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EGN_5623 Detailed Scheduling
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Transcript of EGN_5623 Detailed Scheduling
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Detailed Scheduling (DS)
EGN 5623 Enterprise Systems Optimization(Professional MSEM)
Fall, 2012
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Detailed Scheduling (DS)
Theories & Concepts
EGN 5623 Enterprise Systems Optimization(Professional MSEM)
Fall, 2012
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Topics
DS concepts1. Finite and infinite loading
2. Scheduling directions
3. Sequencing rules
4. Criteria for evaluation of sequencing rules
5. Controlling changeover costs
6. Minimize total production time
DS in SAP APO
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Process-Focused Operations
Process-focused factories are often calledjob shops.
A job shops work centers are organizedaround similar types of equipment or
operations. Workers and machines are flexible and
can be assigned to and reassigned tomany different orders.
Job shops are complex to schedule.
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Scheduling and Shop-FloorDecisions (Review)
MaterialRequirementsPlan (MRP)
CapacityRequirementsPlan (CRP)
Order-Processing orRouting Plans
Planned
Order ReleasesReport
Work Center
Loading andOvertime Plan
Assignment of
Orders toWork Centers
MasterProductionSchedule (MPS)
Product DesignandProcess Plans
Day-to-Day Scheduling and Shop-Floor Decisions
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Pre-production Planning
Design the product in customer order Plan the operations the product must pass
through ..... this is the routing plan
Work moves between operations on amove ticket
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Common Shop Floor ControlActivities
The production control departmentcontrols and monitors order progressthrough the shop. Assigns priority to orders
Issues dispatching lists Tracks WIP and keeps systems updated
Controls input-output between work centers
Measures efficiency, utilization, and
productivity of shop
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Shop Floor Planning and Control
Input-Output Control Gantt Chart Finite and Infinite Loading Forward and Backward Scheduling
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Input-Output Control
Input-output control identifies problemssuch as insufficient or excessive capacityor any issues that prevents the order frombeing completed on time.
Input-output control report comparesplanned and actual input, planned andactual output, and planned and actual
WIP in each time period
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Gantt Charts
Gantt charts are useful tools to coordinatejobs through shop; graphical summary ofjob status and loading of operations
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Gantt Charts (Review)
Machining
Fabrication
Assembly
Test
Tue. Wed. Thu. Fri. Sat.Work Centers Mon.
E F G
C D E
H C
F
ED
H C D
Scheduled Progress Setup, Maint.
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Assigning Jobs to Work Centers:How Many Jobs/Day/Work Center
Infinite loading Assigns jobs to work centers without regard tocapacity
Unless excessive capacity exists, long queues
occur Finite loading
Uses work center capacity to schedule orders Popular scheduling approach
Integral part of CRP
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Order-Sequencing Problems
Sequencing Rules Criteria for Evaluating SequencingRules
Comparison of Sequencing Rules Controlling Changeover Costs Minimizing Total Production Time
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Order-Sequencing Rules (Review)
First-Come First-Served (FCFS)Next job to process is the one that arrived firstamong the waiting jobs
Shortest Processing Time (SPT)
Next job to process is the one with the shortestprocessing time among the waiting jobs
Earliest Due Date (EDD)Next job to process is the one with the earliestdue (promised finished) date among the waiting
jobs
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Order-Sequencing Rules (Review)
Least Slack (LS)Next job to process is the one with the least[time to due date minus total remainingprocessing time] among the waiting jobs
Critical Ratio (CR)
Next job to process is the one with the least[time to due date divided by total remainingprocessing time] among the waiting jobs
Least Changeover Cost (LCC)Sequence the waiting jobs such that total
machine changeover cost is minimized
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Evaluating the Effectivenessof Sequencing Rules (Review)
Average flow time - average amount oftime jobs spend in shop
Average number of jobs in system -
Average job lateness - average amount oftime jobs completion date exceeds itspromised delivery date
Changeover cost - total cost of makingmachine changeovers for group of jobs
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Experience Says (Review)
First-come-first-served Performs poorly on most evaluation criteria Does give customers a sense of fair play
Shortest processing time Performs well on most evaluation criteria But have to watch out for long-processing-timeorders getting continuously pushed back
Critical ratio Works well on average job lateness criterion
May focus too much on jobs that cannot becompleted on time, causing others to be latetoo.
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Controlling Changeover Costs(Review)
Changeover costs - costs of changing aprocessing step in a production systemover from one job to another Changing machine settings
Getting job instructions Changing material Changing tools
Usually, jobs should be processed in a
sequence that minimizes changeovercosts
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Controlling Changeover Costs(Review)
Job Sequencing Heuristic First, select the lowest changeover cost amongall changeovers (this establishes the first twojobs in the sequence)
The next job to be selected will have the lowestchangeover cost among the remaining jobsthat follow the previously selected job
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Minimizing Total Production Time
Sequencing n Jobs through Two WorkCenters When several jobs must be sequenced throughtwo work centers, we may want to select a
sequence that must hold for both work centers Johnsons rule can be used to find thesequence that minimizes the total productiontime through both work centers
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DS in SAP APO
Tasks and activities of detailed scheduling Controlling Detailed Scheduling
Dates/Times and Planning Directions
Resource Availability
Selection of Resources
Time Relationships
Pegging Relationships Automatic Propagation of Changes
Determining the Setup Time for Sequence-Dependent Setup Activities
Synchronizing Activities on Multi-resources
Block planning
Scheduling Log
Terminating Scheduling
Detailed Scheduling Heuristics
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Tasks of Detailed SchedulingDetailed scheduling is used to:
1. Determine the resources and dates/times for carrying
out operations, taking resource and product availability
into consideration.
2. Support the scheduler in scheduling resources when
creating an optimal operations sequence.
