SCHED-UM001F-EN-E 5/2/07 9:10 AM Page 1 INTEGRATED PRODUCTION & PERFORMANCE SUITE Production Management Scheduler USER’S GUIDE PUBLICATION SCHED-UM001F-EN-E–August 2007 Supersedes Publication SCHED-UM001E-EN-P
Contact Rockwell Customer Support Telephone — 1.440.646.3434 Online Support — http://www.rockwellautomation.com/support Copyright Notice © 2007 Rockwell Automation Technologies, Inc. All rights reserved. Printed in USA. This document and any accompanying Rockwell Software products are copyrighted by Rockwell Automation Technologies, Inc. Any reproduction and/or distribution without prior written consent from Rockwell Automation Technologies, Inc. is strictly prohibited.
Contents 1 • Welcome to FactoryTalk Scheduler 1 What is FactoryTalk Scheduler?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is the benefit? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How is it designed?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Where do I begin?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Primary and additional resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift patterns and efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resource sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simultaneous, Singular, and Infinite resource spanning . . . . . . . . . . . . . . . . . . .
Set the planning horizon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach a database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create the fcs file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Develop the shift or time patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Develop a schedule . . . . . . .
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE SHP Blue Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSD Red Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSD Blue Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handlebar Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Assembly . . . . . . . . . . .
1 Welcome to FactoryTalk Scheduler Welcome to FactoryTalk Scheduler, the state-of-the-art finite-capacity system that will help you gain control of your production scheduling. What is FactoryTalk Scheduler? FactoryTalk Scheduler is a client/server application that is an integrated part of the RSBizWare product suite. FactoryTalk Scheduler allows you to generate a detailed, finitecapacity schedule that provides a view into the future.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE you to check the schedule performance against the defined objectives and adjust the schedule if necessary. Since FactoryTalk Scheduler was designed to be highly configurable, your installation may look somewhat different from the examples in this guide. The figures and dialogs shown here are based on the tutorial example of a small manufacturing system (BizBikes, Inc.) that produces bicycles, which is included with the FactoryTalk Scheduler software.
technical support group. Additionally, electronic copies of the FactoryTalk Scheduler Customization Guide and the FactoryTalk Scheduler FDM Configuration Guide are provided on the software CD-ROM. RSBIZWARE ADMINISTRATOR ’S GUIDE The RSBizWare Administrator’s Guide is designed to help the administrator install and configure the software and to understand the components that make up the RSBizWare suite of products.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Get phone support The Rockwell Automation support team of outstanding professionals provides top-notch technical support—monitoring and tracking your experience with our products to pave the road to your success in understanding and improving your factory performance.
Get on-site support For on-site support, Rockwell Automation field support engineers are located around the globe to provide assistance with special projects, unexpected problems, or emergency situations. Field support engineers are available for dispatch 24x7x365 and can arrive at many locations the same day. To learn more about this and other support services, visit the Rockwell Automation Web site at www.rockwellautomation.com/support.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 6
2 The BizBikes Factory Introducing BizBikes This chapter describes a sample company, BizBikes Inc., whose manufacturing system will be referred to in upcoming tutorial chapters. BizBikes manufactures bicycles that are sold to independent bicycle shops. The BizBikes factory was selected because it contains representative key features of the RSBizWare product suite, including FactoryTalk Historian Classic, FactoryTalk Metrics, FactoryTalk Transaction Manager, and FactoryTalk Scheduler.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE BizBikes business problems BizBikes has been losing market share to competitors due to both pricing pressure and problems with on-time delivery. Business conditions have forced a transition from maketo-stock to make-to-order, and the bicycle shops that receive the goods are complaining about frequent late deliveries. Thin margins and decrease in market share have produced losses for the past two quarters.
Learn more about RSBizWare See how RSBizWare solutions impact the BizBikes manufacturing system by visiting www.software.rockwell.com/bizbikes/. For more comprehensive product information and to view application profiles of actual companies’ successes, be sure to visit the RSBizWare Web site at www.software.rockwell.com/rsbizware/.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 10
3 The Factory Overview The BizBikes manufacturing system To begin our assessment of the BizBikes factory, we’ll first examine their manufacturing system and learn about the factory resources and processes. We will then use this model to examine possible scenarios for improving our performance. Bill of materials The bill of materials for BizBikes contains three levels, as shown below, for a generic end item.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE (frames, handlebars, etc.) as well as final assemblies. The components are produced tostock and are consumed during the subassembly and the final assembly and pack of a bicycle. The MRP also nets together purchased components across multiple customer orders. The MRP netting operation generates purchase requests for component parts (brakes, wheels, seats, etc.) based on economic order quantities and lead times.
Order # SHP Red 1 SHP Red 2 SHP Red 3 SHP Red 4 SHP Red 5 SHP Red 6 SHP Red 7 SHP Red 8 SHP Blue 1 SHP Blue 2 SHP Blue 3 SHP Blue 4 SHP Blue 5 SHP Blue 6 SHP Blue 7 SHP Blue 8 SHP Blue 9 SSD Red 1 SSD Red 2 SSD Red 3 SSD Red 4 SSD Red 5 SSD Red 6 SSD Red 7 SSD Red 8 SSD Blue 1 SSD Blue 2 SSD Blue 3 SSD Blue 4 SSD Blue 5 SSD Blue 6 SSD Blue 7 SSD Blue 8 SHP Red Finished Frame 1 SHP Red Finished Frame 2 SHP Red Finished Frame 3 SHP Red Finished Frame 4 SHP Blue Finished Frame 1 SHP Blue Finished Frame 2 SHP
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Order # SSD Red Finished Frame 2 SSD Red Finished Frame 3 SSD Blue Finished Frame 1 SSD Blue Finished Frame 2 SSD Blue Finished Frame 3 SSD Blue Finished Frame 4 Handlebar Assembly 1 Handlebar Assembly 2 Handlebar Assembly 3 Handlebar Assembly 4 Handlebar Assembly 5 Seat Assembly 1 Seat Assembly 2 Seat Assembly 3 Seat Assembly 4 Seat Assembly 5 Handlebar 1 Handlebar 2 Handlebar 3 Neck Post 1 Neck Post 2 Neck Post 3 SHP Frame 1 SHP Frame 2 SSD Frame 1 SSD Frame
ASSEMBLY AND PACK These work cells are used to assemble and pack the finished BizBikes. The setup and process (per item) durations are part dependent. Each assembly operation requires two labor units from the labor pool for its entire duration. SUBASSEMBLY These work cells are used to assemble component parts (manufactured and purchased) into subassemblies that are placed in stock for future required orders. The setup and process (per item) durations are part dependent.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE This matrix shows the setup time for an operation based on the previous production lot that was processed at this work cell. For example, if the last production lot was Handlebar, then the setup time to produce a Neck Post is .26 hours. Bend Setup Matrix: BM SSD Frame SHP Frame Handlebar Neck Post SSD Frame SHP Frame Handlebar Neck Post 0.00 0.42 0.93 0.75 0.35 0.00 0.97 0.78 0.84 0.84 0.00 0.39 0.32 0.32 0.28 0.
