Rockwell Automation FactoryTalk Scheduler User Manual
Scheduler
Production Management
INTEGRATED PRODUCTION & PERFORMANCE SUITE
USER’S GUIDE
PUBLICATION SCHED-UM001F-EN-E–August 2007
Supersedes Publication SCHED-UM001E-EN-P
Contact Rockwell
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Warranty
© 2007 Rockwell Automation Technologies, Inc. All rights reserved. Printed in USA.
This document and any accompanying Rockwell Software products are copyrighted by Rockwell Automation
Technologies, Inc. Any reproduction and/or distribution without prior written consent from Rockwell Automation
Technologies, Inc. is strictly prohibited. Please refer to the license agreement for details.
The following logos and products are trademarks of Rockwell Automation, Inc.:
RSBizWare, FactoryTalk, FactoryTalk Activation, FactoryTalk Administration Console, FactoryTalk Automation
Platform, FactoryTalk Services Platform, RSBizWare PlantMetrics, FactoryTalk Metrics, FactoryTalk Scheduler,
RSSql, FactoryTalk Transaction Manager,
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All other trademarks are the property of their respective holders and are hereby acknowledged.
This product is warranted in accordance with the product license. The product’s performance may be affected by system
configuration, the application being performed, operator control, maintenance and other related factors. Rockwell
Automation is not responsible for these intervening factors. The instructions in this document do not cover all the
details or variations in the equipment, procedure, or process described, nor do they provide directions for meeting every
possible contingency during installation, operation, or maintenance. This product’s implementation may vary among
users.
This document is current as of the time of release of the product; however, the accompanying software may have
changed since the release. Rockwell Automation, Inc. reserves the right to change any information contained in this
document or the software at anytime without prior notice. It is your responsibility to obtain the most current information
available from Rockwell when installing or using this product.
Version: 9.00.00 (CPR 9)
Modified: July 12, 2007 6:00 pm
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Contents
1 • Welcome to FactoryTalk Scheduler 1
What is FactoryTalk Scheduler?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
What is the benefit? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How is it designed?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Where do I begin?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation and startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Where can I go for help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reference the user’s guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Get help online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Get phone support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Get Web support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Get on-site support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Get consulting services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 • The BizBikes Factory 7
Introducing BizBikes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How BizBikes are manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BizBikes business problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How FactoryTalk Scheduler will help solve the BizBikes production problems. . . . . 8
Learn more about RSBizWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 • The Factory Overview 11
The BizBikes manufacturing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The Manufacturing Resource Planning system . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The BizBikes manufacturing resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Process plans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Purchased components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inventories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Previously scheduled orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 • Scheduling Features 23
Resource constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Primary and additional resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shift patterns and efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Resource sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Simultaneous, Singular, and Infinite resource spanning . . . . . . . . . . . . . . . . . . . 25
Adjustable Pooled resource spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sequencing constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
The operation sequence numbering scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
The immediate successor operation(s) scheme . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Sequencing constraint examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Material constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fixture constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 • Scheduling Concepts 39
Finite-capacity scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Algorithmic sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Forward sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Backward sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Bi-directional or bottleneck sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Algorithmic job selection rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Simulation-based sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Selection rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Types of rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sequencing rules: The key to good schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operation selection rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Picking the correct rule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Predefined Job Preference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Minimum Job Tardiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Minimum Job Flow Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Maximum Facility Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Resource rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Summary of independent operation selection rules . . . . . . . . . . . . . . . . . . . . . . . 55
Summary of standard independent resource selection rules. . . . . . . . . . . . . . . . . 56
Summary of dependent selection rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Custom sequencing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 • Using FactoryTalk Scheduler 59
Basic interactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Launch and save an application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Set the planning horizon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Attach a database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Create the fcs file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Develop the shift or time patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Develop a schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
The Attributes window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
The Order Trace View window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Use operation overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Create named views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Unallocate and reallocate orders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Manually edit a schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
View the Project Pane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Evaluate a schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Performance metrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Schedule Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
FactoryTalk Scheduler reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7 • Schedule Analysis 87
• • • • •
Comparing different schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Forward scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Simulation scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Simulation setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Backward scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Bottleneck scheduling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adding pooled resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Analysis summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Additional FactoryTalk Scheduler options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A • Glossary 97
B • Process Plans 105
C • MRP Charts 111
SHP Red Bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SHP Blue Bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SSD Red Bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SSD Blue Bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SHP Red Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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SHP Blue Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SSD Red Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
SSD Blue Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Handlebar Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Pedal and Chain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Derailleur Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Seat Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Neck Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
SHP Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
SSD Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
D • Time Pattern Editors 119
Time pattern types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Developing a time pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Developing exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Attaching a time pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Index 133
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1
Welcome to FactoryTalk Scheduler
Welcome to FactoryTalk Scheduler, the state-of-the-art finite-capacity system that will
help you gain control of your production scheduling.
