Finite Capacity Scheduling
What is Finite Capacity Scheduling?
A scheduling method that matches resource requirements to a finite supply of available resources to develop a realistic production plan.
Finite Scheduling Overview and Discussion
The following are some basic questions you should ask when looking at finite capacity scheduling:
- What is the purpose of production scheduling?
- What does FINITE mean?
- What kinds of resources, if unavailable, could prevent a manufacturing operation from proceeding as scheduled?
- What else can delay orders?
- What kinds of scheduling problems have you encountered?
The following definitions help when thinking about implementing a finite capacity scheduling system.
Scheduling. Scheduling means knowing:
- The status and priority of each order on the shop floor.
- Which machines and other resources (e.g. sub components, materials, tooling and operators) are required for each order.
- When these resources are required and when they will be available. Are we waiting for resources? If so, when do we expect them to arrive or be available?
- Definable operations in the manufacturing process.
- Identifiable delays between operations (e.g. move time, queue time, dry time, cooling time, and inspection).
- Total production time is not equal to the sum of manufacturing time for each manufacturing step. In most plants, manufacturing time is only 5% of the production lead-time.
- A limited quantity
- Examples include a limited number of machine, limited hours per shift (unless overtime is used), limited quantity of raw materials, limited quantity of operators, etc.
- In Taylor Scheduler we define what these limits are using data to model the plant capacity and limitations. Taylor Scheduler then uses those limited quantities of resources to create a constraint based realistic schedule.
Elements of an Advanced Planning and Scheduling System (APS):
APS is a tool designed to help manufacturers develop an attainable schedule while balancing internal constraints and limited resources. APS balances due dates, machine capacity, tooling and labor to develop a realistic plan of action to move orders through various operation steps. Considerable modeling effort, application maintenance and database integrity is necessary. The user benefit is that generated schedules are realistic and achievable on the plant floor because the production constraints on the plant floor are considered and modeled.
- Track each order through each respective routing step and know where each part should be at any particular time.
- Keep track of all required resources for each manufacturing step and know the availability of each resource at any particular time.
- Represent time in a detailed manner (e.g. minute by minute). Machine run time can be defined as pounds per hour, lot time, or time per specified number of pieces.
- Schedule orders (i.e. manufacturing steps) only when all critical resources are available.
- Detailed calendars and shift patterns for operators and machines.
- Ability to organize machines into work centers, production lines and plant areas (departments).
- Ability to share setup time between similar products.
- User-definable scheduling rules with multiple scheduling parameters.
- Scheduling of preventative maintenance and other machine down time.
- Constraints of raw material and component availability.
- Optimized schedule based on product characteristics or attributes.
Potential Taylor Scheduler Benefits:
Taylor Scheduler can provide benefits in the following areas:
- Increase customer service levels
- Current on time delivery levels
- Reduce WIP
- Inventory (WIP$, Raw Material$)
- Queue levels (Pieces and/or orders)
- Manage rush orders better and faster
- Manage higher product mix and smaller lot sizes
- Take advantage of Bar Coding system
- Improved setup optimization – will measure against routing standards
- Visibility and Communication (Marketing, Management, Shop Floor)
- Reacting and planning around downtime
- Scheduling around unexpected machine breakdown
- Scheduling preventative maintenance in true downtime (idle time)
- Predict more accurate $ shipment values
- Better information
- More realistic order promise dates
- More accurate schedule
- Need an automated scheduling tool
- Reduced overtime
- Reduce the overall cost of overtime
- Co-ordinate support resource requirements
- Reduce time spent looking for resources
- Reduce expediting
- Move from standard average queue time to part specific queue time (variable lead time)
Taylor Scheduler can automatically determine a feasible solution to overcapacity situations and level the load to existing or planned capacity.
Taylor Scheduler allows the planner to develop a feasible incremental capacity model reflecting potential additional machines, resources and their implementation plans. This process is critical to developing capacity plans that can actually produce the planned goods, if implemented.
Taylor Scheduler improves the rough-cut capacity planning process by allowing the additional capacity required to be added to current model (machine capacity, calendars, resources, and so on). The current capacity model reflects, as a starting point, the reality of the production facility.
Taylor Scheduler facilitates the inclusion of the current load and allows some or all of it to be treated as a given. Taylor Scheduler further enhances the integration of the actual current plan, based on actual current capabilities, with a potential, less restricted future plan.
Taylor Scheduler helps you model capacity better. Because the models are based on many of the same screens, functions, and reports, the planner and scheduler can more easily build a consistent model, can better communicate and investigate potential plans, and then later implement the mutually selected plan.