chapters inprog (1)
TRANSCRIPT
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Small and Medium enterprises using the MPS methodology is
commonly remote due to the comple-ity involved and lack for resources
especially manpoer ith market intelligence and process knoledge.
"his creates a risk to the SM%s either not meeting the delivery targets
of the customer or ending up in high inventory that too sometimes
having more o!solete stock or resulting in having very lo inventory for
the needed parts. "hese ill create in losing !usiness opportunities or
lo margin !usiness scenario. So a cost effective and simple method of
MPS is required for SM%s ith commonly availa!le or used softare%s
like a spread sheet application. "his pro+ect aims in designing a spread
sheet application ith detailed procedure for customi#ing the same for
visuali#ing the production !ased on the one time input of capacity and
standard time.
1.2OBJECTIVE OF THE PROJECT
"he o!+ective of this pro+ect ork is
to design cost effective and simple method of MPS
to design the MPS tool using spread sheet application
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1.3LITERATURE SURVEY
Scheduling literature covers much ground and a myriad of aspects.&efore discussing these various aspects here are the definition of the
folloing key terms and concepts on scheduling
. scheduling application
. scheduling method
/. scheduling pro!lem
0. scheduling technology
1. scheduling strategy
Sce!"l#n$ a%%l#ca'n(
An e-tension of a scheduling concept in various areas, hich
can !e classified !y scheduling manufacturing, the nature of a
scheduling pro!lem and strategies, or specific scheduling, such as +o!
shop scheduling
Sce!"l#n$ )e&'!(
A technique used in the processing of a scheduling pro!lem,
such as an o!+ect oriented or a knoledge !ased method
Sce!"l#n$ %r'*le)(
A detailed, specific scheduling question or that hich is
difficult to deal ith in a certain domain, such as a constraint pro!lem in
+o! shop scheduling.
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Sce!"l#n$ &ecn'l'$+(
"he mature application of practical scheduling to amanufacturing environment or the methods, theory and practices
governing such a scheduling application, such as the e-isting Material
esource Plan (2MP%) or 'ptimi#ing Production "echnology (2'P"%)
Sce!"l#n$ ,&ra&e$+(
"he science underlying the planning or scheduling process that
employs scheduling technology and scheduling methods used to
schedule an application or a scheduling pro!lem. Scheduling strategy
ill depend on the scheduling pro!lem or the scheduling application
1.- ORGANIATION OF THE THESIS
Ca%&er 1 has introduced the summary, !ackground of the
thesis, o!+ective, literature survey and the organi#ation of the thesis in
detail.
Ca%&er 2descri!es the MPS methodology
3hapter / !riefs Master Production Schedule for Small and
Medium nterprises ith an case study
Ca%&er - presents the conclusion and future scope of this
pro+ect
.
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CHAPTER 2
/ASTER PRODUCTION SCHEDULE
2.1 INTRODUCTION
/a,&er Pr'!"c'n Sce!"le 0,"*,+,&e)
Inputs4
. Actual orders from customers
. stimated future orders (!ased on demand forecasting models
applied to data from enterprise and 3M systems)
/. 5ata from inventory system for finished goods
'utput4
6o of units to !e produced per eek for - eeks
(Master Production Schedule)
/a&er#al Re"#re)en&, Plann#n$ /RP4(
Inputs4. Master Production schedule
. &ill of Materials
/. a materials (parts) inventory
0. Parts master data
part num!er
order policy
1
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safety stock policy
1. 'pen (e-isting) purchase orders for ra materials
'utput4
"ime7phased order requirements schedule for ra materials.
8ill lead to released purchase orders for ra materials !y
the 3P system
3apacity equirements Planning (3P)4
9o many units are to !e produced for the eek and should have
the ra materials required
8e still need
i) machine(s) time and
ii) people time
the a!ove needs convert the ra materials to the finished units desired,
in the correct quantity
Inputs4
- information from MPS on ho many units to produce this
eek
- information on availa!ility of ra materials (!y day)
- outing Master (hat machines and ho much la!our is
necessary to produce the units)- availa!le capacity of required machines and people (every
hour of every day of the eek) (hat ill !e availa!le)
'utputs4
- "argeted start :completion times and personnel schedules to
ork centers needed in this production effort (detailed
production schedule)
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- Manufacturing orders that give authority to manufacture a
specific product and descri!e the
material
la!our
and machine requirements for the +o!
