Operation Split

There are two methods on how to split the operations. One of them is to register the lot size for the equipment. In this sample, input 200 as the Resource split size MAX in the equipment Cutter 1.

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This method is used when the quantities, which can be processed, are different for each piece of equipment. Run the reschedule button and you will see that the operations have been split.

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During the assignment of operations, which were split as mentioned above, the corresponding instructions can be assigned separately.

Furthermore, it is also possible to shorten the lead time, by setting the Time constraint method as “ESE”.

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Run the reschedule button and you will see that the operation has been finished earlier than the previous sample.

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Another method of operations splitting is to register the Production lot size MAX for each item at the [Item table].

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When the production quantity is larger than the lot size of the item, the operations will be split and then assigned.

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This is used when the production quantities are different for each item.

Also, when there are several pieces of equipment, parallel production becomes possible and can reduce lead time. This can be done by changing the Time constraint method to “SSEEE”.

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Note also that the operation split function has plenty of effects, such as split by rate, switching workers by shift, etc.

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s online help and search Operation Split or its e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

 

Time Constraint

In this article, we will study the time constraint by which we can specify how to connect the previous operation with the current one given the time delays for each resource and item.

In the case where the next operation starts after completing the previous operation, we can set “ES” as the Time constraint method which means End-Start.

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You then set the time delay between the operations at the Time constraint MIN as seen below.

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Press the Reschedule button and you will see that the operation will be assigned after the end of the interpretational time delay as set in the Time constraint MIN.

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In this sample, the interpretational time delays for resources are different wherein the transfer of the operations can lead to delivery delays, which will also be displayed.

In cases where the previous process and the next process operates at the same time, we can set “SS” as the Time constraint method, which means “Start-Start”.

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By setting “SS” as the Time constraint method for the Injection process, we can get a schedule wherein the Press and Injection resources will operate side by side.

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But you will notice that the next process will be completed earlier. Therefore, this cannot be operated.

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In order to finish the next process after the previous process has completed, we will use “SSEE” as the Time constraint method.

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By doing this, after the previous process ends, the next process will be finished.

The next sample, we will explain how to register different times between operations for each item.

In this case, let’s register the Time constraint method and Time constraint MIN for Input instruction.

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By taking the end time of the previous process for each item and time constraints into consideration, we can calculate the operation’s start time (or end time in the case of a backward operation) and generate the schedule.

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To learn more about Asprova specific to this sample de9monstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

Material Requirement Calculation (Yield, Scrap)

Yield rate and scrap quantity can be specified in the Integrated Master Editor for the Input Instruction and Output Instruction. An input instruction specifies the item and its quantity to be input to the given operation. An output instruction specifies the item and quantity to be output from that operation.

In the order table, order 1 requires to produce 9 items of “AX”.

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You can view order 1 in the Resource Gantt chart.  By looking at the Inventory graph, you will see that 9 items of “AX” are required.

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Please set 0.9 as the yield rate for the output instruction and press the reschedule button.

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As 9 items of “AX” will be supplied to the next process, 10 items of “AX” will be produced and 10 items of “A” will be used. This is because the yield rate is set as 0.9.

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Then, set 1 as the scrap quantity.

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Press the reschedule button and confirm that the required quantity of “A” is increased by 1 to 11.

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Next, let’s set 1 as the scrap quantity for the input instruction and press the reschedule button again.

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The manufacturing quantity of “AX” remains 11 items but the required quantity of “A” was increased to 12 items.

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If we set 0.8 as the yield rate for the input instruction and reschedule it, the required quantity of “A” will change to 15.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

Set up Time (Resource)

In Asprova, it is also possible to schedule the setup time for changing molds and jig tools. This can be specified in the Integrated Master Editor. This article will show you how to generate a schedule setup by switching the main resource and the sub-resource.

In this sample, we will produce item “AX”. Press 1 will be used as a main resource. Mold 1 and Mold 2 will be used as a sub resource.

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Let’s register in the Resource setup table a 120m-setup-time to switch Mold 1 to Mold 2 on Press 1.

