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Chapter 8: Shop Loading

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CHAPTER 8: SHOP LOADING Objectives

The objectives are:

• Provide an Overview of Shop Loading • Perform Loading of Capacities • Execute Finite Loading • Recognize the Reports Available

Introduction Shop Loading refers to the daily shop floor operations. It is important when scheduling in a production environment with limited capacity and bottleneck resources.

This chapter provides an overview of how shop loading is carried out in Microsoft Dynamics® NAV 2009. It shows how to perform loading of capacities using the traditional work center or machine center load windows, and how to execute finite loading for constrained resources. Additionally, the chapter examines other reports available for capacity scheduling.

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Manufacturing II in Microsoft Dynamics® NAV 2009

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Shop Loading Overview Microsoft Dynamics NAV 2009 assumes infinite (unlimited) capacity per default when each production order is scheduled. However, the system also offers a special feature to define and manage finite (limited) capacity for particular resources. Production orders are scheduled using a variety of methods, including:

• During generation from a sales order • From MRP • When an order is entered manually • When refresh or replan functions are run

Each time a production order is scheduled, records are written to the machine and work center task list and production order capacity needs are summarized on the load windows. Records are not removed from the task list until a production order is finished.

The work center or machine center task list Departments>Manufacturing > Capacities > Lists > Work Centers > Related Information > Planning > Task List is similar to a dispatch list, except that it does not net the time remaining on released production orders in progress. The task list displays:

• The original gross time scheduled for the operation. • All production orders scheduled for the work center or machine

center, not just released orders.



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For each production order scheduled in the specific work center or machine center, the Task List window shows the:

• Production order status • Start and end dates • Times

FIGURE 8.1 WORK CENTER TASK LIST

The Work Center Load or Machine Center Load window (path: Departments>Manufacturing > Capacities > Lists > Work Centers > Related Information > Work Ctr > Load) summarizes information from two sources:

• Production Order Capacity Need window • Detailed work center or machine center calendar entries (available

capacity)

The Work Center Load window shows information for both the work center and machine centers assigned to the work center.

The Machine Center Load window shows information for the machine center only.



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Unlike the task list, the load window reflects the time remaining on released production orders.

FIGURE 8.2 LOAD FOR WORK CENTER 100 (DAY VIEW)



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There are four special columns in the Load window .

Field Name Description

Capacity This column represents the gross available capacity based on the: • Shop calendar used • Capacity and efficiency values established in the Scheduling FastTab of the work

center or machine center card It is possible to drill down to the detailed calendar entries for this work center or machine center. The work center calendar entries are for the work center, and any machine center assigned to the work center. The machine center calendar entries are for the machine center only.

Allocated Qty. This column represents the requirements of all production orders except simulated orders. In the Work Center Load window: Drill down to the Production Order Capacity Need window to view all the production orders scheduled on that date for the work center or any machine center assigned to the work center. All production orders except simulated orders have allocated time. In the Machine Center Load window: • Drill down to view all production orders scheduled for that machine center.

• The allocated column for a work center can represent scheduled time for a

production order in the work center and, or machine center assigned to the work center.

• An order may be displayed on the task list without time allocated on the load window for that date. This means the operation step is completed at an earlier time.

Availability After Orders

This column represents the net amount of capacity available after the allocated column is subtracked from the capacity column. If the availability column is a negative number, then there are more production orders scheduled than available capacity.

Load This column represents a percentage of the allocated column to the capacity column. It represents how much of the availability is being used. For example, if the load column is: • 40, then 40 percent of the availability is being used.

• Greater than 100 percent, then there are more production orders scheduled than

available capacity.

To deal with capacity overloading, shop managers can mark critical resources and set them up for finite loading to monitor or plan operations in capacity-constrained resources. This is done in the Capacity-Constrained Resources window (path: Departments > Manufacturing > Capacities > Administration > Setup > Capacity Constrained Resources).



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Loading Capacities To demonstrate shop loading, there must be a production order. Choose a produced item to work with in this example. Note the work and, or machine centers to be able to look at the load later.