- Move tickets that record movement of a +o! from one ork
center to another< such a ticket ould contain department,
machine, operator and time of completion and check !o-es for
inspection< they may contain !ar code id%s
- a materials requisitions to ra materials inventory
- eleased purchase orders for ra materials to vendors
"his is the outline of !asic information necessary to carry out the
production to satisfy the Master Production Schedule.
8e no have to control the production process
5uring the production process, considera!le information is gathered in
real7time to !e a!le to compare planned data to actual data.
"he a!ove is done !y Shop *loor 3ontrol Systems
*or e-ample, e have actual data on
- Machine utili#ation (completed move tickets)
- =a!our utili#ation (>o! "ime tickets for each factory orker)
- a material utili#ation (from M inventory control)3ontrol reports are important for management to note inefficiencies.
Moreover, there can !e cost overruns as compared to ?standard@ costs.
uality control is also done here
C',& Acc'"nn$ S+,&e),
- there are standard quantities of materials, machine time and
la!our and also standard costs for materials and la!our
B
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- these are compared to actual costs incurred and variances
(favora!le or unfavora!le) are calculated
- costs (direct materials, direct la!our and overhead) are
assigned to each unit produced< this may later influence the
pricing of the units produced
8hen all these systems operate in synch ith each other, this total
system is a Manufacturing esource Planning System (MP)
F#$"re 2.- T+%#cal /PS )e&'!
2.2 C",&')er De)an!
A master production schedule may !e necessary for organi#ations
to synchroni#e their operations and !ecome more efficient. An effective
MPS ultimately ill4
Cive production, planning, purchasing, and management the
information to plan and control manufacturing
"ie overall !usiness planning and forecasting to detail operations
D
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na!le marketing to make legitimate delivery commitments to
arehouses and customers
Increase the efficiency and accuracy of a company$s manufacturing
MPS issues4
i) 8idth of the time !ucket
ii) Planning hori#on
iii) olling plan
iv) "ime fencing
v) Schedule free#ing
35P is an important aspect of managing value chains. Cenerally,
the first step of 35P is to forecastproduct demand. A manager canplan
resource deployment in accordance ith the resulting forecasts. It$s a
!ottom7up approach vs. the a top don planning. Associated risks ith
this method are4 =o forecast accuracy and num!ers of planners
required.
"here are various softare systemscreated !y companies such as
i) Avercast, 5emand Solutions
ii) SAS System, Agentrics, Manugistics
iii) 'racle
iv) Petrolsoft 3orporation (no Aspen "echnology)
v) StatSoft, "oolsCroup
vi) CM59 Shell
E
http://en.wikipedia.org/w/index.php?title=Time_bucket&action=edit&redlink=1http://en.wikipedia.org/wiki/Planning_horizonhttp://en.wikipedia.org/w/index.php?title=Rolling_plan&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Time_fencing&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Schedule_freezing&action=edit&redlink=1http://en.wikipedia.org/wiki/Value_chainhttp://en.wikipedia.org/wiki/Forecastinghttp://en.wikipedia.org/wiki/Planninghttp://en.wikipedia.org/wiki/Software_systemhttp://en.wikipedia.org/wiki/Avercasthttp://en.wikipedia.org/wiki/Demand_Solutionshttp://en.wikipedia.org/wiki/SAS_Systemhttp://en.wikipedia.org/w/index.php?title=Agentrics&action=edit&redlink=1http://en.wikipedia.org/wiki/Manugisticshttp://en.wikipedia.org/wiki/Oracle_Corporationhttp://en.wikipedia.org/wiki/Petrolsoft_Corporationhttp://en.wikipedia.org/wiki/StatSofthttp://www.toolsgroup.com/http://www.gmdhshell.com/demand-forecasting-softwarehttp://en.wikipedia.org/w/index.php?title=Time_bucket&action=edit&redlink=1http://en.wikipedia.org/wiki/Planning_horizonhttp://en.wikipedia