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In addition, let’s set a 20m-setup-time to switch Mold 2 to Mold 1.

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Press the reschedule button to see the result. At the Resource Gantt chart, you will see that there is a 120m-setup-time on Press 1 when Mold 1 to Mold 2 is switched. Subsequently, there is a 20m-setup-time on Press 1 when we change Mold 2 to Mold 1.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

 

Set up Time (Item, Spec)

In this article, we have registered 2 items in the Integrated Master Editor table – “AX” and “BX”.

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There are 3 orders in the Order Table as shown below.

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And the orders have already been assigned where there is no setup time between each operation.

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Now, we will change the settings at the Item setup table to register setup, which occurs when we switch “BX” to “AX”. Let’s assume there is no setup time when switching “AX” to “BX” and it takes 120m to setup switching “BX” to “AX”.

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Press the reschedule button. From the Resource Gantt chart, you will now notice that there is no setup time from “AX” to “BX” but a 120m-setup-time from “BX” to “AX”.

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You can also register multiple items, separated by semicolons, to make a group of items. The “*” that is placed in the Resource column relates to all resources.

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You can specify the resource code if you want to in the resource column – just click on the specific resource you want.

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You can also register the setup time by using [Spec 1, 2, 3, and 4]. The spec 1 of each order in this sample is set as white or black.

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Register the Setup time in the Spec 1 setup table. Set the setup time as 0 in “white to black” and 180 in “black to white”.

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The [Spec 1] of orders “1” and “3” is white and order “2” is black. This means that there is no setup time from order “1” to “2” and it takes a 180m-setup-time from order “2” to order “3”.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

 

 

 

Furnace Resource

The furnace resource is a resource where multiple operations start and finish at the same time. This can only happen when all of the specs of the operations are set up the same. In this article, we will show how to schedule the resources with the batch processing capabilities.

In this sample, the Resource class is set as Furnace resource (spec 1).

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This means that orders with the same resource class set as spec 1 will be assigned at the same time.

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In the order table, the Spec 1 of orders 1 and 3 is high.

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The Spec 1 of orders 2 and 4 is low.

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Run the Reschedule button.  You will notice that the orders 1 and 3 are assigned to produce at the same time and so are orders 2 and 4.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

 

Scheduling Logic: Resource Quantity

In Asprova, you can set up how many pieces of equipment and operators are available in a certain time period in the Calendar table. The required resource quantity for each operation is set up in the Integrated Master Editor.

In this sample, we will show you how finite capacity scheduling takes into account the number of resources and production facilities.

There are three orders assigned below in Assembly1.

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Assuming there are 2 workers on the Assembly1 – we can set this up in the Resource Quantity in the Calendar Table.

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You will notice that the related cells in the Assembly 1 in the Resource Gantt chart are now divided into 2 sub rows.

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Press the reschedule button.  Orders 1 and 2 are now piled up and assigned to be produced at the same time – meaning 2 workers will work at the same time, while order 3 is assigned to the right.

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Now, go to the Integrated master editor and set 0.5 as the Required resource quantity.

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Press the Reschedule button to see the result. The 3 orders are now piled up. As the Required resource quantity is 0.5, the total quantity is 1.5 for the 3 orders.

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In the next sample, we will show how to shorten the production time according to the number of workers.

Double-click on the Resource code and set “According to the resource quantity” as the Resource quantity constraints.

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Run the Reschedule button. Since the Resource quantity is 2 and the Required resource quantity is 0.5, this means 2 workers will work at the same time, each performing a double volume of work. As a result, the production time will be shortened by half. See Resource Gantt chart below.

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

Scheduling Logic: Status

When we move operations at the Resource Gantt chart, we can fix them so they can be as stuck as possible. It is also possible to set their status as released, frozen or completed. In this article, we will study the progress for inputting results after moving and adjusting operations.

If we move the operations at the Resource Gantt chart, the mark indicating fixed under the operation bar will be displayed.

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If you do not move the fixed operations, this will draw the other operations nearer to shorten the waiting time. When you don’t want operations to be drawn near to each other, you can set Forced forward or Forced backward as the Assignment direction from the Scheduling Parameter Settings.

