If you are logged into your training environment as a different user, from the Options menu, select Change User.

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From the Main menu, select the company Epicor Education (EPIC06).

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From the Main menu, select the Main Site.

Workshop Constraints The workshops in this course can be performed only once in each instance of a restored (refreshed) database. If a user has already completed these workshops in the database, the database must be restored (refreshed) before another user can complete this course.

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Scheduling Overview

Scheduling Overview Scheduling is the process of determining the time, tasks, and resources required to attain an objective. This objective may be large and complex, such as constructing a new building, or a simple task such as preparing a meal. In order to successfully schedule you must have the following information: •

Tasks that must be completed

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Order in which tasks need to be completed, including identifying any pre-requisites

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Time needed to complete each task

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Projected completion date of each task

The process of scheduling determines when each task (or operation) must be started in order to meet a target completion time, and which tasks may potentially delay meeting this objective. In a manufacturing company the process of scheduling requires the following: 1.

A list of operations to be completed and the order in which they must be completed, usually called a Routing or Bill of Operations.

2.

Estimated times to set up machines and to perform the actual manufacturing operations.

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A target start date or completion date.

The scheduling process then assigns estimated start and completion dates for each operation in one of two ways: Forward Scheduling

This method takes the target start date and adds the estimated operation time of the first operation to compute its estimated completion date. It then uses that date as the estimated, or scheduled, start date for the next operation, continuing until all operations are scheduled and an estimated completion date for the job results. This process is illustrated in the following graphic:

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Scheduling Overview

Scheduling Course

Backward Scheduling

This method begins with the job's target completion date and subtracts the estimated operation time for the last operation to compute its scheduled starting time which, in turn, becomes the scheduled completion time of the previous operation. This process continues until the first operation is scheduled and the scheduled start date for the job results. This process is illustrated in the following graphic:

In both cases the calculations are similar, only the scheduling direction is different.

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Scheduling Overview

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Company Configuration

Scheduling Course

Company Configuration Much of company configuration is completed at the time of implementation. All application modules require some master table definition. This section of the course reviews pertinent configuration options that impact Scheduling. Company Configuration Navigate to Company Configuration. Menu Path: System Setup > Company/Site Maintenance > Company Configuration

Navigate to the Modules > All Modules > General sheet. Options on this sheet i nclude setting defaults for site, warehouse, and costing method. Job Scheduling

Navigate to the Modules > Production > Job sheet. •

Global Reschedule Started Operations - This directs the Global Scheduling process, to allow an operation that is already in process to be moved (if necessary) when running the Scheduling procedure finitely. If you do not wish to move operations that are already in process, you may either clear this check box or lock the job schedule.

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Allow Scheduling Before Today - This applies only when backward scheduling a job using the infinite scheduling assumption, and directs job scheduling to allow an operation to start earlier than the current date. If this check box is not selected, and job scheduling determines that an operation must start earlier than today in order to meet the planned due date (need date) of the job, job scheduling schedules the job in a forward direction beginning with the current date. It is likely that the job will be scheduled to complete after its need date and the user receives an appropriate warning.

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Load Relieved By - When reporting labor hours, the quantity reported to an operation as complete determines the amount of load to be removed from the resource or resource group. If the load is relieved by Quantity (the default setting), then the load hours to be removed are computed based on the quantity completed and the earned hours. If load is relieved by Hours, then the number of labor hours reported will be subtracted from the number of hours estimated (or Loaded) on the resource for the current operation. The latter setting is especially important for companies that manufacture items in job quantities of one.

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Change Impact Grace Periods - When printing the Schedule Impact Report or the Change Impact Informer to view planned what-if changes to the job schedules, these numbers determine whether or not a job is

considered the scheduled completion date of aearly. job isIf earlier by morecompletion than the number indicated inon thetime. EarlyIfGrace Period, the job is considered the scheduled date ofofadays job is later than the number of days in the Late Grace Period, the job is considered to be late. Otherwise, the job is considered to be on time. This determines the number of jobs that fall into each category on the report or inquiry. •

Change Impact Price List - This is used by the Schedule Impact Report and shows the revenue resulting from early, on time, and late jobs for both the actual and what-if job schedules. Specifically, it shows changes in the revenue figures resulting from rescheduling jobs in what-if mode.

Workshop - Review Company Configuration In this workshop, review the Company Configuration options that impact Scheduling. Navigate to Company Configuration. 12

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Company Configuration

Menu Path: System Setup > Company/Site Maintenance > Company Configuration 1. Navigate to the Modules > Production > Job sheet. 2. Select or verify the Global Reschedule Started Operations check box is selected. 3. Select or verify the Allow Scheduling Before Today check box is selected. 4. Review the settings assigned for the Early Grace Period (Days) and Late Grace Period (Days) fields. 5. In the Load Relieved by section, verify Quantity is selected. 6. Click Save. 7. Exit Company Configuration.

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Daily Scheduling Processes

Scheduling Course

Daily Scheduling Processes This section of the course reviews scheduling process that takes place during a typical work day. Scheduling determines the time, tasks, and resources required to attain an objective. This objective can be large and complex, such as constructing a new building, or a simple task such as preparing a meal.

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Scheduling Course

The Role of the Scheduler A scheduler performs an important function in a manufacturing company. The scheduler performs the following tasks: 1.

Determines demand for resource time from all jobs that have been scheduled. This process is referred to as Capacity Management.

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Prepares the shop paperwork, such as the Job Traveler, any necessary drawings or other documentation, and the dispatch list.

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Communicates this information to the appropriate stakeholders, such as manufacturing, material planning, and sales.

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Finishes jobs on time, or ahead of due dates.

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Sequences work in order to make the most efficient use of resources.

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Maintains high quality.

Scheduling can be a very complex task. There are numerous scenarios that can hinder effective scheduling. The following are some of the scenarios: •

Multiple routings and alternate paths through the shop floor. Not all jobs will pass through the same set of resources, with the result that there will be uneven loads on resources during the same time period or across different time periods. It is likely that the planned and actual loads on resources vary from one resource to another, or from one day or week to another. It is also likely that in any given day or week, the resource may have more load planned than it can handle and is said to be overloaded. This in turn both causes, and is caused by: 1.

Uncertain arrival times at resources. In most manufacturing companies the scheduled times and actual times for operations can differ because there are no resources available to perform an operation when it actually arrives at a resource center (or resource group) thereby delaying the actual completion of an operation.

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If a resource is available, it may make sense to start an operation early in order to keep a resource busy or guard against unanticipated demands for the resource's time. Both of these cases cause the scheduled and actual start and completion times to diverge.

The above illustrates the necessity of estimating the resource loads by day and/or week in order to assure that there is adequate time available on the resources and to identify any jobs that may be late due to lack of resource availability. Not only that, but there is an emotional aspect to scheduling. All jobs may display to be equally important to the application while in fact some jobs are more important than others. A job for a key customer will always receive more attention than a job for items destined for inventory. The key questions include Who is the customer? and How important is this order? . When detailed scheduling is not an option, the only questions areHow well will it be done?and How will the application communicate the results?.

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Resource Loading and Capacity Loading

When the Epicor ERP application computes a job schedule, it also computes the load on all resources that the job uses. The load is time-phased in that the hours required to perform an operation are scheduled to be used at the time the operation is scheduled to run. Therefore, load during a given time period such as a day or week represents the demand for time on the resource. While the application is computing scheduled start and completion times it also calculates the load on the resources. Load refers to the amount of work that is estimated to take place in a given time period. Example An operation takes one hour to set up the machine, and five hours to produce the items, requires six hours of load on the resource where it is scheduled to run. Capacity

Capacity is the supply of a resource. It is a measure of the amount of time available or the number of units that can be produced per time period. Capacity must take the available hours per resource per day (in this course we will use daily time periods). This implies the following: 1.

The capacity of a resource is limited, or finite. In any day or week there is a maximum amount of work that can be done on a resource given its availability.

2.

Capacity cannot be stored; if it is not consumed it disappears.

Capacity must take into consideration efficiency and utilization. Efficiency is a measure of actual output as compared to the standard or planned output for the resource. It is usually expressed as a percentage. Example A resource operating at 120 percent produces on average 20 percent more output per time period than the standard, or expected, output for this resource. Utilization refers to the amount of available time that a resource is actually in operation. If a resource is available for ten hours but operates only nine of those hours, the utilization is 90 percent. By definition, resource utilization cannot exceed 100 percent.

Scheduling Tools Scheduling Boards

The Scheduling Boards provide a graphical view of schedules. The following scheduling boards are available: •

Resource Scheduling Board - View all operations scheduled on a resource, or for an entire resource group.

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Job Scheduling Board - View the operations schedule for a job or all jobs linked to a project.

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Multi Resource Scheduling Board - Review and modify scheduled jobs at the resource level. Review the schedule for one resource or for many resources. This scheduling board is available only if Advanced Planning and Scheduling (APS) is licensed.

Overload Informer

The Overload Informer displays a list of resource groups and resources that are overloaded or have more load planned in a given time period than available capacity.

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Scheduling Course

The Overload Informer provides overload information by comparing actual resource overload, what-if resource overload, and overload percentages.

Workshop - Resource Group Scheduling Board This workshop covers the available features of the Resource Group Scheduling Board. Navigate to the Resource Group Scheduling Board. Menu Path: Production Management > Scheduling > General Operations > Resource Scheduling Board Important This program is not available in the Epicor Web Access.

Access the Resource Group Scheduling Board 1. For the Scheduling Board Type, select Resource Group. 2. In the Start Date field, select 01/01/2015. 3. In the End Date field, select 12/31/2015.

The date range must be wide enough to display the load on the resource scheduling board. 4. In the Resource Group field, enter ASM and press Tab. 5. Click Refresh. 6. Navigate to the Schedule sheet.

The load assigned jobs display.

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Locate a Job 1. From the Operation list, select job 2193.

(0/10.10) represents the (Assy Seq/Opr Seq.Opr Detail). 2. Right-click on the operation and select Start Time. 3. Right-click on the 2193 (0/10.10) job operation on the list and select Job Tracker.