.org/w/index.php?title=Rolling_plan&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Time_fencing&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Schedule_freezing&action=edit&redlink=1http://en.wikipedia.org/wiki/Value_chainhttp://en.wikipedia.org/wiki/Forecastinghttp://en.wikipedia.org/wiki/Planninghttp://en.wikipedia.org/wiki/Software_systemhttp://en.wikipedia.org/wiki/Avercasthttp://en.wikipedia.org/wiki/Demand_Solutionshttp://en.wikipedia.org/wiki/SAS_Systemhttp://en.wikipedia.org/w/index.php?title=Agentrics&action=edit&redlink=1http://en.wikipedia.org/wiki/Manugisticshttp://en.wikipedia.org/wiki/Oracle_Corporationhttp://en.wikipedia.org/wiki/Petrolsoft_Corporationhttp://en.wikipedia.org/wiki/StatSofthttp://www.toolsgroup.com/http://www.gmdhshell.com/demand-forecasting-software -
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"hey help !usinesses forecast demand and plan operations. "o
test the added value of implementing !ottom7up approach, SAP AP'
applications are providing simulations functionalities to estimate the
resulting 5emand *orecast Accuracy (e.g. P'S sales < Sales invoices C
" =ob # ? ' ? " " " " " " "
=ob 2 @ ? "" " " " "
=ob + > "" "C " " " " "
@ =ob E A "C @ " " " " " " " "
> =ob B " @ C " " " " " " " " " " " "
- enter this formula ,3#/+3JAKJ+"'3JAGJE"'.".
,t tests the cell to see 6hether the hour number in the column heading is bet6een the start and stop$
,f it is it returns a " if not it returns a blank.
0he JIs ensure that 6hen the formula is copied it continues to reference columns + and E for the start and stop
and ro6 A for the hour number$
- set 3ormat2onditional 3ormattingPattern2olour if the cell )alue " to emphasi;e the cell 6ith a colour
- copy the formula in 3"' and paste it to the range 3"'5#9"@
0ry changing the figures in the
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APPENDI 6
Setting up a Calendar
So far 6e ha)e assumed that the 6ork centre 6orks @ hours a day 6ithout a break as 6ould a continuous process such as
an oil refinery or a paper mill$ $> C$?> ' min for lunch then 6ork till 5' pm
> ">$?> "A $> D a "> min break in the afternoon then 6ork till C5'' pm
C "D " an hour for dinner then 6ork till "'5'' pm
Expressed as " hour clock times the calendar looks like this5
" "5'' #M "5'' #M ' '
A5'' #M "'5'' #M
"'5"> #M "5'' PM $?> @$?>
@ "5' PM 5' PM C$?>
> 5@> PM C5'' PM $> D
C ?5'' PM "'5'' PM "
8e are counting hours into the schedule beginning at midnight$
Each line is a 6orking period the breaks lie in bet6een$
,n this example 6e begin at A5'' #M end at "'5'' PM 6ork for " hours and ha)e hours of breaks$
0ake a look at the formulas they are )ery simple$
/o6 consider this problem5
,f you start a ? hour =ob at A5' #M at 6hat time 6ill you stopN
4ou could do this5
'egin (nd uration
A$> "' "$>
"'$> " $?>
"$> ">$>
">$?> "C$> '$?>
0otal ?
8ith a bit of trial and error you can 6ork out that the ans6er is at hour "C$> or @5' pm
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APPENDI
Calculation of Job Stop Time Through the Calendar0his gets complex so you can skip this part if you 6ish and =ust accept that the forulae 6ork 6hen you apply them or you can
perse)ere and understand ho6 the formulas 6ork$ 0he start of the =ob could be 6ithin a 6orking period or it could fall bet6een t6o
6orking periods$ @$?> the stages of the calculation to gain
@ "$> ">$> C$?> an understanding of the formulas
> ">$?> "A $> D
C "D "
Starting a =ob at5 A$> A5' #M.
8ork for5 ? hours
Stages of the calculation5
A5' #M is after period begins M#02 M#O:@E"C.
the number of hours from the start of the =ob to the next break "$> :>-:C
cum hours at end of period ,/+EOED5E"@:".
the =ob starts at cum hour '$> of the calendar '$> :A-:?
the =ob stops at cum hour ?$> of the calendar ?$> :DFE"?
the =ob stops during period > > M#02 :-:@
8ith a series of substitutions the "> formulas can be condensed into @ as follo6s5
2alc" M#02 ,/+EO2D52"@B@"".-,/+EOED5E"@B@"".FB@'FE"?
