If a work order is created automatically (e.g. via order recommendation report or sales order to work order, a separate work order position per item-lot size is created. The setup time indicated here refers to the lot size in item master.
Separate reporting of setup times
If "Extend to cost elements" was set to 2 or more in the Resource, the setup time can be reported separately via FDC and evaluated separately in calculation. Enter the cost element to which the accrued costs will be posted.
Setup time Capacity
The set-up for scheduled capacity in hours or minutes is considered in capacity planning and throughput time calculation.
The field designation can be changed in Configuration wizard > Master Data > Resources > Time typesor via Ctrl+ double-click in the text field.
Times are specified in units "Times in ..." (hour/minute) and refer to "Times per .. " finished parts taking account of the utility and work steps in units of usage of the assembly.
The Cost Element field specifies the cost element for which the planned or accumulated costs should be totaled, facilitating detailed analysis.
Tools that determine the throughput time and also alternative operations can only influence the job time (processing time).
In addition to the job time, two other secondary processing times can be specified if "Extend to cost element" is set to 3 or 4 in the resource. The secondary processing times are designated in Configuration Wizard or via Ctrl+Double click in the text field.
Number of resources used (subject to the prerequisite that the resource exists more than once, e.g. if the resource is a group of persons. Where 2 is input for 5 persons, the resource of 2 persons is scheduled at most.
Note:
If this is not 1, the system uses the calculation method Exploit Full capacity for this routing position.
Percent
Percentage utilization of the resource.
Example 1: Group of 6 persons. At a utilization of 50% the resource of 3 persons is used at most.
Example 2: Machine which is only partly utilized. To extend the throughput time, a lower utilization can be specified here. If 20% is specified, throughput time is quadrupled while costs remain the same.
Note:
If this is not 100%, the system uses the calculation method Exploit Full capacity for this routing position.
Simple
Default setting: For "Simple", only one resource is 100% utilized.
Note:
For Detailed planning (i.e. a resource should be planned to the minute) the option must be set to "Simple".
You can set here whether the operation should be included. Apart from Yes/No, a condition is also possible, such as production quantity greater, in between or smaller than a specification defined here. Example: The operation in which a small machine has been defined should only be used when the production quantity is smaller than 30. If it is greater, an operation should be used in which a large machine with a respectively higher set-up time but smaller mach+labor time is stored.
Quantities refer to "per units of usage" of assembly.
In routing it can be set up depending on the quantity:
Yes: Always active. No: Not active.
Quantity bigger: Only active if quantity exceeds the given value.
Quantity smaller: Only active quantity falls below the given value.
Quantity between: Only active if the quantity is between two given values.
Thus you can activate a routing depending on the quantity.
Example:
Depending on the quantity, a certain resource is to be used.
until 10 kg (active quantity < 10 kg): Resource "small bowl", planned duration: 10 minutes
from 10 kg (active quantity > 10 kg): Resource "big bowl", planned duration: 20 minutes
Field description
The value is saved in aktivformel with the following configuration Id=Value1=Value2
G = "Quantity bigger"
K = "Quantity smaller"
Z = "Quantity between"
N = "Not active"
J = "Active" (Default)
If the field is empty, the entry is treated as active.
Example: Only active for quantity between 10 and 20 "Z=10=20"
Only the following values may be returned here if a formula has been stored via the – icon: Y for "Active" or N "Not active". "bigger", "smaller" or "between" are not allowed via the formula system.
Generate Work order
By defining value "N" in the formula, the system does not insert the routing position in the Work order. This is to be activated in Configuration wizard > Production > Create>Apply inactive work order sequence.
Generate Precalculation
In Precalculation the system always transfers inactive routing positions. (beas 9.3 PL 2)
Generate new Item (Product Configurator)
By defining the value "N" in the formula, the system does not insert the routing position in the Work order. This is to be activated in Configuration wizard > Production > Product Configurator>Apply inactive work order sequence(beas 9.3 PL 2)
Active field as Script
If you click in field Pos on – icon, you can define all fields with
setvar=e_[fieldname]=value
If you want to disable a routing position, use the following script:
setvar=e_aktiv=N
With beas 2020.02 the Variable "e_aktivformel" is not supported.
In Precalculation there is an active-field and an "only if quantity" .... The second field has the same meaning as in routing. The operation is only active if the condition is met.
Only active routing positions are transferred to the work order. If you make a selection in the Configuration wizard to accept inactive routing positions as well, these will be transferred to the work order, and deactivated.
You cannot log on to these operations and they do not cause time demand.
This switch can be disabled manually.
Valid Period
In Precalculation Operation: Select the From - To dates of a validity period.
in which the semi-finished part must not be further processed, e.g. drying time, cooling etc.
|--- Transfer time --| |-- Planned time --| |--- Idle time---|
The resource is available at this time for other orders. There are no arising costs .
Forward Scheduling: The next sequence of operations can begin only after the idle period. The idle time should not be used for the extension of lead times. It is recommended to use transit time (seeresources).