The Job Tracker displays. 4. In the tree view, expand the Operation node and select Opr:10 OP: ASSEM. 5. Review the operation detail. 6. Exit the Job Tracker and return to the Resource Group Scheduling Board.

User Preferences 1. From the Toolbar, select User Preferences (fourth icon from the left).

The Scheduling Job Preferences window displays. You can use this window to change the settings on the scheduling board. 2. Review the default Color Settings.

Review the default colors assigned to the sample time bars and their descriptions. Description

Color

CompleteColor

Green

LateColor

Red

LockedColor

Olive Green

QueueColor

Light Blue

WhatIfColor

Yellow

3. In the Assembly Move Option field, verify Assembly - All Operations displays. 4. In the Operation Move Option field, verify Operation Only displays.

These settings are the default options for moving assemblies and operations on the Resource Scheduling Board. Use these fields to change how assemblies and operations are moved on this scheduling board. 5. Exit the Scheduling Board Preferences window.

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Scheduling Course

Tool Bar 1. On the Toolbar, hover over each Toggle button and review the display when turned on or off.

These icons are located to the right of User Preferences and allow changes to the following graphical displays: Toggle Button

Description

Toggle Queue Time

Displays an estimate of how long the operation will wait until starting.

Toggle Completion Time

Indicates the number of units already completed for this operation.

Toggle Original Time

Shows the placement of this operation before performing any rescheduling activities.

Toggle Move Time

Estimate of the time necessary to move this job to its next operatio n.

2. Verify that each Toggle button is on as indicated in red.

Change Grid Scale 1. Between the Left and Right arrows of the date range, click and hold the mouse while moving the mouse left and right.

This expands and contracts the Scheduling Board visible detail. 2. Adjust the scale of the scheduling board so it displays the scope of the schedule you need. 3. Remain in the Resource Group Scheduling Board.

Drag and Drop Scheduling When using drag and drop scheduling on the scheduling board, the load is placed in What-if scheduling mode. The change made to the operation takes place only in the scheduling board. It does not affect the job's schedule until the change is accepted. 1. On the Operation list, right-click job 2193 and select Start Time. 2. Click and hold the operation Time bar, then drag and drop it one week to the left.

When you release the mouse button, the Move Job window displays, allowing you to make the following changes: •

Forward or Backward scheduling enables either the Start Date or Due Date.

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The Move Option field indicates how the job will be impacted by the move.

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Production Complete and Setup Complete remove load when accepted.

3. For the Schedule option, select Forward. 4. In the Move Option field, select or verify Operation Only displays. 5. Click OK.

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The time bars separate with the move. The Yellow time bar represents the What-If schedule and the Blue time bar represents the srcinal schedule. The schedule is not changed until accepted.

Accept or Undo the Schedule 1. From the Actions menu, select Undo All Changes. •

Undo All Changes - Restores moved jobs and operations back to srcinal schedule.

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Undo Current Job Changes

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- Restores only the selected job to its srcinal schedule. Accept All Changes - Changes the srcinal job schedule to the what-if dates.

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Accept Current Job Changes - Changes the srcinal job schedule for the selected job only.

2. Exit the Resourse Group Scheduling Board.

Workshop - Overload Informer In this workshop, explore the general functionality of the Overload Informer dashboard including Advanced Search, Sort Options, and details that displays on the Actual and What-If sheets. Navigate to the Overload Informer. Menu Path: Production Management > Scheduling > General Operations > Overload Informer 1. Click Refresh. 2. Navigate to the Actual sheet to view the dashboard detail. 3. Click the Column Headers for different ways to view the dashboard data. 4. Navigate to the Advanced Search sheet. 5. Click Clear to clear the fields. 6. In the Percent Over >= field, enter 15. 7. Click Refresh and navigate to the Actual sheet.

Resources in excess of a 15% overload display. 8. Click and hold the Resource Group Desc column header, then drag and drop it into the area directly above the heading.

The display is now grouped by a resource group. 9. In the Actual grid, review the list of resource groups. 10. Remain in the Overload Informer for the next workshop.

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Scheduling Course

Workshop - Reschedule a Job This workshop reinforces understanding of the Overload Informer and the use of drag and drop rescheduling. The workshop begins by identifying overloaded resources on the Overload Informer, then opens the corresponding resource scheduling board.

Select the Overloaded Resource 1. Navigate to the Advanced Search sheet. 2. Click Clear to clear the fields. 3. In the Resource Group field, select Asm Bench and click Refresh. 4. Navigate to the Actual sheet.

The occurrences of overload for this resource display. 5. Navigate to the Advanced Search sheet. 6. In the Resource ID field (displaying the AB1 resource), right click and select Open With > Resource Scheduling Board.

The Resource Scheduling Board displays. If the AB1 resource does not display enter it manually. 7. Verify that for the Scheduling Board Type, the Resource radio button option displays. 8. In the Start Date field, select 01/01/2015. 9. In the End Date field, select 12/31/2015. 10. Click Refresh.

Move the Job 1. Navigate to the Schedule sheet. 2. Right-click on job 2193 and select Start Time. 3. Select Job 2193, then drag-and-drop the operation to begin one week later.

The Move Job window displays. 4. In the Schedule field, select Forward.

The date defaults based on the drag-and-drop move. 5. In the Move Option field, select Job - All Operations.

This option reschedules operations on this resource group. All operations are rescheduled after forward scheduling. However if multiple operations for a single job are scheduled at this resource group, this option leaves gaps for any intervening operations on additional resource groups. 6. Accept the remaining defaults.

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7. Click OK.

The what-if schedule is created. 8. From the Actions menu, select Undo All Changes. 9. Exit the Resource Scheduling Board. 10. Exit the Overload Informer.

Capacity Management According to the Association for Operations Management (APICS) dictionary, Capacity Management is: The function of establishing, measuring, and adjusting limits or levels of capacity. It is the process of determining how much Labor and Machine Resources are required to accomplish the tasks of production. Open and Planned Orders are translated into their hours demanded at each resource. There are two different definitions of Capacity Management. The first one establishes, measures, and adjusts. This refers to the supply side and answers the question, How much capacity do we have?. The second determines how much labor and machine resources are required. This refers to the demand side and answers the question, How much capacity do we need?. Capacity Management is the of matching supplyas(capacity) with demand (load). This isknown commonly using various load reports or aprocess graphical display known a load profile . The latter is better as thedone Scheduled Load Graph, which displays the capacity for a resource or resource group along with the scheduled (planned) load, and identifies those periods that are overloaded and under-loaded. The objective of Capacity Management is to identify points of manufacturing constraint on the shop floor and what, if anything, can be done to relieve them. It does not attempt to provide level loads across all resources (or resource groups) nor does it attempt to load level by period. Capacity Management provides a measurement of the capacity needed for all resources to meet the production and shipment schedules. One of the most familiar illustrations of load and capacity is the funnel analogy. Example You can view input to a resource as a liquid poured into the funnel - regardless of how much liquid we pour into the funnel there is a fixed amount which will exit the funnel. The size of the opening at the bottom of the funnel determines this amount - the rate at which liquid will exit the funnel. This is the capacity, or the rate of output. If we pour more liquid into the funnel than it will hold, the level of liquid in the funnel will rise - this is the load. We can expand this analogy to several funnels, with the output

of several funnels becoming the inputs to other funnels. In this example we see the relationship between the output of one resource becoming the input of another. The funnel analogy is also useful for demonstrating another law of capacity planning: No matter how much work is released to a resource there is a finite amount which can be produced in any time period. The only way to increase output is to increase the size of the opening - to increase the output rate. This also helps to identify capacity for what it is: the rate at which a resource can produce.

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Scheduling Course

In general, ERP applications plan to infinite capacity, meaning that it does not consider capacity limitations while computing due dates and release dates on open and planned orders. It is concerned with meeting the build schedule, and provides the part numbers, dates, and quantities necessary. This is the capacity necessary to meet the production and shipment schedules, and the job of the planner is to find the available capacity to meet the order dates. Capacity is not infinite, so the application can also plan to this finite capacity by not scheduling more work for a resource than the resource can perform. In this case, the jobs may be rescheduled to match the available capacity, and the due dates on the jobs may not meet the need dates. This will be covered in Global Finite Scheduling.

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Production Capacity The Epicor ERP application uses data from both the supply and demand sides to correctly plan capacity needs. For the supply side of capacity, the production hours available per day and which days the resource works must be known. Production Calendar

A production calendar is used primarily for scheduling, in that the application will not schedule a job operation to begin or end on a non-working day. It also provides a means of computing resource capacity for time periods exceeding a single day. If resource capacity is to be expressed by week, the number of working days in a given week must be known. The days the resource works is addressed by defining production calendars. A production calendar specifies the particular days per week that a resource, or all resources, are available for work. Calendars can be assigned at multiple levels as follows: 1.

Company - Acts as the default calendar for all sites linked to a company.

2.

Site - The default calendar for all resource groups in the site.

3.

Resource G roup - The default for all resources in the group.

4.

Resource - The default for a resource.

5.

Supplier - Used in scheduling constrained material.