0he meanings of the formulas are5
2alc" A5' #M lies bet6een the beginning and end of period
2alc the =ob starts at cum hour '$> of the calendar
2alc the =ob stops during period >
!ob Stop the =ob 6ill stop at hour "C$> @5' PM.
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APPENDI
Julian ates
0his is the date and time according to the system clock in this computer using the /98. function5
@"?&$C'@D'>>>>C days since " !anuary "D''
-Mar&>-Mar-"@
March-"@
March &> &'"@
M-"@
and by using 0EO05
0ue
0uesday
Mar
March
&'"@
0ake a look also at the date and time functions$
0he spreadsheet takes care of the days in each month and leap years etc$
,t 6as !ulius 2aeser 6ho first established the calendar based on C> days per year 6ith leap years
hence !ulian dates$ 9ne of the reasons 6hy spreadsheets are so good for scheduling is the 6ay that
they handle dates and times$ #ll spreadsheets start counting time in days and decimals of a day from
midnight before "st !anuary "D'' and there are enough decimal places of a day to measure time to the
nearest thousanth of a secondQ
%eep hitting the 3D key to recalculate and 6atch the clock change$ #dd " to it and you get the same
time tomorro6$ 0he really neat thing is that 6e only ha)e one unit for measuring time a day$ 8e don1t
ha)e to 6orry about seconds minutes hours 6eeks fortnights months Huarters years decades and
centuries$
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APPENDI
Setting up a Julian Calendar
Mon "'' "'5"> #M "'' "5'' PM '$"D?D 3ormat 2ells /umber+ate and choose a format that
Mon "'' "5' PM "'' 5' PM '$A" sho6s both the date and time
$> Mon "'' 5@> PM "'' C5'' PM '$?> edit the date and time
Mon "'' ?5'' PM "'' "'5'' PM '$>
0ue "@'' A5'' #M "@'' "'5'' #M '$>A 2opy paste and edit to set up the firs t day
$?> 0ue "@'' "'5"> #M "@'' "5'' PM '$CD?D
0ue "@'' "5' PM "@'' 5' PM '$?A" #dd " for the other days of the 6eek
$> 0ue "@'' 5@> PM "@'' C5'' PM '$A?>
0ue "@'' ?5'' PM "@'' "'5'' PM "
8ed ">'' A5'' #M ">'' "'5'' #M "$'A
$?> 8ed ">'' "'5"> #M ">'' "5'' PM "$"D?D
8ed ">'' "5' PM ">'' 5' PM "$A"
$> 8ed ">'' 5@> PM ">'' C5'' PM "$?>
8ed ">'' ?5'' PM ">'' "'5'' PM "$>
0hu "C'' A5'' #M "C'' "'5'' #M "$>A
$?> 0hu "C'' "'5"> #M "C'' "5'' PM "$CD?D
0hu "C'' "5' PM "C'' 5' PM "$?A"
$> 0hu "C'' 5@> PM "C'' C5'' PM "$A?> 0hu "C'' ?5'' PM "C'' "'5'' PM
3ri "?'' A5'' #M "?'' "'5'' #M $'A
$?> 3ri "?'' "'5"> #M "?'' "5'' PM $"D?D
3ri "?'' "5' PM "?'' 5' PM $A" 8e donIt plan to 6ork 3riday e)enings
$> 3ri "?'' 5@> PM "?'' C5'' PM $?>
Mon ''' A5'' #M ''' "'5'' #M $@>A
$?> Mon ''' "'5"> #M ''' "5'' PM $>?D #dd ? for the other 6eeks
Mon ''' "5' PM ''' 5' PM $C>C
$> Mon ''' 5@> PM ''' C5'' PM $?>
Mon ''' ?5'' PM ''' "'5'' PM $A?>
#fter deleting or inserting ro6s donIt forget to copy do6n the formula in the 2um +ays column$
# Huick 6ay of copying a formula do6n to the bottom of the block of data is to select the top cell then point to the bottom
right corner of the cell and 6hen the solid black cross appears like this5 double click$
So far 6e ha)e scheduled using hours rather than days to measure short periods of time$ Someho6 , ha)e a meeting 6ith a
client it should take about hours sounds better than it should take about '$'A of a day$ 8e ha)e also pegged ;ero hour
at midnight on some arbitrary day rather than midnight " !anuary "D''$ But 6e 6ill need to get used to these ideas if 6e are