The components required before this operation can be started are the manufactured parts SHP Red Finished Frame, Handlebar Assembly, and Seat Assembly and the purchased parts Pedal and Chain Assembly, Wheels, Derailleur Assembly, and Brakes. FINISHED FRAME The process plans for a finished frame (SHP Red, SHP Blue, SSD Red, and SSD Blue) contain two operations. The frame parts are first finished (red or blue) and then the parts are subassembled.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE SHP Frame Plan Seq # 10 20 30 40 Cut SHP Frame Tubing Bend SHP Frame Tubing Machine SHP Frame Tubing Weld SHP Frame 10 CUT FRAME TUBING Setup Time Process Time Cut 0.36 0.120 Bend BM 0.154 Machine MM 0.211 Weld WD 0.
adequate materials will be available. The process plan for Handlebar is summarized below. Handlebar Plan Seq # 10 20 30 Operation Cut Handlebar Tubing Bend Handlebar Tubing Finish Handlebar 10 CUT HANDLEBAR TUBING Setup Time Process Time Cut 0.16 0.055 Bend BM 0.043 Finish 0.14 0.088 Work Cell 20 BEND HANDLEBAR TUBING Additional Resources Notes Place in inventory 30 FINISH HANDLEBAR NECK POST The process plans for a handlebar contain four operations: cut, machine, bend, and finish.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE SEAT ASSEMBLY The process plans for the seat assembly contain a single subassembly operation. In this operation, the previously manufactured seat post and purchased seat are assembled. The subassembly is then placed in inventory where it is available for demand from a final assembly order. The component parts required for this subassembly are a seat post and seat for each subassembly to be produced. The process plan for Seat Assembly is summarized below.
Purchased components In addition to the manufactured components, we also have purchased components that are used in the assembly operations. Purchase orders for these components are automatically generated by the MRP (based on the economic lot size and lead times) to meet the manufacturing demands. The following table summarizes the purchased components for this same sample ten-day production period.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Inventories We have a starting inventory level for both the manufactured and the purchased material. The following table summarizes the starting inventory of these items.
4 Scheduling Features FactoryTalk Scheduler provides a wide range of features for modeling constrained scheduling systems. There are four basic categories of modeling constraints available— resource, sequencing, material, fixture, and operation. We will discuss the major features for each of them and use the BizBikes tutorial from Chapter 3 to demonstrate examples.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE also restrict what operations can be processed at the same time by requiring that certain operation attributes match before they can be processed together. Tutorial: We will not use this resource type in our tutorial system. The Adjustable Pooled resource type is most often used to represent pools of like resources, any one of which fulfills the requirement of the task or operation being performed. Typical examples are labor pools, totes, fixtures, or space.
called Assembly and Pack Area 1 and Assembly and Pack Area 2. We will associate a 1/5shift pattern with all the resources. The combination of the availability of required resources and resource efficiencies determine both where and how FactoryTalk Scheduler places an operation on the planning board during the scheduling process. A resource becomes unavailable for use by an operation in a given time period if it is currently being used by another operation or if it is in an off-shift state.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 7 10 AM 1 4 7 10 PM 1 4 7 10 AM Let us assume that FactoryTalk Scheduler is going to schedule an operation that requires a primary resource that is available 24 hours a day and currently is not being used during Days 1 or 2. This operation also requires two units of labor during its six-hour operation time. If the operation were available to start on or before 9 AM of Day 1, it could be scheduled during the first day.
as shown below. Although this operation time is six hours, this particular process spans a nine-hour period because it’s paced by the labor availability. 7 10 AM 1 4 7 10 PM 1 4 7 10 AM Between 1 PM and 3 PM, there are two units of the resource available. Thus, the operation is assumed to be at 100% efficiency during that time. However, between 3 PM and 9 PM, there is only one unit of labor available.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Although the operation could start at 4 PM, there is only one unit of labor available from 3 PM to 9 PM, so the scheduled start of the operation would be at 9 PM when there are two units available. From 9 PM to 11 PM, the operation is at 100% efficiency—accounting for the first two hours of the operation. From 11 PM of Day 1 to 7 AM of Day 2, there are no units available, resulting in zero efficiency.
Sequencing constraints Sequencing constraints are normally a part of the product or job routing and determine the sequence in which operations can be performed. Many systems have simple or straight routings where the sequence is simply determined by the order in which the operations are listed. The first operation must be completed before the second one can start, the second completed before the third can start, and so on. Other systems allow parallel or concurrent operations in their routings.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE all operations with lower root numbers and a fewer number of suffixes must precede that operation, as long as the remaining suffixes match, all operations with lower root numbers and the same suffixes, but with additional appended suffixes must precede that operation, and the converse defines the operations that succeed that operation.
10 (10) 20 (30) 10 (20) Immediate Successor Table OSN Scheme Operation Number ISO Scheme Operation Number Immediate Successor Operation Number 10 10 30 10 20 30 20 30 The second example extends the previous one by allowing two sets of parallel operations. In this example, the first two operations, labeled 10, can be performed independently, but both need to be completed before the next two operations, labeled 20, which can be performed independently.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE The third example illustrates how to use the numbering schemes to allow a series of operations to be performed independently, as would normally be the case in typical industrial routings. This example has both assembly and disassembly features. In this example, the first two operations with the “1” suffix can be performed independent of the first two operations with the “2” suffix.