What is FactoryTalk Scheduler?
FactoryTalk Scheduler is a client/server application that is an integrated part of the RSBizWare product suite. FactoryTalk Scheduler allows you to generate a detailed, finitecapacity schedule that provides a view into the future. Through this tool, production
schedulers can identify and act on late orders; manage capacities and constraints, including labor and material; and identify the consequences of making changes, like expediting
orders. FactoryTalk Scheduler allows total resource management and, most importantly,
provides time to react to any unintended consequences.
What is the benefit?
FactoryTalk Scheduler considers all factors that reduce the ability of a production
resource to process, including shift patterns, labor/tooling/material availability, planned
maintenance, current loading, and capacities. In summary, FactoryTalk Scheduler
produces a more accurate and realistic schedule.
How is it designed?
FactoryTalk Scheduler was designed using all of the latest available software
technologies. The newest version of FactoryTalk Scheduler is written in Visual C++
Object Oriented Development. FactoryTalk Scheduler uses the ActiveX
(ADO) component of the Microsoft Data Access Components (MDAC) software
development kit to provide direct access to various database types. FactoryTalk Scheduler
provides direct connections to Microsoft SQL Server and Oracle databases. FactoryTalk
®
Scheduler has incorporated Crystal Reports
design and develop your own reports on top of the many standard reports that have
already been developed. FactoryTalk Scheduler was designed with a document-view
interface that makes it very easy for you to navigate through the screens.
for its report writer, which allows you to
®
Data Objects
®
with
Where do I begin?
You start by creating a model of the resource capacities and capabilities of a production
facility considering the scheduling objective(s) of the company. Once your model is
complete, you can select the algorithmic or simulation scheduling rules that best achieve
the defined objectives. FactoryTalk Scheduler is capable of importing product routings
and orders, from which it is simple to generate a detailed schedule. The last part allows
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FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
you to check the schedule performance against the defined objectives and adjust the
schedule if necessary.
Since FactoryTalk Scheduler was designed to be highly configurable, your installation
may look somewhat different from the examples in this guide. The figures and dialogs
shown here are based on the tutorial example of a small manufacturing system (BizBikes,
Inc.) that produces bicycles, which is included with the FactoryTalk Scheduler software.
This example system was selected because it contains many of the key features that are
often used in a typical FactoryTalk Scheduler installation.
Intended audience
We assume that you are a manufacturing or production engineer/manager and are familiar
with the basic concepts and terms used in discrete manufacturing. You are interested in
predicting the performance of your factory or evaluating the impact of some proposed
changes. A familiarity with computers and the Microsoft
assumed. A familiarity with the concepts and terms used in simulation is also helpful.
Installation and startup
Before installing the software, we recommend that you review the product information
contained in the RSBizWare Administrator’s Guide. Then follow the step-by-step
procedures outlined in the guide (or referenced on the quick-start checklist card enclosed
in your package) to attain a successful installation and configuration of your software.
®
Windows® operating system is
The Administrator’s Guide also includes valuable information on hardware/software
requirements; reinstalling the software; activations, privileges, and permissions; and
installing and creating SQL Server databases.
Note: It is also important to review the Release Notes file located on the installation CD-ROM.