going to harness the full po6er of !ulian dates$
# calendar for a li)e scheduling system may be up to se)eral thousand ro6s long so you may 6ish to replace the formulas 6ith
)alues after you ha)e set it up to sa)e on memory and calculation time$ 4ou can allo6 for public holidays by deleting ro6s and
you can allo6 for o)ertime by inserting ro6s or by extending the 6orking periods$
/0
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APPENDI
sing the Calendar Formulas
0he formulas for calculating the =ob s top time through the calendar that 6e de)eloped in section C 6orks =ust as 6ell on days
as it does on hours so it can be applied to the !ulian calendar like this5
Start of fi rs t =ob5 "@'' A5' #M
Se# Jobs Hours ays Start Calc. Calc/ Calc0 Stop
" =ob # ? '$&D& "@'' A5' #M ? '$>& "' "@'' @5' PM
& =ob 2 @ '$"C? "@'' @5' PM "' '$A" "" "@'' D5' PM
=ob + > '$&'A "@'' D5' PM "" '$DA " ">'' "&5@> PM
@ =ob E A '$ ">'' "&5@> PM " "$"D "? "C'' A5' #M
> =ob B "& '$> "C'' A5' #M "? "$>& && "?'' A5' #M
2"'&@ days are hours R &@ - 6e need to con)ert to use the !ulian calendar
,3,D,DEJC. if there is a stop time of the pre)ious =ob start then if not use Start of first =ob in EC
M#02
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APPENDI
1ultiple 1achines or )or* Centres
So far 6e ha)e only considered one 6ork centre$ 3or multiple 6ork centres 6e could create a separate schedule for each
but here is another 6ay of doing it5
Start of firs t =ob5 "@'' A5' #M
)2C Se# Jobs Hours ays Start Calc. Calc/ Calc0 Stop
" " =ob # ? '$D "@'' A5' #M ? '$>" "' "@'' @5' PM
" =ob 2 @ '$"C? "@'' @5' PM "' '$A" "" "@'' D5' PM
" =ob + > '$'A "@'' D5' PM "" '$D?D " ">'' "5@> PM
" =ob E A '$ "@'' A5' #M ? '$>" "' "@'' >5' PM
=ob B " '$> "@'' >5' PM "' '$A>@ "> ">'' >5' PM
=ob 3 C '$> ">'' >5' PM "> "$>@ "A "C'' "'5@> #M
,3#D#A!A3JC. if the 6ork centre is the same as the =ob abo)e then start 6hen the pre)ious =ob stops
else use the Start of first =ob in 3C
,n this example a =ob can be assigned to 8ork 2entre " 9R 8ork 2entre and then assigned a seHuence 6ithin it$
8e shall look one =ob passing through multiple 6ork centres later.
/ote that the "Is and Is in the 8ork 2entre column are codes rather than numbers so they ha)e been formatted as text
3ormat2ells/umber0ext$
4ou can no6 change both the 6ork centre number and the seHuence number and sort 6ith +ataSort
- Sort By 82 #scending
- 0hen By SeH #scending
/;
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APPENDI 1
Joining Te3t Together and 4ndirect "eferences
,n Section " 6e 6ill use separate calendars for each 6ork centre but first 6e need to understand a couple of techniHues5
!oining text together or concatenation
0he F sign is used to add numbers together but the & sign is used to =oin text together or =oin text 6ith numbers e$g$
!ohn Smith !ohnSmith BD&2D
this may look better 6ith a space in bet6een5
!ohn Smith !ohn Smith B"& &2"
it also 6orks 6ith numbers5
Section "" Section "" B"?& &2"?
,ndirect references
DDD
6e can add text together to make something that looks like a cell reference5
B B BC&2C
to make it beha)e like a cell reference add the ,/+,RE20 function
B DDD ,/+,RE20B'&2'.
a direct reference to a cell on another 6orksheet5
# Simple :antt 2hart ISection @IQ#"
an indirect reference to the same cell5
Section @ # Simple :antt 2hart ,/+,RE20I&BA&IQ#".