10.1.1.1 (10) 20.1.1.1 (20) 30.1.1 (40) 10.1.1.2 (30) 10.1.2 (50) 20.1.2 (60) 40.1 (110) 50 (130) 40.2 (120) 20.1.3.1 (80) 10.1.3 (70) 30.1.3 (100) 20.1.3.2 (90) Immediate Successor Table OSN Scheme Operation Number ISO Scheme Operation Number Immediate Successor Operation Number 10.1.1.1 10 20 20.1.1.1 20 40 10.1.1.2 30 40 30.1.1 40 110 10.1.2 50 60 20.1.2 60 110 10.1.3 70 80 & 90 20.1.3.1 80 100 20.1.3.2 90 100 30.1.3 100 110 40.1 110 130 40.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE The final example illustrates a non-traditional network routing structure. Project management and maintenance environments frequently use these types of networks. This example illustrates the flexibility of the two numbering schemes. 20.1.2 (20) 30.1.2 (40) 10 (10) 40 (60) 20.1 (30) 30.1.1 (50) Immediate Successor Table OSN Scheme Operation Number ISO Scheme Operation Number Immediate Successor Operation Number 10 10 20 & 30 20.1.2 20 40 20.
product bill of materials and indicates the amount of each material item required and where in the routing it is required. FactoryTalk Scheduler combines the bill of materials detail with the routing information. You might think of a material as a bucket or bin containing inventory items of the same type.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE attempt to allow the scheduling of the initial item. If there are insufficient materialreplenish orders to allow the final item to be scheduled, FactoryTalk Scheduler will not schedule the final item and will remove all items scheduled in the attempt to produce the material requirements.
A similar feature allows an operation process time to have a resource product dependency. FactoryTalk Scheduler also provides several features that determine how setups and/or teardowns are scheduled. These allow for multiple times, which can be performed in parallel or sequential fashion. They also allow these activities to be performed in off-shift time periods. Additional features provide more control on the timing between successive operations.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 38
5 Scheduling Concepts FactoryTalk Scheduler incorporates both an algorithmic and a simulation-based scheduler. This chapter describes finite-capacity scheduling in general, details the differences between these scheduling methods, and discusses how to select scheduling rules to accomplish your objectives. Finite-capacity scheduling Finite-capacity scheduling (FCS) is the process of creating a production schedule for a set of jobs that is to be produced using a limited set of resources.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Job Sequence Resource Processing Time A 10 1 3 A 20 2 4 B 10 2 5 B 20 1 2 C 10 1 3 C 20 2 4 In this simple example, Job A consists of two operations that are defined by sequence numbers 10 and 20 and must be performed in that order. Operation 20 cannot begin until Operation 10 is complete. Jobs B and C also contain two operations numbered 10 and 20, respectively. The processing time for each operation is also shown in the table.
repeats this process until all jobs (and therefore, all operations) have been loaded. Each operation is loaded on its specified resource at the first available time slot that satisfies the constraints for that operation. In a job-at-a-time sequencer, the schedule is controlled by selecting the order in which the jobs are loaded onto the planning board. Hence, the key to the quality of the schedule that is generated by the algorithmic sequencer is the rule that is used for selecting the jobloading order.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE (due date and slack time) focus on reducing the number of late jobs, whereas the prioritybased rule strives to complete the most important jobs as soon as possible. In some applications, a given operation can be performed on two or more different resources. For example, a drilling operation might be performed on either of two drills.
Although the idea of constructing a schedule that has no late jobs is appealing, backward sequencing has some practical limitations, even in cases where a feasible solution is generated. Backward scheduling shifts all jobs to the right on the planning board so that they start as late as possible while still meeting the due date. This means that there is no time buffer in the system, so any disruptions that occur (machine breakdowns, late material arrivals, etc.) will typically create late jobs.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE as an available ranking order property. FactoryTalk Scheduler will automatically list all specified order properties. Priority: Ranking based on the smallest numeric priority. If you use this rule, a priority field must be included in the order database. Process Time: Ranking based on the sum of the job’s operation times, the smallest sum being ranked first. Release Date: Ranking based on the earliest job release (or early start) date first.
SCHEDULING EXAMPLE 4 The following sets of figures illustrate the simulation-based construction process. In each of the figures, the vertical line denotes the current value of simulated time.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE STEP 4: LOAD OPERATION B-20 Resource 1 Resource 2 A-10 C10 B-10 B-20 A-20 Time 5 10 15 STEP 5: LOAD OPERATION C-20 Resource 1 Resource 2 A-10 C10 B-10 B-20 A-20 C-20 Time 5 10 15 The first step in the simulation-based sequencer is to load all operations that can begin at the current time. In this example, Operation 10 for Job A (A-10) can be loaded on Resource 1, and Operation 10 for Job B (B-10) can be loaded on Resource 2.
Selection rules In a simulation-based sequencer, there are two types of selection rules that can be applied each time an operation is scheduled: an operation selection rule or a resource selection rule. If a resource becomes available and there are several available operations that require that resource, the operation selection rule is used to determine which operation is scheduled.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE determines which operation to load. This rule is the key factor that determines the quality of the resulting schedule. RESOURCE GROUPS AND QUEUES Before discussing the rule mechanisms in FactoryTalk Scheduler, we must first discuss the concept of Resource Groups and Queues. Each of the resources in the system may be assigned to one or more resource groups.
and selects the desired operation using any appropriate logic. This type of rule gives complete flexibility in the selection of the next operation to load. In essence, if you can logically describe how an operation is selected, then you should be able to transform that logic into a user-coded logic rule. Although the primary purpose of a given rule is to make a selection, the rule can be coded to perform other logic based on the selection.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Tardiness, Minimum Job Flow Times, and Maximum Facility Capacity. We will discuss each of these core objectives and the corresponding FactoryTalk Scheduler operation and resource selection rules that support these objectives. This categorization of the rules should help you narrow your choices based on your corescheduling objective.