This file lists the hardware and software that is necessary to use the RSBizWare software
effectively, known issues and anomalies, and new features of the current release of the software.
Where can I go for help?
Our commitment to your success starts with the suite of learning aids and assistance we
provide with FactoryTalk Scheduler. Whether you’re new to finite-capacity scheduling or
a seasoned veteran putting a new tool to use, you’ll quickly feel at home with FactoryTalk
Scheduler.
Reference the user’s guides
Printed copies of the RSBizWare Administrator’s Guide and the FactoryTalk Scheduler
User’s Guide are distributed in the box with the software and an electronic copy of each
guide is available from the RSBizWare software installation CD-ROM or from the
2
1 • WELCOME TO FACTORYTALK SCHEDULER
technical support group. Additionally, electronic copies of the FactoryTalk Scheduler
Customization Guide and the FactoryTalk Scheduler FDM Configuration Guide are
provided on the software CD-ROM.
• • • • •
RSBIZW
ARE ADMINISTRATOR’S GUIDE
The RSBizWare Administrator’s Guide is designed to help the administrator install and
configure the software and to understand the components that make up the RSBizWare
suite of products. The first chapter of the guide provides an overview of the software
components that make up the RSBizWare suite and describes the architecture on which
they are built. The remaining chapters describe the installation steps and the options you
have when deploying the RSBizWare software in your enterprise.
F
ACTORYTALK SCHEDULER USER’S GUIDE
The documentation set also includes the FactoryTalk Scheduler User’s Guide product
manual, which cover the product basics in easy, “click-by-click” tutorials that define and
demonstrate many of FactoryTalk Scheduler’s features.
D
OCUMENT CONVENTIONS
Throughout the guides, a number of style conventions are used to help identify material.
New terms and concepts may be emphasized by use of italics or bold; file menu paths are
in bold with a (>) separating the entries (e.g., go to File > New); text you are asked to type
is shown in Courier Bold (e.g., in this field, type Work Week), and dialog button names
are shown in bold (e.g., click OK).
Get help online
Online help is always at your fingertips! FactoryTalk Scheduler help incorporates general
overview information, comprehensive step-by-step procedures, and context-sensitive
control definitions (e.g., text boxes, drop-down lists, and option buttons) for working with
all of the software features. To view online help while running the FactoryTalk Scheduler
software:
select Help > FactoryTalk Scheduler Help from the FactoryTalk Scheduler main
menu for a full help listing,
click the Help button on any FactoryTalk Scheduler dialog to open help for that dialog
only,
click the Help button on the File toolbar, then click anywhere on the user interface to
receive help on that element, or
click the What’s This? icon in the upper-right corner of any FactoryTalk Scheduler
dialog, then on any control to receive a definition of that control.
3
FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
Get phone support
The Rockwell Automation support team of outstanding professionals provides top-notch
technical support—monitoring and tracking your experience with our products to pave the
road to your success in understanding and improving your factory performance.
Rockwell Automation provides full support for the entire RSBizWare suite of products,
which include FactoryTalk Historian Classic, FactoryTalk Metrics, FactoryTalk
Transaction Manager, FactoryTalk Scheduler. Questions concerning installation and the
use of the software are handled by the Rockwell Automation Customer Support Center,
staffed from 8
holidays—for calls originating within the U.S. and Canada.
To reach the Customer Support Center, call 1.440.646.3434 and follow the prompts. For
calls originating outside the U.S./Canada, locate the number in your country by linking to
support.rockwellautomation.com
presented from which you can locate the number to call inyour country.
W
HEN YOU CALL
When you call, you should be at your computer and prepared to give the following
information:
the product serial number and version number, which can be found in the client
software by selecting Help > About,
AM to 5 PM (in your time zone) Monday through Friday—except U.S.
and selecting the Phone/On-site link. A list will be
the type of hardware you are using,
the exact wording of any errors or messages that appeared on your screen
a description of what happened and what you were doing when the problem occurred,
and
a description of how you attempted to solve the problem.