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It will be leveled down when overlapping and will be assigned back or forward when there is no time to operate.

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To prevent such movements, we can freeze the operations by right-clicking on the operation and select Status, then Freeze.

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You can do this when you don’t want operations to be absolutely moved as they are frozen.

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If we input the results, it will change to Started. Go to Operation option and select Results.

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Input the corresponding results in the table below.

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The uncompleted part will be pushed to the right side of the scheduling basis time and other operations will be pushed back.

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In Asprova, it is possible to make scheduling in consideration of delays or advances. When the result is less than the planned production quantity, the quantity of the next process will be adjusted automatically in consideration of the previous process.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

Parameter

We can change the settings of the scheduling parameters in regard to rescheduling. You can easily get results you want by simply adjusting settings such as assignment direction, resource evaluation to decide which resource to be assigned.

This article will focus on basic functions such as Assignment direction, Resource evaluation, and Dispatching rule.

The Dispatching rule defines which operations to be assigned first. Click on the icon below to show Order priority.

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The Order priority is set as Descending and the Order due date is set as Ascending at the Default scheduling parameter property.

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By dispatching with descending order priority, the operations with higher priority will be assigned first.

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This time let’s consider Order due date to deal with Order due date as the priority.

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This time, the order “1” with an early due date was assigned to start first.

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However, one of the operations was assigned on the right side.

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This is because the Assignment direction was set as “According to order” and only one order was assigned backwards.

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Let’s change the Assignment direction to Forward. You will notice that the order will be assigned left-justified.

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The start order is the same as Dispatching rule.

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Next, let’s switch it to Backward to minimize the inventory.

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With this kind of direction, it is just common sense to set the Order due date to Descending order in the Dispatching rule. Make sure to change this setup.

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Run the re-schedule button and you will see operations are now assigned right justified – assigned according to the due dates in order to minimize inventory.

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On the other hand, we can pile up operations by setting the Assignment type as infinite capacity.

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To be able to control which equipment and workers to assign the operations, set the weighting at the Resource evaluation parameter.

Since we want to place the highest importance on production performance, set a higher value (e.g. 10000) for Weight – production time minimization.

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Run again the reschedule button and the operations have been assigned to minimize the production time in consideration of the waiting time and load.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).

 

 

Scheduling Logic: Command

The commands registered in Scheduling parameter can be confirmed in the Command Editor dialog. Go to Schedule and choose the Command Editor function.

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Each of the commands will be shown in the Default scheduling parameter. They will be executed from top to bottom when the schedule is run.

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The following will discuss each command and how this works in Asprova:

Prepare for assignment
The orders registered in the Order table become the subjects of this command to be prepared for the processing by other commands later.

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Filter orders
This will exclude any unnecessary order.

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Unassign all
It is used to cancel the assignment of operations. By executing this command, the already assigned operations become unassigned.

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Explode orders

This is where all the corresponding operations will be generated from the orders and its master data. As a result, the process-related operations are generated where the generated operation will be assigned later.

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Assign privileged operations
The operations with statuses: “Competed”, “Started”, “Frozen” or “Released” will be assigned.

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Assign time fixed operations
The time fixed (by manual adjustment) operations will be assigned.

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Assign result constrained operations/Assign time fix constrained operations
These are necessary when we use “resource lock and “time constraint MAX” options.
Assign/peg orders
We can assign operations that are newly generated or have not yet been registered.
The setting of the assignment direction will be explained in the topic “Scheduling parameters”.

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Adjustment
This is used for forced assignment of the operations before the “Scheduling basis time” within the “Scheduling period”. In this case, we will need to adjust the starting time and the order of operations.

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Evaluate the Schedule
This will generate report where we can confirm the total number of late manufacturing orders, the total setup time, etc.

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So, let’s take advantage of the schedule adjustment by controlling the resource load, lead time, etc. The scheduling parameters can be switched through the combo box.

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You can schedule with different parameters, which can be registered and selected as explained. You may refer to the online help about Scheduling Logic for the details of the commands. 

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 24. Scheduling Logic).