The predefined job preference rules are generally used in situations where the characteristic of the job (e.g., priority or cost) is the overriding issue in scheduling, rather than job due dates or facility utilization. Since these rules ignore due dates, they are typically more applicable in make-to-stock rather than make-to-order environments. Minimum Job Tardiness In many make-to-order environments, the overriding scheduling objective is to ensure that every job is completed by its assigned due date.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE work (rather than number of operations) to be done. The basic premise is that the remaining slack time itself is not as important in determining the most critical job as it relates to the remaining work to be done. If we have a lot of remaining work, then we need a larger slack time to ensure that we will not be late.
Maximum Facility Capacity category ignore the job due date and are focused on generating a schedule that is efficient in terms of increasing the effective capacity of the facility. The rules in this category include Least Setup Time, Campaign Sequence Up, Campaign Sequence Down, Campaign Sequence Cycle, and Least Setup With Campaign. In addition, each of these rules has an associated Timed rule.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE increase until no orders remain with the same or larger campaign value. When this occurs, the rule then switches to a decreasing campaign and begins selecting orders that have the same or smaller campaign value. When all such orders are exhausted, it then returns to an increasing campaign strategy. This rule continues in this fashion, repeatedly cycling between an increasing and decreasing campaign strategy.
The Non-Bottleneck Earliest End Time rule selects the non-bottleneck resource that will complete the operation first. If there are no identified bottleneck resources in the valid resource group, this rule defaults to the Earliest End Time rule. The Non-Bottleneck Earliest Start Time rule selects the non-bottleneck resource that will start the operation first. If there are no identified bottleneck resources in the resource group, this rule defaults to the Earliest Start Time rule.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Fewest Remaining Operations (static): The operation whose job has the fewest remaining operations is selected. Longest Waiting Time: The operation that has been waiting the longest will be selected. Shortest Waiting Time: The operation that has been waiting the least will be selected. Largest Processing Time: The operation with the largest processing time will be selected.
Campaign Sequence Cycle: The operation with the same or next highest (lowest) campaign value is selected. The sequence starts with the lowest value and selects operations with increasing campaign values. When there are no operations with higher values, the sequence is reversed and the next lowest value is selected. Campaign Sequence Down: The operation with the same or next lowest campaign value is selected.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Timed Least Setup With Campaign: The operation with the least setup time and the closest campaign value is selected. The campaign values are used only to resolve ties in setup. Timed Least Setup Time: The operation with the least setup or changeover time is selected. Custom sequencing Custom sequencing allows the user to take total control of the scheduling activity.
6 Using FactoryTalk Scheduler In Chapter 3 we introduced our tutorial system, and in Chapter 4 we discussed the basic FactoryTalk Scheduler modeling features and how they relate to our tutorial system. Chapter 5 was devoted to a general discussion of the various scheduling procedures available, along with their brief descriptions. Chapter 6 now covers the basics of using the FactoryTalk Scheduler system and shows you how to use many of these concepts in the context of our tutorial system.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Thus, the first time you load a new FactoryTalk Scheduler application, you will have to set up your planning horizon and attach your database. If you inadvertently set up the wrong planning horizon or decide later that you need to change it, you can make changes the next time you load the schedule. There are six different save options available in the File menu; Save, Save All, Save As, Save FCS, Save Log, and Save Report Data.
Attach a database Select the Database > Attach menu option to open the Connect To Database dialog that allows you to select the database file. Since the BizBikes tutorial uses a SQL database, you want to select or highlight the Microsoft SQL Server option. Then click the Next button, which will take you to the Server dialog. The Server dialog requires that you enter your server name, user name, and password. Click the Next button to select the database.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Select the database from the drop-down list (BizBikes) and click the Next button. The last dialog requests that you choose a Table Map. Select the default and click on the Finish button to load the database.
Once all the data is read in, our resource names will be displayed down the left side of the Sequence Overview window, as shown below. Note that the board will be empty until we add jobs to the schedule.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Now we’ll open the Unallocated Jobs window by using the View > Unallocated Orders/Operations window menu option. The resulting window is represented below. Create the fcs file The Unallocated Jobs window contains all operations for all the jobs currently waiting to be scheduled, so now we’ll create our fcs file by using the File > Save As or the File > Save menu option. The default file name is always Scheduler 1.fcs.
and save the fcs file, these changes will automatically be used when you recall an application using the fcs file. Develop the shift or time patterns Shift or time patterns constrain the availability of resources over time. These constraints include off-shift, vacation, holidays, preventive maintenance, breakdowns, etc.—times where resources are unavailable. For normal resources such as machines, it can also include efficiencies that may vary during the available times.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Unallocated Jobs Window and places them on the planning board. The resulting schedule is shown next. Each scheduled operation on the planning board is represented by a colored bar. You will note that all the operations that comprise an order are the same color, and the order name appears on each bar. Unfortunately, it’s difficult to read many of the order names because each bar is scaled to represent the operation time.
The Attributes window You can get more information about each operation by placing your mouse cursor on an operation and right-clicking to reveal a dialog with several options. Click on the Attributes option to show the Attributes window. You can also open this dialog by double-clicking on the selected operation. Let’s select the second operation that is scheduled for the Cutter resource—operation “Cut Handlebar Tubing” for order “Handlebar 1.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE If you want to view the schedule of the Handlebar 1 order in the context of the entire schedule, you can use the View > Find Order menu option. Before you select this option, you need to select the order name by using the drop-down feature located in the Show toolbar, as displayed below.
When you activate this option, all operations that are not a part of the Handlebar 1 order are grayed out, making it easy to find the Handlebar 1 operations, as shown below. Repeating this selection takes you back to the normal sequencer view. Use operation overlap The default view for the Sequence window is structured to provide an overview of the entire schedule. In many implementations, the default view does not show all the information about the schedule.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Labor resource and overlay the time patterns for the Labor and Cutter resources, your overview should appear as shown next. Create named views In FactoryTalk Scheduler applications with a large number of resources, it is sometimes desirable to create different views of the Sequence Overview window or planning board for different users.
use this procedure, your resulting Sequence Overview window, or the default Gantt view, should resemble the window shown next. Now let’s create a new named view called Fabrication, which will only show the Cutter, Bender, Machiner, Welder, and Finisher resources (in that order). You create a new view by selecting the View > Named Views > Modify List menu option, which will open the Named Views dialog shown below. Press the Create button and enter the view name, Fabrication, and click OK.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE This results in a new view being created and assigned the name “Fabrication.” Note that this is basically a copy of the default Gantt view. Now we need to close this dialog, recall the new view (View > Named Views > Fabrication), and modify that view. In this case, we need to remove the assembly areas, subassembly areas, and the labor resource, which is only used in the assembly and subassembly areas.