Before starting the demonstrations, modify the starting date of your routing version for the bicycle as follows:

1. In the navigation pane, click the Routings button. 2. Double-click routing 1000 (Bicycle) to open it. 3. Click Versions. 4. If the routing version for Executive bicycle still exists, modify the

date by going to Actions > Edit. 5. In the starting date field, change it to 2/1/2015. 6. Click OK. 7. Close the routing Version List and go back to the Routing window

for routing 1000 (Bicycle). 8. In the Status field, select Under Development. 9. In the Lines FastTab, check if operation 35 (SUBCONTRACT)

exists. If so, right-click it and select Delete Line. 10. Click Yes. 11. In the Status field, select Certified. 12. Click OK.

Demonstration 1

The following steps show how to create a released production order for 20 pieces of touring bicycles.

1. In the navigation pane, click the Released Production Orders button.

2. Click New. 3. In the Source No. field, type 1001 (Touring Bicycle). 4. In the quantity field, type 20. 5. In the Due Date field, type 02/01/2010. 6. Click Refresh. 7. Accept all default information and click OK. 8. Note the production order number. 9. Go to the Lines FastTab. 10. Click the Actions icon (thunderbolt symbol), then go to Line >

Routing to view the routing on the production order. Note the machine and work centers.

11. Click OK to close 12. Close the production order.



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The Underloaded Machine Center

Before discussing the adjustment of load to an overloaded facility, view an underloaded machine center. In such a facility, there is more than enough capacity to perform the allocated load.

1. In the navigation pane, click the Departments button. 2. Go to Manufacturing > Capacities > Lists > Machine Centers. 3. Double-click machine number 410 (Drilling Machine) to open it. 4. Click Load. 5. In the View by field, select Day.

In an underutilized machine center, the Load column in the work center load form is less than 100 and the Availability After Orders is a positive number. To correctly analyze the load, it is necessary to understand the released production order is for 20 pieces. View the setup and run time for the steps. Since this production order is for 20 units, 20 times the run time is required plus the setup time. This total amount is the total productive time for each operation.

6. Close all open windows.

Demonstration 2

To demonstrate the methods of dealing with an overloaded facility, create an additional production order scheduled in the same time period for the same work and machine centers.

The Overloaded Machine Center

The following steps show how a released production order can cause the machine center to be overloaded.

Create a new released production order with this data:


2. Click New. 3. In the Source No. field, type 1001 (Touring Bicycle). 4. In the Quantity field, type 50. 5. In the Due Date field, type 02/01/2010. 6. Click Refresh. 7. Accept all default information and click OK. 8. Note the released production order number.



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9. Go to the Lines FastTab. 10. Select item 1100 (Front Wheel).

Note: If you do not see this item (1100), change the manufacturing policy of your touring bicycle, front wheel and back wheel to make-to-order.

11. Click the Actions icon (thunderbolt symbol) , then go to Line > Routing to view the routing on the production order.

12. Click OK to close. 13. Close the production order.

Demonstration 3

Move an Operation

In addition to changing schedules, operations may be moved from one machine center to another when they are assigned to the same work center. To illustrate, move an operation from one machine center to another machine center.

This demonstration shows how to find a machine center that is available to have the load moved to it and a machine center that is overloaded. Therefore, you need to create another released production order in order to create an overload.


2. Click New. 3. In the Source No. field, enter 1001 (Touring Bicycle). 4. In the quantity field, enter 23. 5. In the Due Date field, enter 02/01/2010. 6. Click Refresh. 7. Accept all default information and click OK. 8. Note the released production order number. 9. Close all open windows. 10. In the navigation pane, click the Departments button. 11. Go to Manufacturing > Capacities > Lists > Machine Centers. 12. Double-click machine center 410 (Drilling machine) to open it. 13. Examine the load by clicking Load. 14. In the View by field, select Day.

Find a day where there is an overload. Note the date.

15. Close the Machine Center Load window and all open windows. Next, find a machine center with a surplus of available capacity from the same work center.