Amount of Capacity

The amount of hours available per day for production is set by the number of hours defined in the production calendar. The amount of capacity is made up of three components: •

Hours per resource per day

The amount of time a resource is available for production. While a machine may be available 24 hours per day there may not be an operator available to run the machine. If the machine can run unattended this is not an issue, but if it requires an operator, then the available hours will need to be matched to the availability of another resource. •

Resource Utilization

The amount of time an available resource is working. The resource may be available for ten hours per day but is working only nine hours. Reasons for this may include any planned (or unplanned) maintenance, breaks, clean-up periods, lack of material, lack of tooling, or any other contributing factor. Many companies set this figure at 85 to 90 percent. •

Resource Efficiency

This is the result of a calculation based on actual production vs. estimated time. Example Assume a job for a quantity of 100 units has an operation defined as follows:

Set up time: 1 hour Production time: 20 pieces per hour Total time: 6 hours = (100 / 20) + 1 The operator clocks onto the operation at the start of the shift, completes the setup in 1 hour, and completes the production in 4.5 hours. The application computes 6 earned hours and only 5.5 actual hours. The hours earned are based on the quantity completed; in this case the operator earned 1 hour

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by completing the setup and an additional 5 hours by completing 100 units. So efficiency is calculated as: Earned Hours / Actual Hours (6 / 5.5 = 1.09) Since efficiency is usually expressed as a percentage, the result of the above calculation would be 109 percent. •

Calculated Capacity

This is a manual calculation, also known as Rated Capacity. Hours per Resource per Day X Resource Utilization X Resource Efficiency

Assuming 16 calendar hours for a resource and using the examples above, the calculation would be: 16 (hours / day) X 0.85 (Utilization) X 1.09 (Efficiency) = 14.824 or 15 hours per day

For further accuracy of efficiency and utilization, the resource calendar is set up with 15 hours per day, not 16. If there are multiple resources in a resource group, the capacity for that group can be defined as the sum of the capacities of all resources in the group.

Workshop - Define a Production Calendar This workshop demonstrates the process of defining a Production Calendar based on the use of the following capacity components: Hours per Resource per day, Resource Utilization, and Resource Efficiency. Navigate to Production Calendar Maintenance. Menu Path: Production Management > Job Management > Setup > Production Calendar Important This program is not available in the Epicor Web Access.

1. Click New. 2. Enter the following information: Field

Data

Calendar ID

XXXD5H15 (where XXX are your initials)

Description

XXX 5 Days 15 Hours per day (where XXX are your initials)

Default Hours Per Day

24

3. Click the buttons Monday through Friday. 4. Click the hour 21 button twice.

This clears the check boxes for each day of the week. 5. Repeat step 4 for hours 22 through 24 and 1 through 5.

The calendar reflects a schedule of Monday through Friday, 15 hours per day. 6. Navigate to the Working Days > Year sheet to open the yearly calendar.

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7. While pressing the Ctrl key, select the following dates as holidays: •

January 1

•

Last Monday in May

•

First Monday in September

•

Last Thursday and Friday in November

•

December 25

8. Click the Toggle Day button to lock the holidays. 9. Click Save. The Exception Label window displays, displaying the default Exception Label, Non Work Day. 10. Click OK. These dates will now have the Non Work Day designation on the schedule. 11. Exit Production Calendar Maintenance.

Workshop - Assign Calendar to Resource Group This workshop links the calendar to a Resource Group. Navigate to Resource Group Maintenance. Menu Path: Production Management > Scheduling > Setup > Resource Group 1. In the Resource Group field, enter ASM and press Tab. 2. In the Calendar field, search for and select the XXXD5H15 (where XXX are your initials) calendar you created in the Workshop - Define a Production Calendar. 3. Click Save.

The Capacity changed, therefore, the 'Generate Shop Capacity Process' will need to be run to update shopload records' message displays. 4. To the message, click OK. 5. Exit Resource Group Maintenance.

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Scheduling Capacity The scheduling capacity, or the manufacturing lead time for an operation at this resource group, means that a job can be scheduled to run on more than one resource. This can be set at the resource group level by entering the number of scheduling blocks. The scheduling blocks indicate the number of resources used to manufacture an item through this resource group. If two resources are used, then the number of scheduling blocks is two. The number of scheduling blocks at the resource group level defaults to the scheduling block definition in the Engineering Workbench. This applies only if the operation is scheduled at the resource group level. The calculations in theProduction Capacitysection of this course define the production capacity. A job operation that requires 30 hours is scheduled to run for 2 days on the above resource. 30 (load hours) / 15 (capacity hours) = 2 days

Given the 30 hours of load from the above job operation, and assuming two scheduling blocks, a job through this resource group would be scheduled to run for one day. 30 (load hours) / (15 (capacity hours) X 2 (scheduling blocks)) = 1 day

If the Asm Bench resource group has four resources, and the number of scheduling blocks is changed, the manufacturing lead time for all jobs through this work center is as follows: Assume a job operation with 30 load hours. Scheduling Blocks

Planned Lead Time

1

2 days

2

1 day

3

0.667 day

4

0.5 day

The load hours do not change, only the amount of time the job spends at this resource group. Select the Split Operations check box to indicate that resources in this resource group are available to share work on an operation. The number of hours that an operation requires can be divided by the number of resources that have this check box selected.

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Workshop - Schedule Jobs with Multiple Resources You want to schedule large jobs through the ASM Bench resource group using multiple resources, while leaving small jobs on a single resource. This can be accomplished by assigning more Scheduling Blocks to the job operation, then rescheduling the job. Another way to handle this is to use the scheduling board which schedules it in What - If mode. After reviewing the schedule it can then be accepted or undone. Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry 1. In the Job field, enter 2051 and press Tab. 2. In the tree view, expand the Operations node and select Opr. 30: TURN.

The Scheduling Blocks field is used to assign additional resources to this job's operation and requires rescheduling of the job. Alternately, this process can take place on the Job Scheduling Board. 3. In the Scheduling Blocks field, enter 2. 4. Click Save. 5. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays. 6. Navigate to the Schedule sheet. 7. Right-click on the job number and select Start Time. 8. Double-click the time bar to open the Move Job window. 9. In the Schedule field, verify Forward defaults and click OK. 10. In the Start Date field, select the date one week forward and click OK. 11. On the Scheduling Board, view the What-if results. 12. From the Actions menu, select Undo Current Job Changes. 13. Exit the Job Scheduling Board and Job Entry.

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Manufacturing Lead Time The lead time for a manufactured part consists of four elements: 1.

Queue - Amount of time a j ob must wait at a resource before it can be started.

2.

Move - Amount of time necessary to move the items to the next operation or resource.

3.

Set up

4.

- Amount of time necessary to prepare a resource for an operation. Production - Amount of time expended to produce the items.

Setup and run time, often referred to as the operation time, is a small percentage of the total manufacturing lead time for most jobs. The majority of manufacturing lead time is attributed to inter-operation time, which is queue time plus move time.

Queue Time Queue time is an estimate of the time a job waits for a resource to become available. Queue time is determined by the following: •

The number of jobs scheduled through the resource group.

•

The timing of the release of jobs to the shop floor.

•

The arrival rate of jobs at the particular resource group.

•

The time necessary to complete the jobs already in process according to their priority.

The queue time for a job is highly variable and cannot be predicted with any certainty, however, an average queue time for all jobs can be set at a Resource Group or a Resource level. Queue time tends to be the largest component of a job’s lead time. Queue Time is assigned to a Resource Group, not a part. All jobs that are scheduled through a Resource Group are assigned the same (planned) queue time. As more queue time is added, more lead time is required, leading to earlier job releases, which adds more queue. It is possible to manage queue time, but requires monitoring. Managing Queue Time

There are many ways to manage queue time, but the most common is to view the planned lead time for any job against its actual lead time: •

If jobs complete ahead of their scheduled (planned) completion date, there is too much queue time in its schedule.

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•


If jobs complete after their scheduled completion date, there is too little queue time in its schedule.

How do you know this? If a job completes ahead of schedule, all things being equal, there is too much queue time in the schedule and its scheduled start date was too early. If a job completes behind schedule, there is not enough queue time in the schedule and the start date was too late.

Workshop - Manage Queue Time In this workshop, Queue Time hours are modified to view the impact on a job schedule. In this example, Queue Time is increased at the resource level and expands the job manufacturing lead time. Navigate to Resource Group Maintenance. Menu Path: Production Management > Scheduling > Setup > Resource Group

Change Queue Time 1. In the Resource Group field, enter ASM and press Tab. 2. In the Queue Hours field, enter 15. 3. Navigate to the Resources > Detail sheet. 4. In the Scheduling section, verify theUse Resource Group Values check box is selected for all 10 Resources.

Queue Hours can be setup at both the Resource Group and Resource levels. If queue hours need to be changed at the Resource level, clear the Use Resource Group Values check box and enter the queue hours. If no queue hours are established at the Resource level, the Resource Group queue hours are used. 5. Click Save and exit Resource Group Maintenance.

Verify/Undo Queue Time Change Navigate to the Resource Group Scheduling Board. Menu Path: Production Management > Scheduling > General Operations > Resource Scheduling Board Important This program is not available in the Epicor Web Access.

1. In the Scheduling Board Type section, verify Resource Group defaults. 2. In the Start Date field, select 01/01/2015. 3. In the End Date field, select 12/31/2015. 4. In the Resource Group field, enter ASM and press Tab. 5. Click Refresh. 6. Navigate to the Schedule sheet. 7. Right-click job 2193 and select Start Time. 8. Double click on the Time Bar to open the Move Job window. 9. In the Schedule field, select Backward.

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10. Click OK.

The job shows a change in the queue time hours. 11. From the Actions menu select Undo Current Job Changes. 12. Exit the Resource Group Scheduling Board.

Move Time Move Time is the time required to move an item to the next resource, or to stock after the last operation.

The following are the Move Time rules: •

If moving a job in the same building, it may not be necessary to add Move Time on top of queue time at the next resource.

•

If the move requires scheduling special equipment, such as an overhead crane or fork lift truck, then a Move Time may be appropriate.

•

If moving an item to another building or site, and it is necessary to use a company or vendor truck, a Move Time is mandatory.

Other uses of Move Time include: •

Move Time adds an allowance for inspection activities without adding an inspection operation to the job.

•

Certain processes, such as painting or epoxy, require that an item not be moved until it is dry or cured. Move Time can add this time to the operation.

•

It may be desirable to complete a job a few days prior to its scheduled ship date to make sure that any necessary rework is done or that all shipment paperwork is ready . Adding Move Time to the last operation will accomplish this.

Move Time is managed the same way as queue time. Update the Resource or Resource Group to add Move Time. An increase in Move Time increases the planned (scheduled) lead time for all jobs using that Resource or Resource Group.