Get Web support
In addition to phone support, the Rockwell Automation Customer Support Center offers
extensive online knowledgebases of tech notes and frequently asked questions for support
of non-urgent issues. These databases are updated daily by our support specialists.
To receive regular e-mail messages with links to the latest tech notes, software updates,
and firmware updates for the products that are of interest to you or to submit an online
support request, go to support.rockwellautomation.com
4
and select the Online link.
1 • WELCOME TO FACTORYTALK SCHEDULER
Get on-site support
For on-site support, Rockwell Automation field support engineers are located around the
globe to provide assistance with special projects, unexpected problems, or emergency
situations. Field support engineers are available for dispatch 24x7x365 and can arrive at
many locations the same day.
To learn more about this and other support services, visit the Rockwell Automation Web
site at www.rockwellautomation.com/support
.
Get consulting services
Rockwell Automation provides expert consulting and turnkey implementation of the
RSBizWare suite. Please call your local Rockwell Automation representative for more
information.
Contact us
We strive to help all of our customers become successful in their manufacturing
improvement efforts. Toward this objective, we invite you to contact your local
representative or Rockwell Automation at any time that we may be of service to you.
Numbers for the support group are listed on the copyright page of this book.
• • • • •
5
FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
6
2
The BizBikes Factory
Introducing BizBikes
This chapter describes a sample company, BizBikes Inc., whose
manufacturing system will be referred to in upcoming tutorial
chapters. BizBikes manufactures bicycles that are sold to
independent bicycle shops. The BizBikes factory was selected
because it contains representative key features of the RSBizWare
product suite, including FactoryTalk Historian Classic, FactoryTalk Metrics, FactoryTalk
Transaction Manager, and FactoryTalk Scheduler.
Roll up your sleeves and take a walk through the factory with us as we study the system
and how it operates. Let’s start by learning about the business environment, and then we’ll
spend some time getting familiar with the manufacturing process.
How BizBikes are manufactured
BizBikes produces bicycles in two different styles (Standard (SSD) and High Performance (SHP)) and in two different colors (red and blue). With the exception of the frames,
the two models and color variations use all the same manufactured and purchased components.
The BizBikes manufacturing facility can be broken into these logical areas:
Machining and Fabrication
Paint Shop
Subassembly
Final Assembly and Ship
There are also two Original Equipment Manufacturers (OEMs) resident on the BizBikes
campus who manufacture sprockets and seats. These finished goods are supplied to
BizBikes for final assembly.
In the machining and fabrication area, BizBikes manufactures the frames, seat posts,
handlebars, and neck post. These component parts are produced by processing raw
material through a series of work cells that cut, bend, machine, weld, and finish
components. After parts complete the machining and fabrication steps, the frames are
batched and sent to the paint shop, and the other component parts go into inventory where
they can be pulled from stock as needed to meet demand in the assembly area. In the next
stage, each bicycle is assembled based on customer order requirements with parts and
subassemblies (both manufactured and purchased) supplied from inventory. In the last
step, the bicycle (with its wheels and handlebar removed) is packed in a corrugated box
and shipped.
7
FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
BizBikes business problems
BizBikes has been losing market share to competitors due to both pricing pressure and
problems with on-time delivery. Business conditions have forced a transition from maketo-stock to make-to-order, and the bicycle shops that receive the goods are complaining
about frequent late deliveries. Thin margins and decrease in market share have produced
losses for the past two quarters. A task force was set up to analyze the problem and to
recommend a solution that will improve key performance indicators, such as lowering our
manufacturing costs, shortening our production time, and improving our on-time delivery.
Challenges:
Must quote accurately and meet delivery dates
Compete with competitor information and alternative suppliers that are readily
accessible via Internet
Must provide accurate, up-to-the-minute information on order and shop-floor resource
status to the rest of the organization
Critical to monitor, analyze, and improve the manufacturing processes through up-to-
date software and information technology
Must drive down the cost of manufacturing while maximizing resource utilization and
machine uptime
How FactoryTalk Scheduler will help solve the BizBikes production problems
Through FactoryTalk Scheduler’s finite-capacity scheduling strategies and simulationbased scheduling, the management and shop-floor teams at BizBikes now perform “whatif” analyses of the production sequences in a fraction of the time they previously spent.
