Introductionto

RhythmFactoryPlannerKwokPoonMay17,2000Introductionto

RhythmFactor1AgendaWhatIsRhythmFactoryPlanner(FP)RhythmFPArchitectureRhythmFactoryPlanner(FP)PlanningConceptRhythmFPfeaturesAgendaWhatIsRhythmFactoryP2WhatIsRhythmFactoryPlanner(FP)?WhatIsRhythmFactoryPlanner3WhatIsRhythmFactoryPlanner(FP)FactoryPlannerusestheinformationfromtheexistingtransactionsystem(ERP)toprovideintelligentdecisionsupportcapabilityinPlanningandSchedulingFactoryPlannerprovidesaglobalintegratedview

PurchasingOrderEntryShippingMRPFactoryPlannerFloorControlDataDecisions&DataWhatIsRhythmFactoryPlanner4WhatCanRhythmFPDo?FactoryPlannerprovidesasystematicandconstraint-basedplanningconceptFactoryPlannercanhelptominimizethecurrentad-hocplanningprocessFactoryPlannercanquicklyrevealtheproductionconstraint,whichisalmostimpossiblefortraditionalplanningprocessWhatCanRhythmFPDo?Factory5RhythmFPArchitectureRhythmFPArchitecture6RhythmFPArchitectureClient-ServerArchitectureBothserverandclientprocessescanrunonWindowsNTmachinesMayrunserverandclientonseparatemachinesUseexistingdata(fromTritonandSFCS)MemoryResidentMulti-UsercapabilityRhythmFPArchitectureClient-S7RhythmFPArchitecture

(cont.)RhythmFPClientRhythmFPClientRhythmFPClientDataFilesRhythmFPServerRhythmFPServerProductionPlannerMaterialPlannerReportReaderProductionServerWhat-ifServerRhythmFPArchitecture(cont.)8RhythmFPFramework

(Input&Output)RhythmFPServerDemandProductStructure:PartnumberBOMRoutingsFactoryModel:ResourcesResourceCalendarMaterialAvailability:UnassignedInventoryP.O./VendorInfo.WIPOtherInformation:Tools...ProductionPlan:CapacityMaterialRhythmFPFramework

(Input&9RhythmFPFramework(cont.)FPrequiresACCURATEandSUFFICIENTdatainput(garbagein&garbageout)OpenloopplanningprocessinthefirstphasePlannersexecutetheproductionplanbasedonFP’ssuggestionRhythmFPFramework(cont.)FP10BasicFPDataObjectsBOMdataDemandorderdataPartnumberdataUnassignedinventorydataSupplierpartdataResourcedataRoutingdataBasicFPDataObjectsBOMdata11MoreFPDataObjectsWipdataOperationresourcedataResourcecalendardataVendorcalendardataVariablecapacitybucketsizedataMoreFPDataObjectsWipdata12FPOutputFilesCriticaldeliverydataPurchaseorderEDCrecommendationsManufacturingorderdataPlannedstarttimesProcurementdataProcurementbypartdataetc.FPOutputFilesCriticaldelive13FPDataObjectsRelationshipDemandOrders&ForecastOrdersBOMUnassignedinventoryRoutingdataVendorInfoResourcedataResourcecalendardataWIPdataFinishedGoodsPartNumbersMfgOrdersFPDataObjectsRelationshipDe14RhythmFPPlanningConceptRhythmFPPlanningConcept15FPPlanningConceptBTO(Build-to-order)engine:useDemandsasthedrivertocreateplanConsiderbothmaterialandcapacityconstraintsatthesametimeConsiderbothSalesOrdersandForecastsasthedemandinputwithdifferentprioritiesStartasanInfiniteCapacityPlanandprogresstoaFiniteCapacityPlanFPPlanningConceptBTO(Build-16FPPlanningConcept(cont.)MaterialsareassignedaccordingtotheBOMexplosionfromthefinishgoodlevelalsoconsiderTimefactorsRawMaterials(ProcuredParts)aresuppliedbyon-handinventoryorP.O.fromvendors.Manufacturedparts(finishgoodsandintermediateparts)aresuppliedbyWIPormanufacturingorders(workorders).FPPlanningConcept(cont.)Mat17ProcessFlowinFPInfiniteCapacityPlanningFiniteCapacityPlanningCAO(constraintanchoroptimization)DetailSchedulingIdentifyMaterialandCapacityProblemsFixMaterialProblemsAttempttofixCapacityProblemsCreatedetailedschedulesProcessFlowinFPInfiniteCap18FPInfiniteCapacityPlanning(ICP)BuildfactorymodelphaseInventoryAssignmentphasePlannedstarttimephaseCapacityutilizationphasePresentsplanthroughuserinterface(client)FPInfiniteCapacityPlanning19ICP--BuildFactoryModelReadfilesintomemoryandcreateresidentmemorymodelFileformatsinSpecFilesDoconsistencycheckingICP--BuildFactoryModelRead20ICP--InventoryAssignmentExploreBillofMaterialsDeterminesBOMconfigurationandroutingassignmentsCreatesmanufacturingorderstosatisfydemandsNetrequirementsforrawmaterialsandsub-assembliesagainston-handinventoryandWIP(Work-In-Process)CreatesmaterialrequirementsICP--InventoryAssignmentExp21ICP--InventoryAssignment(cont.)BackwardScheduleDefinition:LatestPossibleStartTime(LPST)-thelatestdateamanufacturingtaskcanbeginandstillcompleteontimeLPST=TaskDueDate-TaskProcessingtimeCalculatestheLPSTforeachmanufacturingtaskEachmanufacturingtaskwillhaveaLPSTSoftconstraint:violateLPSTconstraintwilldeterioratetheorder-fulfillmentperformanceICP--InventoryAssignment(c22ICP--InventoryAssignment(cont.)BackwardScheduleSub