16. Go to Manufacturing > Capacities > Lists > Machine Centers. 17. Double-click machine center 420 to open it.



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18. Click Load. Note that this machine center has 0 load for the days that the created production order is running. This means that it has available capacity

19. Close all open windows. 20. Go to Manufacturing > Capacities > Lists > Machine Centers. 21. Select machine center 410 and click Task List. 22. From the Machine Center Task List window, select your production

order. 23. Go to Actions > Functions > Move. 24. Select machine center 420 and click OK. 25. Repeat steps 22-24 if there are several lines pertaining to your

production order. 26. Close all open windows. 27. Go to Manufacturing > Capacities > Lists > Machine Centers. 28. Double-click machine center 420 to open it. 29. Click Load.

The second machine is allocated the operation originally scheduled in the first machine center.


Demonstration 4

The following steps show how to post time to a production order to view the affect on the work center. Start by selecting a released production order and reviewing a related work center load.


2. Double-click a production order for a touring bicycle to open it and note the production order number.

3. Go to the Lines FastTab. 4. Select item 1100 (Front Wheel).

Note: If you do not see item 1100, ensure that your touring bicycle, front wheel and back wheel has a manufacturing policy of make-to-order.

5. Click the Actions icon, then go to Line > Routing to view the routing on the production order.

6. Note the time displayed in the Run Time column for work center 100 (Rim Assembly) in the Prod. Order Routing window as well as the start and end dates.

7. Click OK and close the production order. 8. In the navigation pane, click the Departments button. 9. Go to Manufacturing > Capacities > Lists > Work Centers.



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10. Double-click work center 100 (Assembly department) to open it. 11. Click Load. 12. From the Work Center Load window, find the start and end dates of

your production order and note the load. 13. Go back to your production order. 14. With item 1100 still selected, click the Actions icon, then go to Line

> Production Journal. 15. Locate work center 100 (Rim Assembly) and enter an amount less in

the Run Time column than what was displayed in the Prod. Order Routing window. For example, enter 1.

16. Review the information before posting it by going to Actions > Posting > Test Report and select Preview. Press Esc to return to the Production Journal.

17. Post the journal by clicking Post and then Yes. 18. Click OK and close all open windows. 19. In the navigation pane, click the Departments button. 20. Go to Manufacturing > Capacities > Lists > Work Centers. 21. Double-click work center 100 (Assembly department) to open it. 22. Click Load.

Note that in the Load column, the time has changed in one of the days (between the starting date and end date) of your selected production order.


Use the Finished field in posting to post time to a machine or work center and to indicate not to use the resource anymore for this production order.

1. Go back to your production order. 2. With item 1100 still selected, click the Actions icon, then go to

Line > Production Journal. 3. Enter a time in the Run Time column again, ensuring the total

expected amount is not being posted. For example, 2. 4. Select the Finished check box. 5. Post the journal by clicking Post and then Yes. 6. Click OK and close all open windows. 7. In the navigation pane, click the Departments button. 8. Go to Manufacturing > Capacities > Lists > Work Centers. 9. Double-click work center 100 (Assembly department) to open it. 10. Click Load.



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As done previously, note that in the Load column, the time has changed in one of the days (between the starting date and end date) of your selected production order

Since a check mark is placed in the Finished field, the entire load for that operation is removed, even though only a part of the time is reported.


The next section discusses a special monitoring and planning tool, to help the Production Planner handle situations where resources are overloaded and capacity cannot be easily and quickly modified using the methods described in this section.

Finite Loading Where the Production Planner foresees a risk of overloading a critical resource, they have the option to select it as a capacity-constrained resource in advance. This ensures the machine center or work center in question is only loaded to a certain critical level. This way, the finite loading routines have a defined spectrum in which to run and the planner gets a certain margin to play with during execution time.

This planning is performed in the Capacity-Constrained Resources window (path: Departments > Manufacturing > Capacities > Administration > Setup > Capacity Constrained Resources).

The finite loading functionality serves two purposes:

• To display and maintain status for constrained resources to provide a clear overview of limited capacities in a production plan.