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Overlap Scheduling When tasks are scheduled, the Epicor ERP application assumes each task is complete before the next task starts, even though several tasks may be done at once to finish the output. Manufacturing, or job scheduling makes the same assumption – tasks are finished in sequence and each task completes before the next (successor) task begins. In some situations you are able to overlap operations so two or more operations run at the same time. The Epicor ERP application is designed to handle this situation and can schedule the operations accordingly. Operations can be scheduled to overlap through the following methods: Finish-to-Start

The default method of scheduling, this method follows the assumption made above, that an operation must be complete before its successor can begin. Finish-to-Start scheduling resembles the following:

Finish-to-Finish This scheduling method overlaps two operations to finish at the same time. This method is very useful for related operations where the first (predecessor) has a much longer run time than its successor. In this case, the assumption is the successor operation must start when sufficient units are complete on the predecessor operation, so that both operations finish at approximately the same time. To accomplish this, the Queue Time at the successor resource is ignored and not included in the scheduling calculation, as shown below.

Example A drill operation that takes 5 minutes per piece followed by a countersink operation that takes 1 minute per piece is a prime candidate for Finish-to-Finish scheduling. If the setup at the countersink operation can be done before the arrival of parts from the drill operation, you can schedule most of the parts to complete at the drill operation, send them to the coun tersink operation, and complete the remaining parts at the drill operation before the countersink operation is done.

The key to Finish-to-Finish scheduling is for the successor resource to not run out of parts. Because of this, the transfer, or overlap batch must be large enough to prevent this from happening as illustrated in the following example: Job Quantity

100

Drill Time

5 min / piece, or 500 minutes

Countersink Time

1 min / piece, or 100 minutes

If we use Finish-to-Start scheduling, the above sequence of operations would last 600 minutes, or 10 hours.

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If we use Finish-to-Finish scheduling, we can produce 80 parts @ 5 min / piece at the drill operation and send them to the countersink operation. These 80 parts would take 400 minutes to run. At the countersink operation these parts will take 80 minutes to complete but, at the same time, the remaining parts are being completed at the drill operation and moved to the countersink operation. One hundred minutes is eliminated from the total lead time through Finish-to-Finish scheduling. Start-to-Start

This method begins both operations at the same time. In this case the scheduling calculation takes the Queue Time at the successor operation into consideration, as there is no assumption that the successor operation will start as soon as the parts arrive. But some of the queue time at the predecessor may be consumed by its Move Time to the successor operation, as shown below.

Workshop - Overlap Scheduling Because the default setting regarding Overlap Scheduling is Finish-to-Start, this workshop uses the Finish-to-Finish and Start-to-Start scheduling factors. As these factors address the relatio nship of one operation to its predecessor, the resulting scheduling impact is reviewed. Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry

Finish-to-Finish Scheduling 1. In the Job field, enter 2381 and press Tab. 2. In the tree view, right-click the job number and select Tree > Expand Tree. 3. In the tree view, select ASM: 3 ML-HZ-4942. 4. Navigate to the Job Details > Operations > List sheet. 5. In the Operations grid, the following operations display: Opr

Operation

Est Prod Hours

10

Saw

6.67

20

Turn

20.00

30

Drill

13.33

The Est. Prod. Hours are greater for Operation 20 than O peration 30. 6. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 7. Verify the Backward option is selected.

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8. Select the What-If Schedule check box and click OK. 9. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays. 10. Navigate to the Schedule sheet. 11. Right-click the job number and select Start Time. 12. Double-click the job number to display the operations. 13. Review the time bar.

Notice that operation 20 finishes before operation 30 starts. 14. In the Job Scheduling Board, select Actions > Undo Current Job Changes . 15. Exit the Job Scheduling Board. 16. Verify the Job Details > Operations > List sheet. 17. In the Operations grid, select Operation 30. 18. Navigate to the Job Details > Operations > Detail sheet. 19. In the Scheduling Factors section, select Finish-to-Finish. 20. Click Save. 21. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 22. Verify the Backward option is selected. 23. Select the What-If Schedule check box and click OK. 24. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays. 25. Navigate to the Schedule sheet. 26. Right-click the job number and select Start Time. 27. Double-click the job number to display the operations. 28. Review the time bar.

Notice that operation 20 finishes at the same time as operation 30. 29. In the Job Scheduling Board, select Actions > Undo Current Job Changes . 30. Exit the Job Scheduling Board. 31. Remain in Job Entry.

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Start-to-Start Scheduling 1. In Job Entry, verify the Job sheet displays. 2. In the Job field, enter 2376 and press Tab. 3. In the tree view, right-click the job number and select Tree > Expand Tree. 4. In the tree view, select ASM: 3 ML-HZ-4942. 5. Navigate to the Job Details > Operations > List sheet.

Note the difference in Est. Production Hours for Operations 10 and 20. 6. In the Operations grid, select Operation 20. 7. Navigate to the Job Details > Operations > Detail sheet. 8. In the Scheduling Factors section, select Start-to-Start. 9. Click Save. 10. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 11. Verify the Backward option is selected. 12. Select the What-If Schedule check box and click OK. 13. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays. 14. Navigate to the Schedule sheet. 15. Right-click the job number and select Start Time. 16. Double-click the job number to display the operations. 17. Review the time bar. Operations 10 and 20 begin at the same time. 18. From the Actions menu, select Undo Current Job Changes. 19. Exit the Job Scheduling Board and Job Entry.

Multi-level Scheduling / Branch Scheduling Jobs with multiple sub-assemblies present a particular challenge to scheduling because a change in one branch (sub-assembly) may or may not affect the scheduled completion of the job. This is determined by a sub-assembly's Critical Path on the job. The Critical Path for a job is determined by the sequence of assemblies, at all levels, that determine the job duration.

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Example A job may have three sub-assemblies, each of which has one of more sub-assemblies. One of the paths (links to sub-assemblies) will take longer than the others, and this determines the job schedule. The path that takes the longest is the Critical Path.

Available Move Options: Move Option

Definition

Operation Only

Reschedules a single operation only.

Assembly – Subsequent Operations

Reschedules an operation and all later operations in the current assembly, but does not affect other assemblies on the job.

Assembly – Preceding Operations

Reschedules an operation and all earlier operations in the current assembly, but does not affect other assemblies on the job.

Assembly – All Operations

Reschedules all operations on this assembly but does not affect any other assemblies.

Branch – Subsequent Operations

Similar to Assembly – Subsequent Operations except that it also reschedules its parent assembly (the next higher one) and, if applicable, the parent of that one (its grandparent) until all assemblies have been rescheduled. This may cause the job to be late, and disrupt the schedules of multiple sub-assemblies.

Branch – Preceding Operations Similar to Assembly– Preceding Operations except that it also reschedules all of its lower level sub-assemblies (if any) and their children as well, until the lowest level sub-assembly has been rescheduled. This may push the start date of operations and the job into a past due period. Job – All Operations

Reschedules the top level assembly and all lower level sub-assemblies.

Workshop - Material Status and Move In this workshop, drag and drop the operation beyond the job's due date. Navigate to the Job Scheduling Board. Menu Path: Production Management > Scheduling > General Operations > Job Scheduling Board Important This program is not available in the Epicor Web Access.

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1. In the Job field, enter 2175-SCH and press Tab. 2. Navigate to the Schedule sheet. 3. Right-click the job number and select Start Time. 4. Double-click the job number and each assembly (three cylinders) icon until all levels have been opened.

Assemblies (2/0 and 3/0) are denoted by a red icon – this indicates that the assemblies are on a critical path. For each assembly on the critical path, there are no open spaces, or gaps, in the schedule. A delay in any on of these operations delays theit completion the job action is taken.without Becauseaffecting assemblythe (1/0) is not a critical path (blue icon), is possible toofdelay oneunless or more operations completion of the job. Multi-Level Scheduling is the same as scheduling a single-level job, except that a change in a lower-level operation may affect the entire job. 5. Under the 2/0 assembly, select operation (2/10) PUNC. 6. Drag and drop the operation beyond the job's due date.

The Move Job window displays. 7. In the Move Option field, select Branch – Subsequent Operations. 8. Click OK. 9. To the warning message, click OK. Since the operation moved into the future, we need to reschedule not only the operation that was moved but all of its successors as well. And, because this operation was on a subassembly, we need to reschedule its parent assembly as well as any higher-level assemblies in the same path.

Note what happened when you clicked OK. The start times for the operation, its successors, and the end item all moved into the future and you received a message that the job can not meet its required date. This is correct; branch scheduling will reschedule as many levels as necessary in order to assure that the job schedule is accurate. 10. From the Actions menu, select Undo Current Job Changes. 11. Exit the Job Scheduling Board.

Global Scheduling Global Scheduling schedules all open engineering jobs with either Infinite Capacity or Finite Capacity logic. The calculation evaluates the priority assigned to each engineered job to determine which jobs should be schedule d ahead of other jobs. Up to this point, the course has assumed no constraints on resource capacity, instead focusing on the relationship between Capacity and Load. However resources do have limitations on the amount of output produced. A resource with 15 hours of daily capacity can produce for only 15 hours per day regardless of the amount of load scheduled on that resource. This is Finite Capacity. Infinite Capacity allows more load to be scheduled above the available capacity within a specific resource.

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Infinite Capacity Under the Infinite Capacity assumption, the focus is on determining the amount of capacity needed to meet the load requirements. These load requirements are generated by the production and shipment schedules. In order to meet scheduled production due dates and/or sales order shipment dates, the load requirements determin e the amount of capacity needed, by time period. This is illustrated in the following graphic:

Capacity Management produces load profiles by loading to Infinite Capacity to determine the labor and machine capacity needed to meet the production dates. The purpose of loading to Infinite Capacity is to identify resources that will be overloaded by the open and planned orders, in each future time period, so additional capacity can be made available or orders can be moved from one resource to another. It is impossible to produce more than the resource capacity allows, so the focus of capacity planning is to prevent resources from being overloaded while still meeting the order due dates. The above graphic indicates a resource overloaded in four periods, with excess capacity in other periods. Given the total capacity demands, it is possible to build everything in the schedule, but not necessarily in time to meet the scheduled dates. If the resource is overloaded in any time period, the planner can increase the capacity or decrease the load. There are several ways to increase capacity, such as overtime, adding another shift, or working additional days. Adding resources also alleviates overloaded periods in a resource group. Load can be decreased by moving it to another resource or moving it to another (under-loaded) time period. It is possible to relieve load by combining jobs that have common setup requirements. Time saved by eliminating setup can be used for production. Loading to Infinite Capacity ignores the job priority – all jobs are equal in their demands on the resources and it is the planner’s job to determine the order in which the jobs are run. Also, Load refers to setup time and run time only. Queue Hours and Move Hours are part of the schedule but are not part of the load.