If you accidentally hide a resource that should be visible, simply right-click in the resource area of the view and select the Unhide menu option to cause the Hidden Rows dialog to appear. Select the resource you want to add to the current view and click the Unhide button. This will display the resource in the current view. Once you have created your new Named View (Fabrication), you’ll need to save the fcs file, which contains the information on the Named Views.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Manually edit a schedule Once you develop a partial or complete schedule, you can also use the drag-and-drop feature to make individual changes in how and where operations are scheduled. To illustrate this feature, let’s start with the schedule of the three orders just created. Before we start, it would be a good idea to save this schedule in case you need to revert to the basic schedule.
resource—the “Cut Neck Post” operation. Move it to the right and note the change in the window. A plus “+” sign appears in front of the Warning entry. Expand this and you will see the message shown next. If you perform a check, Adjust > Check Sequence, it will tell you that Validation is required for one operation, and it suggests that you check the log messages for more details.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE If you have these other types of constraints, you can get information on their validity by selecting both the Adjust > Validate Op On Drop and the Adjust > Extended Validate On Drop menu options. This checks all constraints and reports any violations in the log file. Evaluate a schedule Once you generate a schedule, you might want to evaluate its quality.
Orders are considered to be on time by comparing their order end dates/times to the order due date times. If the difference falls within the specified late- or early-tolerance limits, the orders are considered to be on time. These tolerance limits can be specified by selected the Setup > Performance Parameters menu option as shown below. The default values for Early and Late Tolerance are 24 hours. For this example, any order that is completed within 24 hours of its due date is considered to be on time.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Holding your cursor over the chart will display the legend. In this case, the bars represent the idle, process, off, and setup (in that order). You also have several other options available. You can display these by pointing at the chart and right-clicking. This gives you the options shown, which include showing the data. If you select the Show Data option, a Chart Data window is displayed showing the data that was used to develop the chart.
February 17 to midnight Saturday, February 22, we’ll get a more representative utilization chart. The new chart is shown at the right. When you change the chart horizon, it is applied to all resource, pooled, and waiting time charts. The charts for materials still use the entire planning horizon. This chart horizon will remain until you exit the current FactoryTalk Scheduler application. The next time you open the application, the chart horizon will be reset to the entire time horizon.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE typical information that is included in most applications. These include two activity-based costing reports, daily and weekly resource utilization, scheduled and unscheduled orders, material levels, order details, dispatch lists, and labor pool allocation. These reports were developed using Crystal Reports® software and can be viewed within FactoryTalk Scheduler using the Crystal Reports runtime software provided with FactoryTalk Scheduler.
Clicking on the Neck Post 2 order causes the operations of the order to be displayed in the operations section of the window. The initial sequence of the operations is based on the Op Number. You can re-sequence the order by clicking on any of the operation column headers. Now double-click on the second operation, Op Number 20, which will open the Operation Constraints window for that operation, shown below.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE This window provides additional information on the selected operation. The upper-left part of the window displays the basic operation information, while the upper-right part displays the basic order information. The Attributes button at the far right will open the same Attributes window that you can open by double-clicking on an operation in the Sequence Overview window.
Close the Operation Constraints window and scroll down the on-time orders until you find the SHP Red 6 order. Click on this order and then double-click on the single Operation 10 for this order. This operation requires additional resources (two Labor resources) and materials as shown below. The Resource Utilizations show values of 82% for Assembly and Pack Area 1 and 84.3% for Labor.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Now let’s turn our attention to the Material Prerequisites. This section lists all the materials required and their availability. If the material is a manufactured component, it will also provide the order that produced it. For example, there are two listings for the material Wheels, a purchased material. A total of 20 wheels are required, 11 coming from a material delivery on February 13 and nine wheels from a delivery on February 14.
A section of the Scheduled Orders report showing the orders due on 2/11/03 is shown below. In the actual report, several different colors are used for the values in the completion date column. This allows the user to identify easily the late, on-time, and early orders. A section of a typical dispatch or work-to list for the Assembly and Pack Area 1 resource shows the orders scheduled for 2/13/03. The remainder of this report provides a list of operations scheduled, by day, at each resource in the system.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Where desirable, the information in a report also can be displayed in a graphical format. For example, the Schedule Performance report, shown below, is displayed in a pie-chart format. These examples represent some of the types of information that can be obtained using the Report option. However, you may want to get a more complete picture by looking at the rest of the reports included with the tutorial system.
7 Schedule Analysis In Chapter 6, we covered the basic procedures for using the FactoryTalk Scheduler system. In this chapter, we will show you how to edit some of the underlying data and many of the features that will allow you to perform schedule analysis. Comparing different schedules Once you have generated a schedule, FactoryTalk Scheduler provides several ways to evaluate its quality.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE This filter option uses the data in the last auxiliary Boolean attribute field for orders to determine which orders are to be filtered out. You can check the values for our tutorial system by opening the Attributes window and going to the last field in the Order tab. An entry of Null, 0 (zero), or False means that the order will not be filtered out, or that it will be included in the performance metrics.
This portion of the Baseline Comparison provides summary performance measures, much like the Performance Metrics window. The number of Late, Early, On Time, and Incomplete orders are absolute measures. Note that the values for both the Baseline and Now schedule are the same. Thus, the lower the value, the better the schedule. The Average Late and Average Early provide the average time a late order is late and the average time an early order is early.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE the third column show the relative percent of change between the two schedules using the base schedule as the base for comparison. Using these measures, you can determine whether the current schedule is better than the base schedule. In our example, it appears that the baseline schedule is better, based on the fact that we have one fewer late job. However, you might want more detailed information on the schedule changes before you make this judgment.
to the database. Thus, they will be lost when you exit the FactoryTalk Scheduler session. This method is best used when you are exploring the effects of using different rules. You can make these changes by selecting the Setup > Simulation Rules menu option. This opens the Set Simulation Rules window shown below. If you position and click your cursor on one of the rules, the down arrow appears at the right of the field.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Now if we develop a schedule using simulation, it will use these new rules. This results in a schedule with 11 late jobs—two more than for the default rules. If you want to make the selection permanent, you can exit FactoryTalk Scheduler and edit the FDM Data. Now let’s retain the same base case and try other forms of scheduling as part of our analysis.