• To plan operations in capacity-constrained resources.

It is important to note that even if a machine center or work center is selected as a constrained resource, the program does not take any immediate action in case of overload. The finite loading plan only takes effect when the user triggers a change in the plan by, for example, refreshing the corresponding production orders, accepting messages in the MRP worksheets, and so on.



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Look at the capacity constrained resources setup form. Follow the path Manufacturing > Capacities > Setup > Capacity Constrained Resources to view the form.

FIGURE 8.3 CAPACITY CONSTRAINED RESOURCES

The fields are defined as follows:

Field Description

Capacity Type Choose Work Center or Machine Center.

Capacity No. Choose the number of the center.

Name The default name of the center.

Critical Load %

Enter the percentage of the available capacity of a work center or machine center that the program is allowed to apply load to. Enter as a whole number, for example, 90% is entered as 90.0.

Dampener (% of Total Capacity)

Enter the allowable tolerance (as a percent) the critical load percent can be exceeded. This allowable percent tolerance enables the program to schedule a load to a work center or machine center at the last possible day by slightly exceeding the critical load percent. Enter as a whole number, for example, 5% is entered as 5.0.



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Demonstration 5

The following demonstration repeats the previous demonstration where an overload is created at a machine center because of the release of an additional production order with the same due date. This time, however, select a machine center as a capacity-constrained resource before releasing the new order. Now the system automatically adjusts process periods to facilitate a production plan without overload.

Continue from the current load status of the machine center being analyzed, where the manual adjustments performed left available capacity.

When creating another production order for 35 pieces of the item with the same due date, normally an overload is created. Use the finite loading feature to avoid this.

1. In the navigation pane, click the Departments button. 2. Go to Manufacturing > Capacities >Administration > Setup >

Capacity Constrained Resources. 3. Define capacity constraints for the machine center. For this

demonstration, use machine center 110. Choose 90% for the critical load and 5% for the dampener, which allows scheduling up to 95%.

4. Click OK.

Next, create a production order based on sales order.

1. In the navigation pane, click the Sales Orders button. 2. Click New. 3. Press Enter to automatically insert the next number in the default

number series for sales orders. 4. Go to the Sell-to Customer No. field and select customer number

10000, The Cannon Group PLC. 5. On the sales line, select Item in the Type field. 6. Go to the No. field and select item number 1001, Touring Bicycle. 7. In the Quantity field, type 35 . 8. Click Yes, if the Check Availability window appears. 9. Click on the Shipping FastTab. 10. Type 02/5/2010 in the Shipment Date. 11. Delete any information in the location code field. 12. Go to Related Information > Order > Planning. 13. Go to Actions > Functions > Create Prod. Order. 14. Accept the defaults of firm planned order and item order by selecting

Yes. 15. A confirmation message appears, stating that a Firm Planned order

has been created. Note the production order number and click OK. 16. Close all open windows.



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17. In the navigation pane, click the Firm Planned Production Orders button.

18. Double-click the production order that was created from the sales order to open it. In the Lines FastTab, note that start and end dates.

19. Close the production order. 20. In the navigation pane, click the Departments button. 21. Go to Manufacturing > Capacities > Lists > Machine Centers. 22. Double-click machine center 110 to open it. 23. Examine the load by clicking on Load. 24. In the View by field, select Day.

View the entry and notice how machine center 110 is loaded to exactly 90% capacity and the remaining process time is allocated to the closest available period within the due date.


Dampener

The capacity constraints are set up to allow for the load to be exceeded slightly (5%) to finish operations that need only a little more capacity than is available. This is defined in the Dampener % field.

For example, if the newest production order for 50 items is small and it finished on the date, then the dampener feature allows an additional load of 5 % (above the critical load of 90). Meaning, if production can be completed within the time of (critical load + dampener), then it is scheduled for that day. If the load is greater (critical load + dampener), then the work is assigned up to the critical load for one day and the remaining assigned to another day.