Workshop - Increase Capacity In this workshop, increase the production calendar capacity. Navigate to Production Calendar Maintenance. Menu Path: Production Management > Scheduling > Setup > Production Calendar

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Important This program is not available in the Epicor Web Access.

1. In the Calendar ID field, enter D5H16 and press Tab. 2. From the Actions menu, select Duplicate.

The Duplicate Calendar window displays. 3. In the New Calendar ID field, enter XXXD5H24 (where XXX are your initials). 4. Click OK. 5. Enter the following information: Field

Data

Description

XXX 5 Days 24 Hrs per day (where XXX are your initials)

Default Hours Per Day

24

6. Select hours 1, 2, 3, 4, 5, 22, 23, and 24 Monday through Friday for a total of 24 hours per day. 7. Click Save. 8. Exit Production Calendar Maintenance.

Workshop - Review the Resource Group Overload In this workshop, review the overload for the Assembly Bench resource group. Navigate to the Overload Informer. Menu Path: Production Management > Scheduling > General Operations > Overload Informer 1. In the Resource Group field, select Asm Bench and click Refresh. 2. Navigate to the Actual sheet.

Overload occurrences display. 3. Minimize the Overload Informer.

Workshop - Update Resource Capacity In this workshop, link the previously created production calendar and link it to the resource group to increase its capacity. Navigate to Resource Group Maintenance. Menu Path: Production Management > Scheduling > Setup > Resource Group 1. In the Resource Group field, enter ASM and press Tab. 2. In the Calendar field, search for and select XXXD5H24 (where XXX are your initials).

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3. Click Save. 4. If a message displays, click OK. 5. Exit Resource Group Maintenance. 6. Maximize the Overload Informer. 7. Verify the Actual sheet displays. 8. Click Refresh. In the Actual grid, all of the overload occurrences clear. 9. Exit the Overload Informer.

Finite Capacity Finite Capacity assumption does not allow more load to be scheduled into a time period than the available capacity. If the resource capacity is 15 hours per day, loading to Finite Capacity will not exceed that amount at the resource level. If overload is encountered, and material and capacity are available, the Epicor ERP application pulls as much load as possible into earlier time periods. When scheduling to Finite Capacity, the scheduling calculations must find an available block of time large enough to runhave the operation. an operation one hourhours of setup and six of production time, theschedule. resource must an availableIf block of time calls of atfor least seven to insert thehours operation into the resource If that block of time is not available when the operation needs it, the application attempts to find the required time in an earlier time period. If it is not available, or if doing so would violate material availability, the application pushes the operation into the future until an available block of time is found. The job is then late. Its scheduled completion date is beyond its need (required) date. This is illustrated in the following graphic:

Loading to Finite Capacity means that capacity planning will not schedule more work into a resource than the capacity available. Using the above example, the excess load from the first two periods is scheduled into the third period, and the excess load from the fourth period is scheduled into the future periods with excess capacity.

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While this guarantees that no resources will be overloaded in any time period, scheduling orders into the future will cause job need dates to be missed, with the result that the production and ship schedules will not be met.

Finite and Infinite Scheduling Determine the scheduling process based on the expectation of scheduling and reaction to overloaded resources. Infinite Scheduling- Shows how much capacity is needed by resource and date to meet production and shi pment schedules. Help

Hindrance

Overload and under load information is available.

Does not automatically level resource loads.

The planner is the ultimate decision maker.

Manually intensive process.

Changing a job need date does not disrupt the schedule.

Relies on queue time to provide an allowance for irregular arrivals at resources.

Finite Scheduling - Shows when a job is expected to be completed based on the current load in the site from all open jobs. Help

Hindrance

No resource marked as finite will be overloaded.

May overload other resources not marked as finite.

The Epicor ERP application makes scheduling decision based on priority and need date.

Gaps in a job schedule.

Can run in What-if mode.

Changing a job’s need date may cause all job schedules to change.

Infinite scheduling uses queue time to separate jobs at a resource and to allow for a job that is not placed into production when it arrives at the resource. Finite scheduling does not use queue time in its calculations since the job will not be scheduled to start until a resource is available and there is a large enough block of time for that resource. If not, the job will wait. In this case, queue time is a result of the schedule and not one of its inputs.

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Global Scheduling Process Global Scheduling reschedules all open, engineered jobs. This process uses the scheduling priority code assigned to each job to determine which jobs should be scheduled before other jobs. All the jobs selected by the Calculate Global Scheduling Order process are placed within the schedule, either on the actual schedule or on a What-If schedule. There are four steps in the Global Scheduling process: 1.

Determine Schedule Order.

2.

Schedule All Locked Jobs.

3.

Compute New Dates.

4.

Copy Dates to Job Schedule.

Scheduling Order

The Epicor ERP application needs to determine the order in which jobs are selected for scheduling. These are all jobs that are currently open on the Scheduled Start Date. Since capacity is limited, there needs to be selection criteria, which is the job priority. The order in which these jobs will be scheduled is calculated using the Priority value selected on each job by running the Calculate Global Scheduling Order process. The Calculate Global Scheduling Order schedules each job infinitely and does not create load, or dates. It passes a date back to the calculation procedure and this date is used in the job priority calculation. To determine the scheduling order, the Calculate Global Scheduling Order process reschedules all open jobs using either the Finite Capacity or Infinite Capacity logic to calculate the number of days late (or early). The job that is the earliest (or least late) becomes the benchmark. This is illustrated in the following graphic:

The numbers after the bars represent the number of days late or days early (negative). The earliest (least late) job becomes the benchmark; its number of days late (early) is used to adjust all other job dates. The Epicor ERP

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application computes the shifted days late based on this value by adding (if negative) or subtracting this value from the days late for all jobs. In the above graphic, job C is the benchmark - it is the earliest of all jobs to be scheduled. In terms of importance, this job becomes the least important because it is so far ahead of schedule that it can be delayed 35 days and still finish on time. By adding 35 to this job ’s earliness figure, the application computes a shifted days late of zero (0). But that will not let us include the job priority in the calculations, so the application adds 1 to this value. The calculation for Shifted Days Late becomes: Job Earliness (Lateness) + 35 (benchmark value) +1

The Shifted Days Late for job C becomes one (1). To include the impact of the job priority, multiply this number by the Priority Factor in the Scheduling Priority Code. Assuming a factor of 100, the calculation now becomes 100. The following table shows the calculations for all jobs: Job

Days Late/Early

Shifted Days Late

Priority Factor

Weighted Priority

A

-2

34

100

3400

B

8

44

110

4840

C

-35

1

100

100

D

15

51

120

6120

E

2

38

90

3420

Ranking the weighted priority from highest to lowest shows that job D has the highest priority and would be selected first for scheduling. This would be followed by jobs B, E, A, and C. The Scheduling Priority Code is assigned to each job as it is created, based on defining one of the codes as the default. You can create as many codes as you wish, but the one you consider to be a normal job priority should be designated as the default. It is not the value of the Priority Factor that is significant. Rather, it is the value relative to the other codes that matters. Once the Calculate Global Scheduling Order process is run, the results of this calculation are adjusted manually by running Adjust Global Scheduling Order. This allows changes to be made in the scheduling sequence value of each job to re-order the scheduling priority. When saved, Global Scheduling either schedules these jobs, or produces a what-if scenario of the schedule. Adjust Global Scheduling Order is not a required step in this process, but is available if needed. Schedule All Locked Jobs Schedule all locked jobs into the available capacity. In the above example, that is job D. This assures that any job schedule designated as Locked is not changed.

When this phase is complete, there is an option to pause the process and potentially override the scheduling order. If not satisfied with the results of the calculations, re-order the jobs manually. Compute New Dates

Compute the scheduled start and due dates for all job operations. The Epicor ERP application places scheduling blocks (load) against the designated resources (or resource groups) that have available capacity closest to the need date, and large enough to insert the operation. If an available block of time cannot be found near the start date, the application attempts to place the scheduling blocks into available capacity within an earlier time period, unless this violates a material constraint. If not, then the application pushes the scheduling blocks ahead until it can find available capacity.

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Copy Dates to Job Schedule

Copy the scheduled dates to the job ’s What If schedule, or to the job’s current schedule. At this point, the process can be stopped, but it will not undo any job changes. Log File and Log level

The log file contains the log for the global reschedule process. The log level refers to the depth of how the log file gets created. The following describes each logging level: •

Basic – The log will display the Start Date and Start Time with the number of schedulers (processors) that were run. The log displays when each processor finished and if any errors occurred during the process.

•

Process – This log displays the Basic information in addition to a l og for each scheduler that displays the jobs that were scheduled.

•

Process and Scheduling – This log displays the Basic and Process information in addition to a log that displays how each operation was scheduled, including constrained materials and the Finite Capacity used against each resource.

Workshop - Calculate Global Scheduling Order In this workshop, select several jobs to test the impact of job priority. Using the Calculate Global Scheduling Order process, compare the Scheduling Order before and after scheduling priorities are changed. The process precedes the Global Scheduling process. Important Due to necessary setup and specific data used to execute the global scheduling process, this workshop can only be performed by one person on a shared database. If you are unable to complete this workshop, this does prohibit you from completing Workshop - Set Global Scheduling Options and Workshop - Process Global Scheduling.

