BSCM - 5 - Capacity Management and Production Activity Control Flashcards
Name the 4 basic scheduling and loading techniques.
- FORWARD SCHEDULING
- BACKWARD SCHEDULING
- INFINITE LOADING
- FINITE LOADING
Activities are scheduled from a known start date through the finish date.
FORWARD SCHEDULING
Activities are scheduled back from the due date.
BACKWARD SCHEDULING
Assumes that capacity is infinite at any work center.
INFINITE LOADING
Assumes that there is a definite limit to capacity at any work center.
FINITE LOADING
-Involves establishing start and finish dates for each operation needed to complete an order.
OBJECTIVES:
- Meet delivery dates
- Effectively use manufacturing resources.
SCHEDULING
A facility, function, department, or resource whose capacity is less than the demand placed on it.
Throughput can be constrained by __________ operations in intermittent, flow, and project manufacturing processes.
BOTTLENECKS
The ______________ volume of a system during a specified time period is constrained by the bottleneck work center.
THROUGHPUT
Between the release of materials to the gateway operation and receipt of WIP at the bottleneck is equal to the MFG lead time plus some safety time. The latter is meant to allow a bank of WIP to accumulate at the bottleneck to ensure that the bottleneck will never be short of work.
TIME BUFFER
Communicates the schedule of raw material releases to the gateway operation; this establishes a flow of materials to the bottleneck that ensures the bottleneck will never be short of work.
ROPE
Should produce at the rate of the bottleneck as well–generally neither faster nor slower.
WORKCENTERS AFTER THE BOTTLENECK
What are the PRIORITY CONTROL DISPATCHING RULES?
- First come, first served
- Earliest Job Due Date
- Earliest Operation Due Date
- Shortest process time
- Critical ratio
= time remaining / work remaining
- Also called LEAD TIME REMAINING
- If this is less than 1.0, the order will be late
**The lower the CR, the later the order, and the higher its priority.
CRITICAL RATIO (CR)
- Method used when material flow is based on a set production rate in a continuous MFG system.
- Characterized by uninterrupted production runs, fixed routings, committed production lines (capacity)
- In lean, the rate of __________ is controlled by:
- rate of customer demand (takt time)
- Kanban signals that trigger pull from upstream workstations
- control of WIP levels by resource balancing among workstations
FLOW CONTROL
- 2nd check on availability of critical resources
- Validates resource availability for the MPS
- Based on the quantity of a resource required to make one unit of the specific models or types of end items in a product family.
RCCP - ROUGH CUT CAPACITY PLANNING
Includes:
- order status
- exception reports
- inventory status
- labor reports
- machine performance
OTHER USES BESIDES MFG:
- Finance and Accounting
- Customer Service & Sales
PRODUCTION TRACKING & REPORTING
Begins once the shop order has been released and operations begin:
- Establish and maintain priority: Rank shop orders in a dispatch list to establish priority.
- Monitor and control WIP, lead times, and queues.
- Track and report production status and completion. Compare work orders vs. the plan and make adjustments.
- Report work center performance:
- Efficiency
- Operation Times
- Order Quantities
- Scrap
CONTROL (PAC)
EXECUTE THE PLAN:
- ->SHOP ORDER PACKET
- Order number, part number, name and description, and quantity
- Engineering drawings
- BOMs
- Route Sheets
- Material Issue Tickets
- Tool Requisitions
- Job tickets and more tickets
PAC IMPLEMENTATION
- MRP
- Item Master File
- Product Structure File
- Routing File
- Work Center File
- Shop Order File
INFORMATION REQUIREMENTS (PAC) SOURCES
What are the objectives of Production Activity Control (PAC)? (4)
- Execute the MPS and MRP.
- Optimize use of resources
- Minimize Work In Process (WIP)
- Maintain Customer Service
- Monitors and evaluates its progress and makes adjustments as necessary.
- Example: PAC
- Plan/Replan
- Implment
- Control
CLOSED-LOOP SYSTEM
Involves getting ready to release the shop order to the shop floor:
- Ensure resources are available.
- ->materials, tooling, workers, and info
- Schedule start and completion dates
- After completing the implementation and the control cycle, if adjustments are necessary, a replanning process will occur.
PLAN/REPLAN (PAC)
-Includes activities leading up to and including the release of shop orders.
- Gather necessary information from various sources to prepare a SHOP PACKET, including the shop order and instructions for operators. - Release shop orders to manufacturing to proceed with operations.
IMPLEMENT (PAC)
- 2nd step of simplified CRP Model
- Graphic comparison of each work center’s available capacity and the load established by the planned and released orders for each time period of the plan.
ESTABLISHING LOAD PROFILES