/B
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APPENDI 11
Separate Calendars for each )or* Centre
0he next t6o 6orksheets contain calendars and the follo6ing table assignes a calendar to each 6ork centre5
)2C Ca le ndar
" 2alendar "
2alendar
Start of first =ob5 "@'' A5' #M
)2C Se# Calendar Jobs Hours ays Start Calc. Calc/ Calc0 Stop
" " 2alendar " =ob # ? '$D "@'' A5' #M ? '$>" "' "@'' @5' PM
" 2alendar " =ob 2 @ '$"C? "@'' @5' PM "' '$A" "" "@'' D5' PM
" 2alendar " =ob + > '$'A "@'' D5' PM "" '$D?D " ">'' "5@> PM
" 2alendar =ob E A '$ "@'' A5' #M C '$DC D "@'' >5' PM
2alendar =ob B " '$> "@'' >5' PM D '$?D "> "C'' "'5@> #M
2alendar =ob 3 C '$> "C'' "'5@> #M "> "$D "? "C'' >5' PM
7L99%*P#"#JC5BJ?. look up the 6ork centre in the table abo)e and return the contents of the nd column
M#02 5'' "C "5'' :89 789 789 .89
C =ob 2 " 2" "? 2' /# "" '5'' ' "C "5'' "C "A5'' ;89 789 /89
? =ob # # A #" D "> 5'' "D "> 5'' "> ""5'' :89 089
? =ob B B "@ B" "' "C "5'' "@ "C "5'' "C ">5'' ;89 ;89
? =ob 2 2 C 2" "" "C "A5'' "C "A5'' "? '5'' ""5'' "C '5'' :89 789
A =ob B B "" B " "C ">5'' "> "C ">5'' "? 5'' .89 789 /89
A =ob 2 2 " 2 "@ "? '5'' ' "? 5'' "? 5'' "?5'' ' "@ A5'' "> 5'' 789 789 089
C =ob B " B" B ? "C "5'' ' "> 5'' "C "5'' :89 789 789 .89
C =ob 2 " 2" "? 2 A "C '5'' "C 5'' "C '5'' :89 789 =89
? =ob # # A # D "C 5'' ' "> "?5'' "C "5'' ;89 .89
? =ob B B "@ B ' "C ">5'' ' "C "5'' "C ">5'' ;89 ;89
? =ob 2 2 C 2 " "? 5'' > "C '5'' "? 5'' =89 /89
A =ob # # " #@ /# "? 5'' ' "C 5'' "C ">5'' "C "?
"> "C "?
/D
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APPENDI 13
"epetitive Production Through 1ultiple )or* Centres - Pull Schedule
PSH SCH(5(6 '$ '$ '$ '$ '$ '$ '$ '$ '$ '$ '$ '$0he next operation can start " hour after the start of the pre)ious operation Lag. Start of f irst =ob5 "@P @5''
) 2C Product !p Prod2!p >ty
ni s
per
H our Hou rs
Previous
!p
Previous
!p "ow
Sar o f
Previous
!p ?5ag
S op of
Previous
!p ?5ag
)ait
hours Start Stop
(ffec ive
nits per
Hour '5 '' A5'' "C 5'' '5'' A5'' "C5'' ' 5'' A 5'' "C 5'' '5'' A5'' "C5'' '5' '
C prod # " #P" ">'' C> &$" #P' /P# 'P" '5'' 'P" '5'' '$' "@P @5'' ">P 5'@ C> / &>$ 2P' /P# 'P" '5'' 'P" '5'' '$' "CP ">5@@ "?P "?5'@ ?> .@ 5'' ">P @5'@ C> .@: :/9 :/9 / &$& BP" "' ">P @5'@ "CP "C5@@ '$' ">P @5'@ "CP "C5@@ C' /0: =79 =79 =79 =79 =:
? prod 2 & 2P& "D'' ""' "?$ 2P" "" "CP "C5@@ "?P "A5'@ '$' "CP "C5@@ "?P "A5'@ ?> :== P >5'@ "CP "?5@@ C' .;: =79 =79 =79 =79 .9:
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