Implementing FactoryTalk Scheduler in their “toolbox” allows for the generation of
realistic production scenarios that show the effects of schedule changes, maintenance
downtimes, tooling, shifts, and other key factors that determine the factory capacity and
delivery times. In minutes, FactoryTalk Scheduler generates production schedules that
used to take hours, so the teams spend their time managing the bicycle orders, not
calculating capacity.
And with FactoryTalk Scheduler’s accurate representation of the system and its operation,
the teams at BizBikes can constantly monitor the factory’s performance and make timely
decisions to increase throughput and cut the WIP, overtime, and on-hand inventory.
In the next chapter, we’ll take a look at the impact of FactoryTalk Scheduler in the
BizBikes factory by first examining their manufacturing system.
8
Learn more about RSBizWare
See how RSBizWare solutions impact the BizBikes manufacturing system by visiting
www.software.rockwell.com/bizbikes/
For more comprehensive product information and to view application profiles of actual
companies’ successes, be sure to visit the RSBizWare Web site at
www.software.rockwell.com/rsbizware/
• • • • •
2 • THE BIZBIKES FACTORY
.
.
9
FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
10
3
The Factory Overview
The BizBikes manufacturing system
To begin our assessment of the BizBikes factory, we’ll first examine their manufacturing
system and learn about the factory resources and processes. We will then use this model to
examine possible scenarios for improving our performance.
Bill of materials
The bill of materials for BizBikes contains three levels, as shown below, for a generic end
item. There are actually four end items (or BizBikes), 15 unique manufactured items, and
five purchased parts. The shaded items in the bill of materials represent manufactured
components. This generic bill of materials also includes information on manufacturing
lead times, number required per subassembly, and lot size information.
FINAL
ASSEMBLY
AND PACK
(1,1,1)
FINISHED
FRAME
(1,1,24)
FRAME
(4,1,50)
KEY: (Lead Time, Quantity, Lot Size)
PEDAL AND
CHAIN
ASSEMBLY
(3,1,60)
HANDLEBAR
(3,1,100)
HANDLEBAR
ASSEMBLY
(1,1,75)
NECK POST
(3,1,60)
WHEELS
(3,1,48)
DERAILLEUR
ASSEMBLY
(4,1,60)
SEAT POST
(3,1,100)
SEAT
ASSEMBLY
(1,1,75)
SEAT
(2,1,100)
BRAKES
(2,1,75)
The Manufacturing Resource Planning system
BizBikes employs a Manufacturing Resource Planning (MRP) system that performs
master planning and scheduling of weekly production. The MRP system consolidates
orders from multiple customers and plans the purchase and manufacturing of the
associated components. The MRP produces a set of manufacturing orders that are
released to the factory floor. These manufacturing orders are for both component parts
11
FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
(frames, handlebars, etc.) as well as final assemblies. The components are produced tostock and are consumed during the subassembly and the final assembly and pack of a
bicycle. The MRP also nets together purchased components across multiple customer
orders. The MRP netting operation generates purchase requests for component parts
(brakes, wheels, seats, etc.) based on economic order quantities and lead times. The MRP
system also plans out and issues purchase requests for materials consumed in
manufacturing component parts. The purchase requests for both component parts and raw
materials are issued to suppliers who then ship these components to our factory. In the
final assembly, we combine the manufactured and purchased components into a bicycle,
which is then packed and shipped to the customer.
The following table shows production requirements for a typical ten-day period. These
manufacturing orders have been downloaded from the MRP and include orders for SHP
and SSD bicycles in both red and blue, along with MRP-generated orders for components
required during assembly. The 70 manufacturing orders include 33 orders for finished
BizBikes, 25 subassemblies, and 12 component parts.