assembly1R.W.#1R.W.#2Subassembly2ComputerOrderDueDateTaskDueDate(LPST)LPSTLPSTMfgorder#1Mfgorder#3Mfgorder#2ICP--InventoryAssignment(c23ICP--InventoryAssignment(cont.)InventoryAssignmentPrioritizedemandorders(duedate,priority,quantity)SortprioritizeddemandordersSortpartsfromend-itemtorawmaterialsCalculatedemandsAllocatesuppliesICP--InventoryAssignment(c24ICP--InventoryAssignment(cont.)ForwardScheduleDefinition:EarliestPossibleStartTime(EPST)-theearliestdatethatamanufacturingtaskcanbegin(constrainedbymaterials)EPST=max(ServerStartTime,MaterialAvailableTime)CalculatestheEPSTforeachmanufacturingtaskEachmanufacturingtaskwillhaveanEPSTHardconstraint:productioncannotbestartedwithoutmaterialsavailableICP--InventoryAssignment(c25ICP--InventoryAssignment(cont.)Subassembly1R.W.#1R.W.#2ComputerOrderCompletionTimeMaterialAvailableTime(EPST)EPSTEPSTMfgorder#1Mfgorder#3Mfgorder#2ForwardScheduleSubassembly2ICP--InventoryAssignment(c26ICP--PlannedStartTimeAssignPSTforeachtaskDefinition:PlannedStartTime(PST)istheexpectedstartdatethatataskwillbegintakingmaterialavailabilityintoconsiderationCalculation:PST=max(EPST,LPST)EachmanufacturingtaskwillhaveaPSTPSTvaluesmaybeoverridenthroughtheuserinterfaceICP--PlannedStartTimeAssig27ICP--CapacityUtilizationDeterminebucket(operationtimeinterval)configuration--fromvariablecapacitybucketsizedataCalculatecapacityforeachbucket--fromresourcecalendardataCalculateworkloadineachbucketbasedonPSTandruntimeofeachtaskICP--CapacityUtilizationDet28FPFiniteCapacityPlanningIdentifytheconstrainedresourcesBalanceandoffloadloadsforconstrainedresourcesinaGLOBALview(Globaloptimization)Planbasedonflexiblestrategyoptions(e.g.MinimizeWIP)RespondquicklyFPFiniteCapacityPlanningIde29FPDetailSchedulingSchedulebasedonflexiblestrategyoptions(e.g.FIFO)AbletospecifytheschedulinghorizonAbletogenerateaglobaloptimizedproductionscheduleGeneratethedispatchlistforexecutionIntelligentschedulingalgorithmandresultsFPDetailSchedulingScheduleb30HowtomakeitsuccessfulUser-ownprojectTrustandCooperationWhatareourgamerules?Forecast/Acceptance,S/O,P/O,etc.Thinkingoffuture,reasonableproceduresDataClean-upShouldbestartedfromtheverybeginningWhere,when,who,how,etc.etc.HowtomakeitsuccessfulUser-31RhythmFPFeaturesRhythmFPFeatures32ListofSomeFeaturesTransferBatchingManufacturingLotSizing(CMO)ProcurementLotSizingWIPReportingAdvancedScheduler(AS)DueDateQuotingBatchClientAlternatesAlternatePartsAlternateResourcesAlternateRoutingECNEffectivityDateeffectivityUse-upeffectivitySequence-DependentSetupsResourceModelingListofSomeFeaturesTransfer33UsingRhythmFPUsingRhythmFP34UsingFP--BasicUIentitiesProblemwindowsRep