Now, use the Sequence > Forward > By Release Date menu option to schedule the remaining orders. Reviewing the comparison indicates that we have reduced our number of late orders by 12 compared to our base case. A closer inspection of our comparison shows that we have increased the lateness of our late jobs significantly. If determining the better schedule is your responsibility, you may have to take a closer look at the details of the late orders, which you can do easily by using the Schedule Analyzer.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE developed is a “2 by 5 Pool 4,” which is what we need. If we attach this time pattern to our Labor resource, we can check our results using the Sequence > Simulate option. The comparison reveals that the number of late orders is now four. Using the backward method followed by the forward by release date option provides an increase in the number of late orders (eight) with all orders scheduled.
One might conclude that Case 8 provides the best results. It also yields one of the better values for the latest end order. You might note that Case 6 also had only four late jobs and about the same value for the latest end order time. Since this option requires one fewer labor resource, you might want to consider it over Case 8. Of course, Cases 6, 7, and 8 assumed you could increase the labor pool. If this were not feasible, you would need to consider the first five options.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE would be the scheduling of a preventive maintenance activity or a breakdown, which only applies to one resource. Global calendar exceptions are typically used for holidays or factory shutdowns and are intended to affect the entire system. Both of these exceptions can be added using the Exceptions Editor (see Appendix D).
A Glossary Activity Area—a generic term for sites, areas, or lines within a production enterprise. An enterprise may contain one or more sites, which in turn may contain one or more areas, which may be comprised of one or more lines, which may have one or more work cells. A work cell may belong to an activity area at any level in this hierarchy. Statistics are automatically rolled-up through the activity area hierarchy.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Composite Time Pattern—a base pattern with exceptions that is used to define a shift pattern for a resource. Conveyor—a continuous transfer device that moves production lots from one station to the next. A transfer via a conveyor requires a free space on the conveyor. Conveyors come in many different types including belt, roller, chain, and bucket. Conveyors can have both accumulating and non-accumulating exit points.
generated to produce components or subassemblies to-stock that are required for manufacturing orders for finished products. Manufacturing Order Plan—an actual plan for manufacturing an order in the facility. The manufacturing order plan is comprised of a collection of operations that define the detailed work for operations to be performed, as well as actual data on operations that have been completed. The manufacturing order plan is an order-specific and expanded version of the process plan for a product.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Operation Constraint—a restriction placed on the duration, start, or end time of an operation. Operation constraints include Maximum Span, which limits the maximum operation duration, and Minimum End Offset, which limits the offset time between the end of the previous operation and the start of this operation. Operation Parameter—a named value associated with a manufacturing operation.
Primary Resource—a resource that is specified as a primary resource at a work cell. Every work cell has a primary resource that is always seized and held for the duration of an operation. The primary resource may also be carried across multiple operations. Process Plan—a generic plan for manufacturing material in a facility. It is associated with a material and is independent of any specific order for the material.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Resource Efficiency—alters the rate at which work is performed using a resource. The actual work duration is the planned work duration divided by the efficiency. Hence, values greater than 1 shorten the time and values less than 1 lengthen the time. An efficiency of 0 makes the resource unavailable. Resource Idle Cost—the cost accrued per unit time for an unallocated resource.
Time Pattern—a collection of calendar values, shift states, or other time patterns that have been assigned to specific blocks of time. For example, a time pattern named First Shift might define time blocks 8 to 12 as Available, 12 to 13 as Unavailable, and 13 to 17 as Available. Time patterns are building blocks that are used to construct complete work schedules for a resource. Transfer—the movement of a production lot from one work cell station to the next work cell station.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 104
B Process Plans SHP RED BICYCLE Seq # 10 Operation Work Cell Assemble and Pack SHP Red Assembly and Pack Setup Time Process Time Additional Resources 0.43 0.37 Labor (2) Notes Components required: SHP Red Finished Frame Pedal and Chain Assembly Handlebar Assembly Wheels Derailleur Assembly Seat Assembly Brakes 10 Assemble And Pack SHP Red SHP BLUE BICYCLE Seq # 10 Operation Work Cell Assemble and Pack SHP Blue Assembly and Pack Setup Time Process Time Additional Resources 0.43 0.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE SSD RED BICYCLE Seq # 10 Operation Work Cell Assemble and Pack SSD Red Assembly and Pack Setup Time Process Time Additional Resources 0.37 0.43 Labor (2) Setup Time Process Time Additional Resources 0.37 0.
SHP RED FINISHED FRAME Seq # 10 20 Operation Finish SHP Red Frame Assemble SHP Red Frame 10 Finish SHP Red Frame Setup Time Process Time Finish 0.11 0.155 Subassembly 0.19 0.083 Labor (1) Setup Time Process Time Additional Resources Finish 0.11 0.155 Subassembly 0.19 0.083 Labor (1) Setup Time Process Time Additional Resources Finish 0.11 0.155 Subassembly 0.19 0.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE SSD BLUE FINISHED FRAME Seq # 10 20 Setup Time Process Time Finish 0.11 0.155 Subassembly 0.19 0.
SSD FRAME Seq # 10 20 30 40 Setup Time Process Time Cut 0.32 0.12 Bend BM 0.154 Machine MM 0.211 Weld WD 0.234 Operation Work Cell Cut SSD Frame Tubing Bend SSD Frame Tubing Machine SSD Frame Tubing Weld SSD Frame 10 Cut SSD Frame Tubing 20 Bend SSD Frame Tubing 30 Machine SSD Frame Tubing Additional Resources Notes Place in inventory 40 Weld SSD Frame HANDLEBAR ASSEMBLY Seq # 10 Work Cell Setup Time Process Time Additional Resources Subassembly 0.21 0.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE NECK POST Seq # 10 20 30 40 Setup Time Process Time Cut 0.21 0.065 Machine MM 0.120 Bend BM 0.072 Finish 0.14 0.