By default, factory calendar and resource calendar are not considered. These can be taken into consideration by changing the settings in the Configuration wizard.
The earliest start date of the following operation can be the same as the first one or the next possible start. The next possible start may also be earlier than the one of the previous operation.
Example 1 :
Pos 1 is defined as parallel, so Pos 2 can start parallel to Pos 1
View in Beas
Start of 3. routing position is after the end of the latest parallel routing position.
Example 2:
Pos 2 needs less time than Pos 1.
View in Beas
Start of next routing position is always after the end of the latest parallel routing position.
Example 3:
Scenario: Position 3 is parallel to Position 2, but after Position1 finishes, resource for Pos 2 is not available.
For example Resource is reserved by another work order.
If the resource is not available immediately, the routing position starts at the next available time.
In this example, the position 3 can start BEFORE the first position:
Example 4:
Scenario: 2 work order positions. Both WOs have defined the 2. operation as parallel. Start date is same.
First operation has different resource, but the second parallel operation has same resource for both WOs.
Explanation: The parallel resource uses the start date, on which the resource is free. For the first WO this is the time when operation 1 starts.
In the second work order position you see that the start date of second operation does not start together with the first operation.
The reason is that WO 1 already occupies the resource. So the second operation of WO can only start after the operation 2 of WO 1 stopped.
In that case the the second operation does not start parallel but delayed:
You can set parallel-defined operations to always run in parallel in the Configuration wizard.
Result with setting "Overlap limit = fix"
Start date of Pos 40 on Resource i1001-1 start later, because the next resource i1004 is not available before.
- Parallel resource have always same start / end time
- Use Parallel resource, if you don't need this resource 100%
(Example: A worker is the "parallel resource", but is working on 4 machines in parallel. In this case he must invest only 25% for his time for this operation)
Parallel Operation:
- is not always parallel. Only if the resource of parallel operation is available
The Overlap time define, when the next operation can be started. The time, which you define, is the delay in hours/minutes, until the
next operation starts.
The defined time is the earliest time.
Example:
2 hours means, the next operation can start
- 2 hours after start current operation or after end of this current operation (if the current operation is less than 2 hours)
- if resource of next operation is not available after 2 hours, then at the time, when the resource is available.
Example:
In this scenario the start date of the third routing position is the real start date of the second routing position + defined overlapping time in hours,
here 1 hour.
An overlap is specified in hours – based on a 24-hour day. The specified overlap always applies to the following routing position.
The overlap time is not bound to a resource calendar. This is purely hour-based time excluding time reservations or other factors.
The overlap time begins AFTER the transit time. The next routing position cannot possess a transfer time, otherwise it will be appended to the transfer time.
Example:
Scenario: 2 Work orders, same routing plan. In first operation different resources. Overlap limit = 0.5 hours
First work order: Position 20 start 0.5 hours after start of position 10
Second work order: Position 20 start later, because the time is reserved from first work order
If you want, that the overlap have always exact the same overlap time, a setting is available. SeeConfiguration wizard
Example:
Scenario: Work time of second work order position is less than the work time of the first operation.
In the first operation, overlap time is defined:
In this case you're ready with second routing position before you're ready with first routing position. But you can start with third routing position only, if all parallel / overlapped routing positions are done. In this case after end of Routing position 10.
In a simple example the result of backward calculation is same as forward calculation
Example: Work time 1 hour, overlap 0.5 hour in first operation
But is the duration of second operation is not same as first operation, then the result is different to forward calculation:
The system calculate backward: First 30, then 20 - from 20 the overlap is calculated (Start time from Operation 20 + Overlap time from Operation 10 = End time from Operation 10.
Alternative for backward calculation is "forward late as possible"
Note:
The backward calculation cannot calculate the correct start date. It is only capable of calculating the duration.
Note:
The last operation corresponds to the last "reportable operation".
If an overlap is also configured in the last operation, <%PROGRAMNAME%> does not recognize this as the last operation.
However, the automatic assembly receipt or adjustment of the backflushed material depends on this.
Overlapping using assemblies
Assemblies can also overlap in an order-related structure.
Example:
|- Main assembly -|
|--- Subassembly -|
Start date of the main group is normally the end date of the last routing position of the subassembly. If this last routing position has an overlap, this is also considered.
Important: If an overlap is entered in the last routing position, it is no longer recognized as the "last routing position" in the backflushed posting transactions.
Information field – if applicable, for information on number or pay slip printouts.
Expand to Cost Elements
In Precalculation Operation:
Select the number of cost rates. The default is one cost element (processing time), which can represent a mixed calculation of machinery and personnel costs. Select the number of cost elements you are to use in Precalculation, update the window, and the selected cost elements appear in the Costs tab.
If this option is activated, a separate cost rate can be stored for personnel costs and the "Labor cost rate" field appears in the Cost tab. See also Costs.