12
3 • THE FACTORY OVERVIEW
• • • • •
Order # Product Name
SHP Red 1 SHP Red Bicycle 15 2/11/03 11 PM 2/12/03 11 PM
SHP Red 2 SHP Red Bicycle 9 2/12/03 11 PM 2/13/03 11 PM
SHP Red 3 SHP Red Bicycle 8 2/13/03 11 PM 2/14/03 11 PM
SHP Red 4 SHP Red Bicycle 12 2/14/03 11 PM 2/17/03 11 PM
SHP Red 5 SHP Red Bicycle 17 2/17/03 11 PM 2/18/03 11 PM
SHP Red 6 SHP Red Bicycle 20 2/18/03 11 PM 2/19/03 11 PM
SHP Red 7 SHP Red Bicycle 9 2/19/03 11 PM 2/20/03 11 PM
SHP Red 8 SHP Red Bicycle 7 2/20/03 11 PM 2/21/03 11 PM
SHP Blue 1 SHP Blue Bicycle 11 2/10/03 11 PM 2/11/03 11 PM
SHP Blue 2 SHP Blue Bicycle 6 2/11/03 11 PM 2/12/03 11 PM
SHP Blue 3 SHP Blue Bicycle 4 2/12/03 11 PM 2/13/03 11 PM
SHP Blue 4 SHP Blue Bicycle 14 2/13/03 11 PM 2/14/03 11 PM
SHP Blue 5 SHP Blue Bicycle 11 2/14/03 11 PM 2/17/03 11 PM
SHP Blue 6 SHP Blue Bicycle 16 2/17/03 11 PM 2/18/03 11 PM
SHP Blue 7 SHP Blue Bicycle 8 2/18/03 11 PM 2/19/03 11 PM
SHP Blue 8 SHP Blue Bicycle 6 2/19/03 11 PM 2/20/03 11 PM
SHP Blue 9 SHP Blue Bicycle 15 2/20/03 11 PM 2/21/03 11 PM
SSD Red 1 SSD Red Bicycle 11 2/10/03 11 PM 2/11/03 11 PM
SSD Red 2 SSD Red Bicycle 9 2/11/03 11 PM 2/12/03 11 PM
SSD Red 3 SSD Red Bicycle 8 2/12/03 11 PM 2/13/03 11 PM
SSD Red 4 SSD Red Bicycle 14 2/13/03 11 PM 2/14/03 11 PM
SSD Red 5 SSD Red Bicycle 12 2/17/03 11 PM 2/18/03 11 PM
SSD Red 6 SSD Red Bicycle 7 2/18/03 11 PM 2/19/03 11 PM
SSD Red 7 SSD Red Bicycle 6 2/19/03 11 PM 2/20/03 11 PM
SSD Red 8 SSD Red Bicycle 12 2/20/03 11 PM 2/21/03 11 PM
SSD Blue 1 SSD Blue Bicycle 5 2/11/03 11 PM 2/12/03 11 PM
SSD Blue 2 SSD Blue Bicycle 16 2/12/03 11 PM 2/13/03 11 PM
SSD Blue 3 SSD Blue Bicycle 9 2/13/03 11 PM 2/14/03 11 PM
SSD Blue 4 SSD Blue Bicycle 12 2/14/03 11 PM 2/17/03 11 PM
SSD Blue 5 SSD Blue Bicycle 8 2/17/03 11 PM 2/18/03 11 PM
SSD Blue 6 SSD Blue Bicycle 13 2/18/03 11 PM 2/19/03 11 PM
SSD Blue 7 SSD Blue Bicycle 18 2/19/03 11 PM 2/20/03 11 PM
SSD Blue 8 SSD Blue Bicycle 15 2/20/03 11 PM 2/21/03 11 PM
SHP Red Finished Frame 1 SHP Red Finished Frame 24 2/10/03 11 PM 2/11/03 11 PM
SHP Red Finished Frame 2 SHP Red Finished Frame 24 2/13/03 11 PM 2/14/03 11 PM
SHP Red Finished Frame 3 SHP Red Finished Frame 24 2/14/03 11 PM 2/17/03 11 PM
SHP Red Finished Frame 4 SHP Red Finished Frame 24 2/17/03 11 PM 2/18/03 11 PM
SHP Blue Finished Frame 1 SHP Blue Finished Frame 24 2/10/03 11 PM 2/11/03 11 PM
SHP Blue Finished Frame 2 SHP Blue Finished Frame 24 2/13/03 11 PM 2/14/03 11 PM
SHP Blue Finished Frame 3 SHP Blue Finished Frame 24 2/17/03 11 PM 2/18/03 11 PM
SHP Blue Finished Frame 4 SHP Blue Finished Frame 24 2/19/03 11 PM 2/20/03 11 PM
SSD Red Finished Frame 1 SSD Red Finished Frame 24 2/10/03 11 PM 2/11/03 11 PM