Calculate Global Scheduling Order Navigate to the Calculate Global Scheduling Order Process . Menu Path: Production Management > Scheduling > General Operations > Calculate Global Scheduling Order Important The calculating global scheduling process can only be performed by one person at a time. If multiple people are completing this exercise at once, one person must be selected to run this process. 1. Enter the following information: Field

Data

Scheduled Start Date

Today's date

Dynamic

clear

Scheduled Start Time

accept default

Log File

XXX Schedule (where XXX are your initials)

Log Level

Basic

Accept the defaults for the remaining fields. 2. Click Submit.

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The Calculate Global Scheduling Order process schedules the jobs to determine how late they are. It schedules each job infinitely and does not create load or dates. Instead, it passes a date back to the calculation procedure and this date is used in the job priority calculation to determine the scheduling sequence value. 3. Exit the Calculate Global Scheduling Order Process. 4. To verify the process is complete, navigate to the System Monitor. Menu Path: System Setup > System Maintenance > System Monitor Important This program is not available in the Epicor Web Access.

The process may take several minutes to complete.

View the Calculation Results Navigate to Adjust Global Scheduling Order. Menu Path: Production Management > Scheduling > General Operations > Adjust Global Scheduling Order 1. Click the binoculars (search) icon and search for and select all jobs.

The Job Search window displays. 2. Click the Options button.

The Search Options window displays. 3. Select the Return All Rows check box. 4. Click OK.

All the current jobs in the database display in the Search Results grid. Tip If you are using the Epicor Education database, you should have about 286 jobs.

5. Click Select All and click OK. 6. In the Job Order List grid, click on the SchedSeq column header. 7. In the Job Order List grid, click on the Job column header. 8. Record the SchedSeq for jobs 2331 and 2391 ________ ________. 9. Exit Adjust Global Scheduling Order. If you are asked to save changes, click No.

Modify Scheduling Priority Codes Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry 1. In the Job field, search for and select job 2391. 2. In the Scheduling Priority section, in the Priority field, select Very High.

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3. Click Save. 4. Repeat steps 1 through 3 for job 2331. 5. Exit Job Entry.

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Recalculate Global Scheduling Order Navigate to the Calculate Global Scheduling Order Process . Menu Path: Production Management > Scheduling > General Operations > Calculate Global Scheduling Order 1. Enter the following information: Field

Data

Scheduled Start Date Dynamic

Today's date clear


accept default

Log File

XXX Schedule 1 (where XXX are your initials)

Log Level

Basic

Accept the defaults for the remaining fields. 2. Click Submit. 3. Exit the Calculate Global Scheduling Order Process. 4. To verify the process is complete, navigate to the System Monitor. Menu Path: System Setup > System Maintenance > System Monitor Important This program is not available in the Epicor Web Access.

The process may take several minutes to complete.

View the Recalculation Results Navigate to Adjust Global Scheduling Order. Menu Path: Production Management > Scheduling > General Operations > Adjust Global Scheduling Order 1. Click the binoculars (search) icon and search for and select all jobs.

The Job Search window displays. 2. Click the Options button.

The Search Options window displays. 3. Select the Return All Rows check box. 4. Click OK.

All the current jobs in the database display in the Search Results grid. Tip If you are using the Epicor Education database, you should have about 286 jobs.

5. Click Select All and click OK.

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6. Click the Job column to locate jobs 2331 and 2391. 7. Record the scheduling sequence (SchedSeq) value for each job __________ __________.

The scheduling sequence codes should be a lower number, such as 20 and 30. This indicates these jobs are now higher in the job scheduling priority, and will now be placed earlier in the schedule. 8. Remain in Adjust Global Scheduling Order.

Override Global Scheduling Order 1. In the SchedSeq field for job 2331, enter 5. 2. In the SchedSeq field for job 2391, enter 3. 3. Click Save. 4. Click the binoculars (search) icon and search for and select all jobs. In the search window, be sure to click the Options button and the Return All Rows check box. 5. In the Job Order List grid, click the SchedSeqv column heading.

The jobs reflect the updated Schedule Sequence and Scheduling Code. Jobs 2391 and 2331 should display at the top of the list. 6. Exit Adjust Global Scheduling Order.

Workshop - Set Global Scheduling Options This workshop introduces three additional Global Scheduling features: Finite Horizon, Job Schedule Locking, and Rough Cut Scheduling. Important If you were unable to complete Workshop - Calculate Global Scheduling Order you will not be able to complete this workshop.

Set Finite Horizon Instead of running Global Scheduling for all jobs, you can define an upper limit on the process by limiting the time horizon resource (group). settingoutside the Finite Global as finite for afor setaperiod of time, andByinfinite thatHorizon, period of time.Scheduling considers a resource (group) Navigate to Resource Group Maintenance. Menu Path: Production Management > Scheduling > Setup > Resource Group 1. In the Resource Group field, enter SAW and press Tab. 2. In the Finite Horizon field, enter 60. 3. Click Save. 4. Click Clear. 5. In the Resource Group field, enter PPL and press Tab. 6. In the Finite Horizon field, enter 60.

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7. Click Save. 8. Exit Resource Group Maintenance.

Lock a Job Schedule Global Scheduling makes no changes to a job schedule that is locked. Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry 1. In the Job field, enter 2382 and press Tab. 2. In the Scheduling Priority section, select the Locked check box. 3. Click Save. 4. Exit Job Entry.

Workshop - Rough Cut Scheduling Rough Cut Scheduling ignores resource and shop load records that are normally included within the scheduling calculation. To use this feature, you must define the Rough Cut Horizon value. This field is located in Site Maintenance. Every job scheduled past the horizon value ignores the resource and shop load records. To add the Shop Load for the Rough Cut Scheduled jobs, use Save Resource Load.

Set the Rough Cut Horizon Navigate to Site Maintenance. Menu Path: Production Management > Job Management > Setup > Site Maintenance 1. Click the Site... button, search for and select the Main site. 2. In the Rough Cut Horizon field, enter 30. 3. Click Save. 4. Exit Site Maintenance.

Review the Rough Cut Load Navigate to the Save Resource Load. Menu Path: Production Management > Scheduling > General Operations > Save Resource Load 1. In the Start Date field, verify today's date defaults. 2. In the End Date field, enter the date one year from today. 3. Select the Edit list of Jobs check box. 4. Click Submit.

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The Save Resource Load window displays. 5. Click Cancel. 6. Exit the Save Resource Load.

Workshop - Process Global Scheduling Previous workshops calculated global scheduling orders,scheduling then adjusted the order. on those changes, run the Global Scheduling Process with Finite Load. Global can also be runBased with Infinite Load. Important If you were unable to complete Workshop - Calculate Global Scheduling Order or Workshop - Set Global Scheduling Options you will not be able to complete this workshop.

Global Scheduling Process Navigate to Global Scheduling. Menu Path: Production Management > Scheduling > General Operations > Global Scheduling 1. Enter the following information: Field

Data

Scheduled Start Date Dynamic

Today's date clear


Accept default

Log File

XXX Schedule 2 (where XXX are your initials)

Log Level

Process and Scheduling

What-If Schedule Only

select

Finite Load

select

The default Scheduled Start Date is the current date. If the configuration setting Allow Scheduling before Today is selected, jobs can schedule into the past. If not selected, the Scheduled Start Date defaults to today's date and jobs will not schedule into the past. Jobs that would otherwise schedule into the past reschedule with a forward schedule from the current date. These Jobs may become late jobs and display on the schedule with a Late Job alert. 2. Click Submit. 3. To verify the process is complete, navigate to the System Monitor. Menu Path: System Setup > System Maintenance > System Monitor Important This program is not available in the Epicor Web Access.

The process may take several minutes to complete. 4. Exit Global Scheduling.

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View Resource Load Navigate to the Save Resource Load. Menu Path: Production Management > Scheduling > General Operations > Save Resource Load 1. Enter the following information: Field

Data

Start Date End Date

Today's date 12/31/2015

Edit list of Jobs

select

2. Click Submit.

The Save Resource Load window displays a list of rough cut schedule jobs. 3. Click Cancel. 4. Exit the Save Resource Load.

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Scheduling Reports There are several standard reports that provide valuabl e information related to scheduling. Some of the information presented in these reports is available in the displays we viewed earlier but presented in a more concise form in the reports. Shop Load Report Menu Path: Production Management > Job Management > Reports > Shop Load

The Shop Load report displays the scheduled load by resource group for six future user-defined time periods. This report can be printed in a summary form, to view load vs. capacity by resource group, or in full detail to view the composition of the load (the individual job operations that make up the load). Priority Dispatch Report Menu Path: Production Management > Scheduling > Reports > Priority Dispatch

The purpose of Priority Dispatch Report is to communicate the relative priority of each job; that is, which job(s) should be completed in any given time period in the order to be completed. This report lists all jobs by resource group and sorts them by the scheduled start date of the operation to be performed. The report is divided into three sections: 1.

Current Work - These are jobs that have started at this Resource Group, the previous operation has been completed, or this is the Resource Group of the first operation.

2.

Available Work - These jobs are at the predecessor Resource Group and are in process, and at least one unit has been marked as completed.

3.

Expected Work - These jobs can be anywhere in the site, but are expected to be at this Resource Group by the scheduled start date.

It is not necessary to process the jobs in the exact order listed on the report, as long as each job is completed by its scheduled date. Schedule Impact Report Menu Path: Production Management > Scheduling > Reports > Schedule Impact

Use the Schedule Impact Report to view the changes to jobs, and revenue, as a result of What-If schedule changes. Before accepting changes made through drag-and-drop scheduling, load leveling, or running Global Finite Scheduling, users should run this report to see how these changes will impact all open jobs. The report will display the number of jobs early, late, or on-time, and the changes in these numbers from the current job schedules. For more detail, users may view the actual changes by job to see the current and proposed (What If) start and completion dates by making the appropriate selections. Job Status Report Menu Path: Production Management > Job Management > Reports > Job Status

The Job Status Report displays only those jobs that meet the user-selected criteria: 1.

The job actual hours exceed the estimated hours.

2.

The job is delinquent.

3.

Labor efficiency has fallen below a certain level.