C MRP Charts SHP Red Bicycle LEVEL: 0 Period LEAD TIME: 1 2/12 2/13 2/14 2/17 2/18 2/19 2/20 2/21 Gross Req 2/10 2/11 15 9 8 12 17 20 9 7 Sched 15 9 8 12 17 20 9 7 9 8 12 17 20 9 7 2/12 2/13 2/14 2/17 2/18 2/19 2/20 On Hand (0) Order Rel 15 SHP Blue Bicycle LEVEL: 0 Period LEAD TIME: 1 2/10 2/11 2/21 Gross Req 11 6 4 14 11 16 8 6 15 Sched 11 6 4 14 11 16 8 6 15 6 4 14 11 16 8 6 15 2/11 2/12 2/13 2/14 2/17 2/18 2/19 2/20 2/
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE SSD Blue Bicycle LEVEL: 0 Period LEAD TIME: 1 2/12 2/13 2/14 2/17 2/18 2/19 2/20 2/21 Gross Req 2/10 2/11 5 16 9 12 8 13 18 15 Sched 5 16 9 12 8 13 18 15 16 9 12 8 13 18 15 On Hand (0) Order Rel 5 SHP Red Finished Frame LEVEL: 1 Period LEAD TIME: 1 2/11 2/12 2/13 2/14 2/17 2/18 2/19 2/20 Gross Req 15 9 8 12 17 20 9 7 Sched 24 24 24 24 12 19 23 14 7 7 24 24 2/21 On Hand (8) Order Rel 2/10 LO
SSD Red Finished Frame LEVEL: 1 Period Gross Req LEAD TIME: 1 2/10 2/11 2/12 2/13 11 9 8 14 Sched On Hand (17) Order Rel LOT SIZE: 24 24 6 21 24 2/14 2/17 2/18 2/19 2/20 12 7 6 12 24 13 23 2/21 24 23 11 24 4 22 10 10 2/19 2/20 2/21 15 24 SSD Blue Finished Frame LEVEL: 1 Period LEAD TIME: 1 2/10 Gross Req 2/11 5 Sched On Hand (6) 6 Order Rel 1 LOT SIZE: 24 2/12 2/13 16 9 2/14 2/17 12 8 24 24 9 12 24 24 2/18 13 18 24 24 4 15 21 6 6 24 24 2
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Seat Assembly LEVEL: 1 Period Gross Req LEAD TIME: 1 LOT SIZE: 75 2/10 2/11 2/12 2/13 2/14 2/17 2/18 2/19 2/20 22 35 37 45 35 53 48 39 49 75 75 12 34 61 75 75 Sched 75 On Hand (36) 14 Order Rel 75 54 75 17 47 75 2/21 75 22 48 48 2/21 75 Pedal and Chain Assembly LEVEL: 1 Period LEAD TIME: 3 LOT SIZE: 60 2/10 2/11 2/12 2/13 2/14 2/17 2/18 2/19 2/20 Gross Req 22 35 37 45 35 53 48 39 49 Sched 60 60
Wheels LEVEL: 1 Period Gross Req LEAD TIME: 3 LOT SIZE: 48 2/10 2/11 2/12 2/13 2/14 2/17 2/18 2/19 2/20 22 35 37 45 35 53 48 39 49 48 48 48 48 48 48 19 28 27 27 2/21 Sched 48 On Hand (540 32 45 8 11 24 19 Order Rel 48 48 48 48 48 48 2/21 Derailleur Assembly LEVEL: 1 Period Gross Req LEAD TIME: 4 2/10 2/11 2/12 2/13 2/14 2/17 2/18 2/19 2/20 22 35 37 45 35 Sched On Hand (54) LOT SIZE: 60 60 32 Order Rel 53 48 39 49 60 60 60 60 60 7
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Handlebar LEVEL: 2 LEAD TIME: 3 Period 2/10 Gross Req 2/11 75 Sched LOT SIZE: 100 2/12 2/13 75 100 On Hand (55) 80 Order Rel 80 5 100 100 5 2/14 2/17 75 75 2/18 2/19 75 2/20 2/21 100 100 100 30 55 55 80 80 80 2/17 2/18 2/19 2/20 2/21 100 Neck Post LEVEL: 2 LEAD TIME: 3 Period 2/10 2/11 LOT SIZE: 60 2/12 2/13 2/14 Gross Req 75 75 75 75 75 Sched 60 60 60 120 60 On Hand (58) 43 13 58 58 43 43 43
SSD Frame LEVEL: 2 Period LEAD TIME: 4 LOT SIZE: 50 2/10 2/11 2/12 2/13 Gross Req 24 24 24 24 Sched 50 On Hand (4) 30 Order Rel 2/14 2/17 2/18 24 48 50 50 34 2/17 50 6 32 50 50 8 8 2/19 2/20 2/21 36 36 36 36 2/18 2/19 2/20 2/21 79 79 Seat LEVEL: 2 Period Gross Req Sched On Hand (54) Order Rel LEAD TIME: 2 2/10 2/11 75 LOT SIZE: 100 2/12 2/13 75 100 79 79 4 4 100 100 2/14 75 75 75 100 100 100 29 54 54 79 100 117 • • • • • C • MRP CHARTS
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 118
D Time Pattern Editors In this appendix, we’ll introduce the three available time pattern editors and show you how to use them in the context of FactoryTalk Scheduler. Time pattern types Time patterns are an important part of the FactoryTalk Scheduler application as they determine the availability—and in some cases, the efficiency—of your constraining resources. Each resource in your application will have two time patterns: capacity and efficiency.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 3 hours, the machine would be available and processing at a 90% rate (capacity of 1 and efficiency of 0.9). For the last 9 hours, the machine would be unavailable (capacity of 0). Developing a time pattern We’ll lead you through the development of time patterns using those included with the tutorial systems. Let’s start with the capacity time pattern for our Singular resources.