Order
Quantity Release Date Due Date
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FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
Order # Product Name
SSD Red Finished Frame 2 SSD Red Finished Frame 24 2/12/03 11 PM 2/13/03 11 PM
SSD Red Finished Frame 3 SSD Red Finished Frame 24 2/18/03 11 PM 2/19/03 11 PM
SSD Blue Finished Frame 1 SSD Red Finished Frame 24 2/11/03 11 PM 2/12/03 11 PM
SSD Blue Finished Frame 2 SSD Blue Finished Frame 24 2/13/03 11 PM 2/14/03 11 PM
SSD Blue Finished Frame 3 SSD Blue Finished Frame 24 2/17/03 11 PM 2/18/03 11 PM
SSD Blue Finished Frame 4 SSD Blue Finished Frame 24 2/18/03 11 PM 2/18/03 11 PM
Handlebar Assembly 1 Handlebar Assembly 75 2/10/03 11 PM 2/11/03 11 PM
Handlebar Assembly 2 Handlebar Assembly 75 2/12/03 11 PM 2/13/03 11 PM
Handlebar Assembly 3 Handlebar Assembly 75 2/14/03 11 PM 2/17/03 11 PM
Handlebar Assembly 4 Handlebar Assembly 75 2/17/03 11 PM 2/18/03 11 PM
Handlebar Assembly 5 Handlebar Assembly 75 2/19/03 11 PM 2/20/03 11 PM
Seat Assembly 1 Seat Assembly 75 2/10/03 11 PM 2/11/03 11 PM
Seat Assembly 2 Seat Assembly 75 2/12/03 11 PM 2/13/03 11 PM
Seat Assembly 3 Seat Assembly 75 2/14/03 11 PM 2/17/03 11 PM
Seat Assembly 4 Seat Assembly 75 2/17/03 11 PM 2/18/03 11 PM
Seat Assembly 5 Seat Assembly 75 2/19/03 11 PM 2/20/03 11 PM
Handlebar 1 Handlebar 100 2/11/03 11 PM 2/14/03 11 PM
Handlebar 2 Handlebar 100 2/12/03 11 PM 2/17/03 11 PM
Handlebar 3 Handlebar 100 2/14/03 11 PM 2/19/03 11 PM
Neck Post 1 Neck Post 60 2/11/03 11 PM 2/14/03 11 PM
Neck Post 2 Neck Post 120 2/12/03 11 PM 2/17/03 11 PM
Neck Post 3 Neck Post 60 2/14/03 11 PM 2/19/03 11 PM
SHP Frame 1 SHP Frame 50 2/10/03 11 PM 2/14/03 11 PM
SHP Frame 2 SHP Frame 50 2/11/03 11 PM 2/17/03 11 PM
SSD Frame 1 SSD Frame 50 2/11/03 11 PM 2/17/03 11 PM
SSD Frame 2 SSD Frame 50 2/12/03 11 PM 2/18/03 11 PM
Seat Post 1 Seat Post 100 2/12/03 11 PM 2/17/03 11 PM
Seat Post 2 Seat Post 100 2/14/03 11 PM 2/19/03 11 PM
Order
Quantity Release Date Due Date
14
The BizBikes manufacturing resources
The BizBikes manufacturing plant contains seven work cells (Cut, Machine, Bend, Weld,
Finish, two Subassembly areas, and two Assembly and Pack areas), and a three-person
labor pool per shift (labor required by Subassembly and Assembly and Pack). All work
cells and labor are available for two eight-hour shifts, five days a week (a 2/5 composite
shift pattern). The first shift starts at 7
and ends at 11
PM. There are no scheduled breaks in either shift. The key differences for
the processes at the various work cells are summarized below. Keep in mind that all setup
and process durations are expressed in hours.