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You can further filter this report by part number, product group, customer, or site. The purpose of this report is to display those jobs that may become late, miss their scheduled ship dates, or consume more resources than estimated. Even though this report contains valuable information related to job schedules, it is contained in the Job Management folder.

Workshop - Shop Load Report Navigate to the Shop Load Report. Menu Path: Production Management > Scheduling > Reports > Shop Load 1. Enter the following information: Field

Data

Cut Off Date

Next Sunday

Dynamic

clear

Units

Week

Interval

1

First Bucket is Infinite?

select

Summary Only

select

2. Navigate to the Filter > Resource Group sheet. 3. Click the Resource Group button and search for and select resource group PPL (Punch Press Large Wiedeman). 4. Click Print Preview. 5. Review and close the report.

Note the load by period and resource group. 6. Exit the Shop Load Report.

Workshop - Priority Dispatch Report Navigate to the Priority Dispatch Report. Menu Path: Production Management > Scheduling > Reports > Priority Dispatch 1. Enter the following information: Field

Data

Max No of Operations to List Per Resource Group

accept default

Operations due to start on or before

blank

New Page Per Resource Group

clear

2. Navigate to the Filter > Resource Group sheet.

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3. Click the Resource Group button and search for and select resource group PPL (Punch Press Large Wiedeman). 4. Click Print Preview. 5. Review and close the report. 6. Exit the Priority Dispatch Report.

Workshop - Schedule Impact Report This report uses the early and late grace period defined in Company Configuration and defines a job as on time if its scheduled completion date falls within this interval. Navigate to the Schedule Impact Report. Menu Path: Production Management > Job Management > Reports > Schedule Impact 1. Enter the following information: Field

Data

Job Required Dates On or Before

one month from today

Dynamic

clear

Early Grace Period (Days) Late Grace Period (Days)

Accept the default Accept the default

Report Name

Leave blank

Summary Only

select

2. Click Print Preview. 3. Review the report. Note the number of jobs in the Actual and What-If categories, as well as the changes to work in process and revenue. 4. Close the report. 5. Repeat the steps above with the following information to see which jobs are contributing to these changes. Field

Data

Job Required Dates On or Before

one month from today

Dynamic

clear

Early Grace Period (Days)

Accept the default

Late Grace Period (Days)

Accept the default

Report Name

Leave blank

Summary Only

clear

Late Jobs as One Group

select

Ontime Jobs as One Group

select

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Field

Data

Early Jobs as One Group

select

Optionally, drill down further in each section to view late jobs that are later or less late. For example, run this report using various selections to get the full view. 6. Exit the Schedule Impact Report.

Workshop - Job Status Report Navigate to the Job Status Report. Menu Path: Production Management > Job Management > Reports > Job Status 1. Enter the following information: Field

Data

Due Dates On or Before

six months from today

Dynamic

clear

% Over Estimated Time Greater Than

Accept the default

Delinquent Days Greater Than

5

% Efficiency Less Than

Accept the default

2. Click Print Preview. 3. Review and close the report.

This report can be re-run as many times as desired - each time specifying different selection criteria. 4. Exit the Job Status Report.

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Specialized Scheduling Processes

Specialized Scheduling Processes This section of the course discusses special scheduling process capabilities of the Epicor application. Saving What-If Schedules

You may want to make several changes and evaluate each of these by printing the Schedule Impact Report. You can save the What-If changes, make additional changes, and at any time restore an earlier saved schedule. You can save an unlimited number of What-If reschedules. Multi-Constraint Scheduling

The base application allows up to two resources to be assigned to each operation, and each of these resources can be identified as constrained; that is, Finite Capacity is set for each resource. This means that a job operation cannot be scheduled unless both resources are available at the same time. This is determined by the calendars assigned to each resource and, if using finite scheduling, the current load on each resource. Example There is a resource or group that is available 16 hours per day (based on the availability of operators). Any job using that resource or group could be run at any time during those 16 hours. Let us assume further that the resource requires a setup operation for each job, but the setup operator is available only 8 hours per day. This would constrain a job schedule that required the resource to be set up if no setup resource is available. Minimize WIP

The Minimize WIP feature allows Scheduling to reduce the gaps that can occur between operation s and assemblies during the Global Scheduling process. It causes this process to run the scheduling engine an additional time against the jobs that meet a specific condition. If Scheduling discovers that the Start Date on ajob will occur before the Scheduled Start Date, it forward schedules the job. After the new End Date is calculated for this job, it backward schedules from that date, which tightens the points where the assemblies are placed within the schedule. This allows child assemblies to have a Just In Time relationship with their parent assemblies. By eliminating the unnecessary gaps between the assemblies, the jobs are scheduled more accurately.

Batch Scheduling This section of the course reviews job batching functionality. The job batching feature enables you to combine two or more jobs that either partially, or completely, use the same routing. It allows you to select an operation shared by the jobs and indicate from which direction – backwards or forwards – you will combine the routing. Important Combine the operations from a start operation and then move backwards or forwards through the routing. You cannot combine a range of operations that occur in the middle of routing.

When the batching process is complete, a new job is created that manufactures the part quantities defined on all the srcinal source jobs. Always batch jobs that share similar operations. If you batch jobs that do not have similar operations, you could get unexpected results.

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Once you create a batched job, the Epicor ERP application treats the job the same as a regular job. A batched job can be scheduled and transactions can be placed against it. If necessary, you can even batch together other batch jobs! Important To complete the Batch Scheduling course section, you must have the Advanced Production License installed.

Batch Jobs with Identical Methods You can batch two jobs with identical methods of manufacture so that they can run together for efficiency. Note At times, two jobs can be exactly al ike except for the last operation. For example, a paint operation where the colors are different can have the same operations up to the paint operations batched for efficiency with Auto Receive selected. The parts would then be transferred back to their srcinal job for the paint operation.

Workshop - Batch Jobs with Identical Methods You can batch two jobs with identical methods of manufacture so that they can run together for efficiency. In this workshop, create two jobs for parts that have identical methods of manufacture and combine both into one job.

Create Jobs In this workshop task, create two jobs for the EAD-400-BLK and EAD-400-RED parts. Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry 1. From the New menu, select New Job. 2. The New Job Number window displays. 3. Click the Next Job button and click OK. 4. In the Part field, search for and select part EAD-400-BLK. 5. In the Req By field, select the date one month from today. 6. Click Save. 7. From the New menu, select New Demand Link > Make To Stock .

At the bottom of the Job sheet, the Make To Stock > Detail sheet displays. 8. In the Quantity field, enter 10. 9. Click Save. 10. From the Actions menu, select Job > Get Details .

The Get Details window displays. 11. In the Revisions grid, select A and click OK.

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12. On the Job sheet, select the Engineered check box. 13. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job XXXX (where XXXX is your job number) window displays. 14. Accept the Backward scheduling default and click OK. 15. On the Job sheet, select the Released check box. 16. Click Save. 17. Record the job number____________. 18. Repeat steps 1-16 to create another job for the EAD-400-RED part. 19. Record the job number____________. 20. Minimize Job Entry.

Batch Jobs In this workshop task, batch the previously entered jobs. Navigate to the Resource Group Scheduling Board. Menu Path: Production Management > Scheduling > General Operations > Resource Scheduling Board Important This program is not available in the Epicor Web Access.

1. In the Resource Group field, enter WLDS and press the Tab key.

This is the Resource Group used for Operation 40 on both previously entered jobs. The Operation 50 on both jobs is subcontracted. 2. Navigate to the List sheet. 3. In the Operations grid, in the Batch column, select the check boxes for the two jobs created in the previous workshop task. 4. From the Actions menu, select Batch Operations. The Batch Operations window displays. 5. In the Pull Direction section, verify Backward defaults. 6. In the Job Processing Mode section, verify Sequential defaults.

The Job Processing Mode options define if operations should be performed at the same time or one before the other. Use the Concurrent option when two parts are created at the same time; use the Sequential option when time for the operation will be accumulated for the duration of the operation. 7. Select the Auto Receive check box.

When selected, this check box indicates that labor or receipt transactions against this batch operation will create automatic receipts to inventory. If you use this feature, this receipt updates the quantity on hand on the part record. The process is triggered when you post labor quantities against this batch operation that exceed the quantities required for the sales order.

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Normally, you will select this check box for the last operation on the assembly or the final assembly. Parts are received to inventory at the current unit cost, based on the part costing method (average, standard or last). 8. Click the Create Batch button. 9. From the Batch Job Number field, record the job number_____________. 10. Click the Close button. 11. Exit the Resource Group Scheduling Board.

Schedule the Batch Job In this workshop task, schedule the batch job created in the previous task. 1. Maximize Job Entry. 2. On the Standard toolbar, click Refresh. 3. Verify the Job sheet displays. 4. In the Job field, enter the batch job created in the Create a Batch workshop task and press Tab. 5. Clear the Released check box. 6. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 7. Accept the default of Backward scheduling and click OK. 8. Select the Released check box. 9. Click Save. 10. Exit Job Entry.

Review Jobs In this workshop task, review all three previously entered jobs to see how the Job Batching process affected the methods of manufacture used on the jobs. Navigate to the Job Tracker. Menu Path: Production Management > Job Management > General Operations > Job Tracker 1. Click the Job button.

The Job Search window displays. 2. In the Starting At field, enter the first job number created i n the Create Jobs workshop task and click Search.

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3. In the Search Results grid, using the Ctrl key, select all three jobs created in the Create Jobs and Batch Jobs workshop tasks. 4. Click OK. 5. In the Job field, verify the first job number created in the Create Jobs workshop task displays.

The Open status displays. 6. In the tree view, right-click on ASM: 0 EAD-400-BLK and select Tree > Expand Tree.

The first four operations in the method of manufacture are marked as complete. This is because the operations 10, 20, 30, and 40 will be completed on the batch job. Operation 50 is subcontracted, so once the EAD-400-BLK part is received back from painting, it will be received back to the srcinal job. As a result of the job receipt, operations 60 and 70 can be worked on. Only material 40 (CS-060) in the method of manufacture is marked as issued, because it belongs to operation 10. The rest of materials belong to operations 50, 60, and 70. 7. In the Navigation toolbar, click the right arrow button to select the second job created in the Create Jobs workshop tasks.