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Activities of Detailed SchedulingBasic DS Activities:
Scheduling dispatching operations to resources at a specific
date/time
Rescheduling
dispatching already scheduled operations to adifferent date/time or to different resources
De-allocating
removing scheduled operations from the resource
schedule
Adjusting a new date/time or new resources are assigned to a
de-allocated operation.
Fixing
the resource and date/time for the operation is fixed.
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Activities of DS: Schedule
Schedule:For an operation of a newly created order or for a de-
allocated operation
1. The resources are determined on which the operation
should be processed
2. The date/time is determined when the operation
should be processed on the resources
With scheduling, the operation is dispatched to the
resources. Scheduling an order means scheduling all theoperations of the order.
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Activities of DS: Reschedule
Reschedule:
1. A new date/time or new resources are specified for a
scheduled operation.
2. With rescheduling, the operation remains loaded onresources.
3. After rescheduling, it loads either the previous resources
or the new resources.
4. Rescheduling an order means rescheduling all the
operations of the order.
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Activities of DS: De-allocate Remove an operation from the resource schedule.
With de-allocation, an operation is given the status
de-allocated. The operation no longer loads any
resources.
De-allocating an order means de-allocating all the
operations of the order.
An operation in the SAP APO system is
either scheduled(with no separate status),
or de-allocated (in this case it has the status de-
allocated).
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Activities of DS: Adjust
A new date/time or new resource is assigned to a de-
allocated operation.
In the case of an adjustment, the operation retains the
status de-allocated. The operation does not load the
resources to which it is assigned. Adjusting does notchange any resources schedules.
Adjusting is a detailed scheduling activity that is carried
out automatically by the system for dependent objects
(for example, if relationships or pegging relationships
have to be adhered to). You cannot adjust de-allocated
operations manually.
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Activities of DS: Fix
1. The resource and date/time for the operation is fixed.
2. Through the fixing process, a scheduled or de-allocated
operation is assigned the status fixed.
3. A fixed scheduled operation cannot be rescheduled or
de-allocated, and a fixed de-allocated operation cannot
be scheduled or adjusted.
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Integrated Distribution &Production Planning
SAP Implementation
EGN 5623 Enterprise Systems Optimization(Professional MSEM)
Fall, 2012
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Prerequisites of DS
The system can trigger detailed scheduling activitiesautomatically. For example, it automatically schedules the
order operations when an order is created.
Three ways to start detailed scheduling activities:
production planning run,
detailed scheduling planning board, or
resource planning table specifically forselected
operations or orders.
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Production Planning Run
The user may execute planning online, or in the backgroundfor selected orders:
1. online planning: for small data quantities (for
example, for test purposes),
2. background planning: for mass planning.
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Detailed Scheduling Planning BoardPurpose:
Graphical representation of the planning situation
Graphically represent different aspects of scheduling in the charts of
the detailed scheduling planning board. For example, you can show
the situation of operations on resources over time and the
development of the resource utilization or pegging relationships
between orders over time.
Interactive solution of planning problemsYou can perform interactive scheduling on the detailed scheduling
planning board to solve scheduling problems such as sequence or
date/time problems on resources. Various scheduling functions andheuristics are available in addition to manual scheduling with
Drag&Drop.
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Detailed Scheduling Planning Board
Integration
The detailed scheduling planning board is integrated indifferent Production Planningapplications.
You can call up the detailed scheduling planning board
directly:
In the area menu for production planning In order processing
In the product planning table
SAP provides the detailed scheduling planning board
with standard settings (for example, for setup or layout).If you want to configure a detailed scheduling planning
board for your specific scheduling requirements, you
must make the appropriate settings.
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Detailed Scheduling Planning Board
Layout of the Detailed Scheduling Planning BoardWhen you invoke the detailed scheduling planning board for
the first time, the selection area is shown in the left-hand
part of the screen. You can control the display of the
selection area via Settings -> User Settings and save the
setting on a user-specific basis.
The setting you make on the detailed scheduling planning
board is independent of the setting in the resource planning
table (see Configuring the Resource Planning Table).The selection area serves to provide an overview of the
loaded products and resources and to show and hide
objects (see Hiding and Showing Objects).
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SAP APO Planning Board (Interface)
SAP APO Production Planning Interactive Production Planning DetailedScheduling Detailed Scheduling Planning Board/Variable view
(APO/CDPS0)
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SAP APO Planning Board
SAP APO Production Planning Interactive Production Planning DetailedScheduling Detailed Scheduling Planning Board/Variable view
(APO/CDPS0)
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SAP APO Planning Board (Legend)
SAP APO Production Planning Interactive Production Planning DetailedScheduling Detailed Scheduling Planning Board/Variable view(APO/CDPS0)
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Detailed Scheduling Heuristics
DS Heuristics Features:Strategy settings
Depending on the heuristic, you can change the selected
strategy settings that the heuristic uses to schedule or
reschedule operations. Certain strategy settings are
permanently set by SAP and cannot be changed.
Planning period
The system uses heuristics to reschedule operations that
start in the planning period.
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Detailed Scheduling Heuristics
DS Heuristic Activities1. If you want to start a heuristic on the DS planning
board, select the desired objects and call up the
heuristic by choosing FunctionsHeuristics. You can
change the settings for the heuristics on the DS planning
board by choosing SettingsHeuristics.
2. If you want to use a heuristic in the production planning
run, enter the heuristic and the objects for which you
want to execute the heuristic in the correspondingprocessing step in the production planning run.
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Homework for DS
1. Change demands for Distribution centers
2. Run network plan with multilevel heuristic
3. Review planning board
4. Define SNP deployment profile
5. Define transport load builder profile (TLB)
6. Assign TLB profile to the transportation lanes
7. Run deployment heuristics