Creating and Planning Capacity and Load

Outcome

The capacity required for future production, on detailed or work center level, has been determined and compared with the load. The result has been displayed in several different ways. The work center scheduling through M3 Scheduling Workbench (M3 SWB) is based on this result.

Before you start

• Each work center must be entered in, 'Work Center. Open' (PDS010).
• For each product, enter a product structure in 'Product Structure. Open' (PDS001) Note that the structure must have at least one operation.
• For queue and transit time when products change from one work center to another, see 'Work Center. Open' (PDS010) and 'Work Center. Enter Queue & Transit Time' (PDS020).
• For capacity calendar with information about available capacity per work center and day, see 'Work Center. Change Capacity' (PDS015).
• For load of released but not completed manufacturing orders, see 'Manufact Order. Open' (PMS100).
• If used, bottleneck planning is set in 'Settings - Capacity Planning' (CRS786).
• If used, infinite/finite capacity scheduling is set in 'Work Center. Open' (PDS010).

Follow These Steps

1. Generating Load

   Load is automatically generated when a manufacturing order or planned manufacturing order is generated or replanned. The load is based on the requirements of time in the work centers according to the used product structure. The requirements of time is compared with the existing capacity and possible other already existing orders (finite loading). This comparison will result in a planned start and stop time per operation. The required time has then been converted to a load in the work center.

2. Setting Type of Load

   Load can be divided into type A and B. Type A load can for example represent manufacturing orders generated by customer orders, and type B can represent manufacturing orders into stock. In (CPS150) you can decide which load to view in the display programs.

   (CPS150) can be accessed from the display programs via option F4 in the Sel option field. Load type A or B is set on the order type in (PMS120).

3. Displaying Capacity/Load

   When there is load in the system, the load compared to capacity can be displayed. This can be done in different ways such as Display Load on product level, totals, detailed, over- and under-load and Gantt Chart. In 'Work Center Schedule. Open', the load is analyzed. If necessary, action is taken (for example, orders are rescheduled or split to adjust the load to the capacity over time). Finally, when all necessary adjustments are done, a scheduled load can be defined.

   This process is an ongoing way of working more or less all the time to keep the load in balance with the capacity.

   To get relevant information about the load compared to the capacity at all times, it is important that every operation is reported.

   • Displaying Load – over and under

     It is possible to focus on over and under load. By setting a high load percentage to a certain amount, the system will only display those work centers/periods with load greater than this amount. The same is true for a low load percentage, but this time those work centers/periods with a load less than the set amount will be displayed. See 'Load. Display Over & Under' (CPS120).

   • Displaying Load – product

     To display the total and periodic capacity compared with total load and the load for the specific order entered, see 'Load. Display per Product' (CPS110).

   • Displaying Load – totals

     The load can be displayed in different ways. It can be displayed per work center, department and foreman area in daily or weekly periods. It is possible to display cumulative load compared to cumulative capacity. Detailed information with all orders causing the load can be displayed; or, orders that are over loaded or under loaded can be displayed. See 'Load. Display Totals' (CPS100).

     A capacity and load report can be printed from 'Load. Print' (CPS600).

   • Displaying Load – detailed

     The manufacturing order that causes the load can be displayed via 'Manufact Order. Open' (PMS100) or 'Planned Manufact Order. Open' (PMS170), depending on the order category.

     The separate order's load on the work center compared to the total load can be displayed via 'Load. Display Detailed' (CPS105).

   • Displaying Gantt Chart

     'Load. Display Gantt Chart for MOs' (CPS130) allows access to other display programs. The Gantt Chart can also be accessed by using option 23 in 'Work Center Schedule. Open' (PMS230).