The Open status displays. 8. In the tree view, right-click on ASM: 0 EAD-400-RED and select Tree > Expand Tree.

The first four operations in the method of manufacture are marked as complete. This is because the operations 10, 20, 30, and 40 will be completed on the batch job. Operation 50 is subcontracted, so once the EAD-400-RED part is received back from painting, it will be received back to the srcinal job. As a result of the job receipt, operations 60 and 70 can be worked on. Only material 40 (CS-060) in the method of manufacture is marked as issued, because it belongs to operation 10. The rest of materials belong to operations 50, 60, and 70. 9. In the Navigation toolbar, click theright arrow button to select the job created inthe Batch Jobs workshop task.

The Open status display. 10. In the tree view, right-click on ASM: 0 EAD-400-BLK-0-40 and select Tree > Expand Tree.

The method of manufacture includes only first four operations and one material, material 10 (CS-060). Material 10 is linked to operation 10 in the method. None of the operations are complete or material issued because the job has not started yet. Once the job operation 40 is complete, both parts will be sent to a subcontractor for painting. After the subcontractor paints the parts, they are received back to their srcinal jobs, in order to complete work on operations 60 and 70. 11. In the tree view, under the Operations node, select Opr: 30 OP: FORM .

The Job Details > Operations > Detail sheet displays. 12. In the Production Per Machine pane, in the Est Hours field, verify 0.10 displays. 13. Record the estimation hours_____________. 14. In the tree view, under the Materials node, select Mtl: 10 CS-060.

The Job Details > Materials > Detail sheet displays. 15. In the Quantity pane, in the Required Qty field, verify 1.60 displays. 16. Record the required quantity______________.

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17. In the Navigation toolbar, click the right arrow button to select the first job created in the Create Jobs workshop task. 18. In the tree view, right-click on ASM: 0 EAD-400-BLK and select Tree > Expand Tree. 19. In the tree view, under the Operations node, select Opr: 30 OP: FORM .

The Job Details > Operations > Detail sheet displays. 20. In the Production Per Machine pane, in the Est Hours field, verify 0.05 displays.

The estimation hours are half the estimation hours on the batch job. Note Refer to the previously recorded Estimation Hours value to cross compare.

21. In the tree view, under the Materials node, select Mtl: 40 CS-060.

The Job Details > Materials > Detail sheet displays. 22. In the Quantity pane, in the Required Qty field, verify 0.80 displays.

The required material quantity is half the required quantity on the batch job. Note Refer to the previously recorded Required Quantity value to cross compare.

23. Repeat steps 17-22 to review details for the second job created in the Create Jobs workshop task. 24. Exit the Job Tracker.

Workshop - Save and Restore a Schedule In this workshop, save and restore schedule for various jobs.

Enter Scheduling Changes Navigate to the Job Scheduling Board. Menu Path: Production Management > Scheduling > General Operations > Job Scheduling Board Important This program is not available in the Epicor Web Access.

1. In the Job field, search for and select job 2381. 2. Navigate to the Schedule sheet. 3. Right-click on job 2381 and select Start Time. 4. Move the job out one month.

The Move Job window displays. 5. In the Move Option field, select Job - All Operations and click OK. 6. To the Schedule Move Warning message, click OK.

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7. From the Actions menu, select Save Schedule. Schedule Maintenance displays. 8. In the Description field, enter XXX Class Exercise. 9. Click OK. 10. Minimize the Job Scheduling Board.

Generate Schedule Impact Report Navigate to the Schedule Impact Report. Menu Path: Production Management > Scheduling > Reports > Schedule Impact 1. In the Job Required Dates On or Before field, select 12/31/2016. 2. In the Report Name field, enter XXX (where XXX are your initials). 3. Verify the Summary Only check box is selected. 4. Click Print Preview. 5. Review and close the report. 6. Exit the Schedule Impact Report.

Undo the Changes 1. Maximize the Job Scheduling Board. 2. From the Actions menu, select Undo All Changes. 3. Exit the Job Scheduling Board.

Workshop - Multi-Constraint Scheduling When multiple resources are assigned to a job operation they need to be available simultaneously when scheduling finitely. The process begins by creating a new Resource Group and Resource.

Add New Resource Navigate to Resource Group Maintenance. Menu Path: Production Management > Scheduling > Setup > Resource Group 1. From the New menu, select New Resource Group. 2. Enter the following information:

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Field

Data

Resource Group

XXX-SUOP (where XXX are your initials)

Description

XXX Setup Operators (where XXX are your initials)

Department

Sheet Metal Department

Calendar

D5H8

Input Warehouse

Production Floor

In Bin

MCH

Important The Input Warehouse and Bin records must be entered only if the AMM license is installed.

3. Click Save. 4. If the Capacity changed, therefore, the 'Generate Shop Capacity Process' will need to be run the update ShopLoad records message displays, click OK. 5. From the New menu, select New Resource.

The Resources > Detail sheet displays. 6. Enter the following information: Field

Data

Resource

XXX-SHSU (where XXX are your initials)

Description

XXX Shear Setup (where XXX are your initials)

Finite Capacity

Select

Calendar

D5H8

Input Warehouse

Production Floor

In Bin

MCH

Important The Input Warehouse and Bin records must be entered only if the AMM license is installed.

7. In the Scheduling pane, clear the Use Resource Group Values check box. 8. In the Scheduling pane, in the Daily Production Capacity field, enter 8.00. 9. Click Save. 10. If the Capacity changed, therefore, the 'Generate Shop Capacity Process' will need to be run the update ShopLoad records message displays, click OK. 11. Exit Resource Group Maintenance.

Add Resource to Job Operation Navigate to Job Entry.

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Menu Path: Production Management > Job Management > General Operations > Job Entry 1. In the Job field, enter 2031 and press Tab. 2. Clear the Engineered check box. 3. Click Save. 4. In the tree view, expand the Operations node. 5. Select Opr 10 OP: SHEAR . 6. Navigate to the Job Details > Operations > Scheduling Resources > Detail sheet. 7. Enter the following information: Field

Data

Resource Group

XXX Set Up Operators

Resource

XXX Shear Setup

Required For

Both

8. Click Save.

Reschedule the Job 1. Navigate to the Job sheet. 2. Select the Engineered check box. 3. Click Save. 4. From the Actions menu, select Schedule > Job Scheduling . 5. Enter the following information: Field

Data

Schedule

Backward

Finite Capacity

select

What-If Schedule

select

6. Click OK.

View the Schedule Change 1. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays.

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2. Navigate to the Schedule sheet. 3. Right-click on job 2031 and select Start Time. 4. In the time bar, review the schedule. 5. Exit the Job Scheduling Board. 6. Select the Released check box. 7. Click Save. 8. Exit Job Entry.

Workshop - Minimize WIP In order to see the impact of theMinimize WIP process, create a backward scheduled jo b with multi-level assemlies (which normally minimizes WIP). The backward schedule is then compared to a forward schedule on the same multi-level job. The forward schedule normally does not Minimize WIP.

Create Scheduling Priority Code Navigate to Scheduling Priority Code Maintenance . Menu Path: Production Management > Scheduling > Setup > Scheduling Priority Code Important This program is not available in the Epicor Web Access.

1. Click New. 2. In the Scheduling Code field, enter XXXNMW (where XXX are your initials). 3. In the Description field, enter XXX Normal - Minimize WIP (where XXX are your initials). 4. In the Priority Factor field, enter 30. 5. Verify the Schedule Backwards check box is selected. 6. Select the Minimize WIP check box. 7. Click Save. 8. Exit Scheduling Priority Code Maintenance.

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Create a Job with Multiple Assemblies Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry 1. From the New menu, select New Job. 2. Click the Next Job button and click OK. 3. In the Part field, enter DCD-200-ML and press Tab. 4. In the Req By field, select a date one month from today. 5. Click Save. 6. From the New menu, select New Demand Link > Make to Stock.

The Job > Make To Stock > Detail sheet displays. 7. In the Quantity field, enter 200. 8. Click Save. 9. From the Actions menu, select Job > Get Details .

The Get Details window displays. 10. Select Rev B. 11. Click OK. 12. Remain in Job Entry.

Backward Schedule the Job 1. Select the Engineered check box. 2. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 3. Accept the default of Backward scheduling and click OK. 4. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays. 5. Navigate to the Schedule sheet and double-click the job number. 6. Double-click on all assemblies and subassemblies to expand them.

Note the job's current scheduled and the current start and end dates of the operations and job. When a backward schedule is applied to a multi-level job, WIP is minimized. A child assembly will complete in time for its parent assembly to begin.

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7. Exit the Job Scheduling Board.

Forward Schedule the Job 1. From the Actions menu, select Schedule > Job Scheduling . 2. Select Forward and click OK. 3.

Actions Schedule > Job Scheduling Board From the menu, select . The Job Scheduling Board displays.

4. Navigate to the Schedule sheet and double-click the job number. 5. Double-click on all assemblies and subassemblies to expand them.

When a forward schedule is applied to a multi-level job, WIP is not minimized. A non-critical path child assembly will start at the same time as the start of the lowest critical path assembly. 6. Exit the Job Scheduling Board.

Re-schedule the Job 1. In Job Entry, in the Req By field, select a date one week from today.

In order for WIP to be automatically reduced, the job must bounce. A job will bounce if a job schedule is prevented from being scheduled in the past. 2. In the Priority field, select XXX Normal - Minimize WIP (where XXX are your initials). 3. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 4. Accept the default of Backward scheduling and click OK. 5. From the Actions menu, select Schedule > Job Scheduling Board .

The Job Scheduling Board displays. 6. Navigate to the Schedule sheet and double-click the job number. 7. Double-click on all assemblies and subassemblies to expand them.

Because the job schedule was forced to bounce, WIP was minimized regardless of the Forward schedule. 8. Exit the Job Scheduling Board and Job Entry.

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Conclusion

Conclusion Congratulations! You have completed the Scheduling course.

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scheduling.pdf

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