Now we’ll show you how to develop this time pattern under a different name. To do this, right-click in the Time Pattern section and select the New Folder option. When the folder appears, change its name to My Patterns. Next click on the new folder followed by a right-click and select the New Time Pattern option. When the new time pattern appears, change its name to My Shift 1.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 122
We’ll leave the Default Value as the Unavailable state. Next click on the button to the right of the Duration field to open the Time Pattern Duration dialog. Select the Custom option for the Duration Type and change the duration time to be 8 hours, as shown below. At this point, we have defined a time pattern for a resource, which is unavailable for entire eight hours. Now we go to the Time Span section and double-click anywhere in the grid section to open the Time Span dialog.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Accepting this dialog will populate the first row of the grid with your values. Note that the graph has now changed to show a capacity of 1 for the entire 8 hours. Comparing this newly created time pattern to our first time pattern, Shift 1, shows that they are the equivalent, except for our new names. If you examine the Shift 2 time pattern, you should notice that except for the name, it is identical to the Shift 1 time pattern.
the time span grid and assign the new My Shift 1 time pattern to the hours from 7 to 15 for Monday, as shown below. Accept this dialog and enter a new time span that assigns time pattern Shift 2 on Monday from 15 to 23. Continue repeating these entries for Tuesday through Friday. The resulting Time Pattern is shown next.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE The only difference between this new time pattern and the 2 By 5 Machine time pattern is that we did not define the off-shift times. We simply allowed those times to be assigned the default state Unavailable; the results are the same. The only reason the off-shift state was used in the original time pattern was to allow us to assign a color that would be displayed whenever we viewed the time patterns in FactoryTalk Scheduler.
The resulting 2 By 5 Pool 3 time pattern looks very similar to the 2 By 5 Machine time pattern, except for the capacity of 3 during the on-shift times.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Now let’s assume that one of your resources performs at a 90% level. Let’s develop a new efficiency time pattern named Machine At 90. Select the Time Pattern Type as Efficiency, the Default Value Type as Numeric, and the Default Value as 0.90, as shown below. Note that there are no entries in the Time Span section. We simply allow the efficiency to be at value 0.9 for the entire time period, as the capacity time pattern will be overlaid.
be State and the Value to be the state Unavailable. Now use the drop-down arrows to open the calendar and set the Start Date to July 4 and the End Date to July 5. Next, highlight the Resources entry in the Elements section and press the double arrow symbol (>>). This will cause all the resource names to appear in the Application section. In effect, we have requested that this exception be applied to our entire system.
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE would want to attach the 2 By 5 Pool 3 time pattern to the Capacity selection of the Labor resource and the 2 By 5 Machine time pattern to the Capacity selection of the remaining resources. The Capacity selection for the Bender resource is shown below. You should also note that the July 4 exception we created in the previous section is listed in the Exceptions section of the Composite Editor window.
131 • • • • • D • TIME PATTERN EDITORS
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE 132
Index A ActiveX Data Objects (ADO) 1 activity area 97 activity-based costing 97 additional resources 24, 97 Adjust > Check Sequence menu option 74 Adjust > Extended Validate On Drop menu option 76 Adjust > Validate Op On Drop menu option 76 Adjustable Pooled resources 26 algorithmic job selection rules 43 algorithmic sequencing 40 bi-directional 43 bottleneck 43 algorithmic sequencing rules Ascending Order Property 43 Due Date 43 First Come, First Served 43 Lowest Priority Firs
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE composite time pattern 98 constrained system modeling 23 material 23 operation 23 resource 23 sequencing 23 constructing a schedule 40 algorithmic approach 40 job-at-a-time sequencing 40 conveyor 98 Critical Ratio 51, 55 Crystal Reports 1, 80 runtime software 80 Ctrl+character 59 custom sequencing 58 D database attaching 59 Database > Attach menu option 61 Database > Time Pattern menu option 65 Default Gantt view 70 depend
G Gantt chart good order L 39 98 labor resources 69 Largest Processing Time 50, 56 Latest End Time 54, 56 lead-time offset 35 Least Setup Time 57 Least Setup With Campaign 54, 57 line 98 Log Pane 74 Longest Waiting Time 50, 56 lot splitting 98 Lowest Order Property Field 50, 55 Lowest Priority First 50, 55 H Handlebar 18 Handlebar Assembly 18 help online 3 heuristic rules for sequencing 41 Hide menu option 72 Highest Order Property Field 50, 55 Highest Priority Fi
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Adjust > Validate Op On Drop 76 Database 61, 65, 93 Database > Time Pattern > Composite Editor 129 Database > Time Pattern > Exceptions Editor 128 Database > Time Pattern > Time Pattern Editor 120 Edit > Clear Log 75 File 60, 64, 95 File > Save 84 File > Save All 84 File > Save As 84 File > Save Report Data 84 Performance 77 Performance > Baseline Comparison 88 Performance > Performance Metric 76 Performance > Schedule Analyzer 80
predefined job preference rules Dynamic Highest Order Property Field Dynamic Lowest Order Property Field Highest Order Property Field 50 Highest Priority First 50 Largest Processing Time 50 Longest Waiting Time 50 Lowest Order Property Field 50 Lowest Priority First 50 Schedule File Order 50 Shortest Waiting Time 50 Predefined Job Preferences 49 preventive maintenance 24 primary resources 24, 101 Priority selection rule 44 process plans 16, 101 Assembly and Pack 16 Finished Frame
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Schedule Analyzer 80 Schedule Analyzer menu option 80 schedule evaluation 76 Schedule File Order 50, 55 schedule performance 2 Schedule Performance report 86 Scheduled Orders report 85 Scheduler.
Smallest Operation Slack Time 51 Smallest Order Slack 56 Smallest Order Slack Time 51 Smallest Processing Time 52, 56 Smallest Work Remaining 52, 56 spanning 25, 28 Infinite resource 25 Simultaneous 25 Singular 25 standard independent resource selection rules Earliest End Time 56 Earliest Start Time 56 Latest End Time 56 Non-Bottleneck Earliest Start Time 56 Same As Previous Operation 56 summary of 56 static selection rules 48 station 102 Subassembly 15 T tardiness 102
• • • • • FACTORYTALK SCHEDULER USER’S GUIDE Work-in-Process (WIP) 103 www.rsbizware.