Reports The program provides reports for capacity requirements planning. Although some reports are available in more than one area, all of these reports are accessible by going to Departments > Manufacturing > Execution > Reports and Analysis > Reports.

• Capacity Task List - This report provides a task list of each facility (work and machine center) which prints on a separate page.

• Capacity Gantt Chart - This report illustrates by production order, facility and date when production orders are scheduled to consume capacity.

• Machine Center Load - This report illustrates the load by period and machine center.

• Machine Center Load / Bar - This report graphically displays the load by machine center for a number of periods defined.



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• Work Center Load - This report illustrates the load by period and work center.

• Work Center Load / Bar - This report provides a list of the work centers that are overloaded according to the actual planning. The efficiency and overloading is shown by a bar display. This report graphically displays the load by work center for a number of periods defined.

These reports are accessed by going to Departments > Manufacturing > Capacities > Reports and Analysis > Reports.

• Machine Center List - This report is a master list of available facilities, and indicates the capacity and the efficiency factor currently set for each facility.

• Work Center List - This report lists work center information, including: the unit cost, unit of measure code, capacity, and shop calendar code.

• Capacity Task List - This report provides a task list of each facility (work and machine center) which prints on a separate page.

• Capacity Gantt Chart - This report illustrates by production order, facility, and date when production orders are scheduled to consume capacity.

Summary This chapter discusses the capacity scheduling process. It shows how to perform shop loading both with finite and infinite resources. Finally, this chapter explains some other capacity reports in the system.

Capacity planning and shop loading are very important concepts when operating in a production environment with limited capacity and bottleneck resources.



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Lab 8.1 - Shop Loading Scenario

View Load on Work and Machine Centers

• To load the shop with work, create two production orders for 75 pieces each of the bicycle, Item 1000, with a due date of 1/28/2010.

Step by Step 1. In the navigation pane, click the Released Production Orders

button. 2. Click New. 3. In the Source No. field, type 1000 (Bicycle). 4. In the quantity field, type 75. 5. In the Due Date field, type 1/28/2010. 6. Click Refresh. 7. Accept all default information and click OK. 8. Note the production order number. 9. Go to the Lines FastTab. 10. Click the Actions icon, then go to Line > Routing to view the

routing on the production order. Note the machine and work centers. 11. Click OK to close 12. Note the production order number. 13. Close the production order. 14. Repeat previous steps to create the second production order.

Find Overloaded Facilities • View the machine center load report by day and find the overloaded

areas. • Refer to the January timeframe of the year 2010.

Step by Step 1. In the navigation pane, click the Departments button. 2. Go to Manufacturing > Capacities > Lists > Machine Centers. 3. Double-click machine center 110 to open it. 4. Examine the load by clicking on Load. 5. In the View by field, select Day.



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6. View the January 2010 timeframe. In the Availability After Orders column, there are some days showing a negative amount. This means that this machine center is overloaded. Note: If an overload does not exist, create more production orders with the same parameters as written in the beginning of this lab until you get an overload.


Lab 8.2: Use Move Function to Adjust Load • Use the Move functions to shift the load from machine center 110 to

another facility.

Step by Step 1. Go to Manufacturing > Capacities > Lists > Machine Centers. 2. Double-click machine center 120 to open it. 3. Click Load. 4. In the View by field, select Week. Note that this machine center has

0 load for the days that the created production order is running. This means that it has available capacity.

5. Close all open windows. 6. Go to Manufacturing > Capacities > Lists > Machine Centers. 7. Select machine center 110 and click Task List. 8. From the Machine Center Task List window, select your production

orders. 9. Go to Actions > Functions > Move. 10. Select machine center 120 and click OK. 11. Repeat steps 8-10 if there are multiple lines pertaining to your

production orders. 12. Close all open windows. 13. Go to Manufacturing > Capacities > Lists > Machine Centers. 14. Double-click machine center 120 to open it. 15. Click Load. 16. The second machine is allocated the operation originally scheduled

in the first machine center. 17. Close all open windows.



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Quick Interaction: Lessons Learned Take a moment and write down three key points you have learned from this chapter

1.

2.

3.


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