AM and ends at 3 PM. The second shift starts at 3 PM
3 • THE FACTORY OVERVIEW
A
SSEMBLY AND PACK
These work cells are used to assemble and pack the finished BizBikes. The setup and
process (per item) durations are part dependent. Each assembly operation requires two
labor units from the labor pool for its entire duration.
S
UBASSEMBLY
These work cells are used to assemble component parts (manufactured and purchased)
into subassemblies that are placed in stock for future required orders. The setup and
process (per item) durations are part dependent. Each subassembly operation requires one
labor unit from the labor pool for its entire duration.
F
INISH AND CUT
These work cells are utilized for operations necessary to produce the component parts
required for the subassemblies. The setup and process (per item) durations are part
dependent. These work cells are manned by a dedicated operation and do not require labor
from the labor pool.
M
ACHINE AND BEND
These work cells are utilized for operations necessary to produce the component parts
required for the subassemblies. The process (per item) durations are part dependent. These
work cells are manned by a dedicated operation and do not require labor from the labor
pool. The setup durations for these work cells are sequence dependent and defined in
matrix MM for the Machine work cell and matrix BM for the Bend work cell. These two
matrices are shown below.
• • • • •
Machine Setup Matrix: MM
SSD Frame SHP Frame Handlebar Neck Post
SSD Frame
SHP Frame
Handlebar
Neck Post
0.00 0.12 0.53 0.58
0.14 0.00 0.55 0.62
0.64 0.66 0.00 0.26
0.57 0.61 0.33 0.00
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FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
This matrix shows the setup time for an operation based on the previous production lot
that was processed at this work cell. For example, if the last production lot was
Handlebar, then the setup time to produce a Neck Post is .26 hours.
Bend Setup Matrix: BM
SSD Frame SHP Frame Handlebar Neck Post
SSD Frame
SHP Frame
Handlebar
Neck Post
W
ELD
This work cell is also utilized for operations necessary to produce the component parts
required for the subassemblies. The process (per item) durations are part dependent. These
work cells are manned by a dedicated operation and do not require labor from the labor
pool. The setup duration for this work cell depends upon the frame type; i.e., we have a
different setup time for an SHP Frame and an SSD Frame. The setup time required to
change to an SHP Frame is 0.72 hours, and the time required to change to an SSD Frame
is 0.70 hours.
0.00 0.35 0.84 0.32
0.42 0.00 0.84 0.32
0.93 0.97 0.00 0.28
0.75 0.78 0.39 0.00
16
Process plans
There are eight different manufacturing order types, each with a different process plan or
routing.
F
INAL ASSEMBLY AND PACK
The process plans for assembly and packing of the SHP Red, SHP Blue, SSD Red, and
SSD Blue bicycles contain a single assembly operation. In this operation, a bicycle is
assembled from its components and subassemblies and then packaged for shipping. The
process plan for SHP Red Bicycle final assembly is summarized below.
SHP Red Bicycle Plan
Seq
#
10 Assemble
Operation Work Cell
and Pack
10
ASSEMBLE
AND PACK
Assembly
and Pack
Setup
Process
Time
0.37 0.43 Labor (2) Components required
Time
Additional
Resources
Notes
3 • THE FACTORY OVERVIEW
The components required before this operation can be started are the manufactured parts
SHP Red Finished Frame, Handlebar Assembly, and Seat Assembly and the purchased
parts Pedal and Chain Assembly, Wheels, Derailleur Assembly, and Brakes.
F
INISHED FRAME
The process plans for a finished frame (SHP Red, SHP Blue, SSD Red, and SSD Blue)
contain two operations. The frame parts are first finished (red or blue) and then the parts
are subassembled. The finished frame is then placed in inventory where it is available for
demand from a final assembly order. The process plan for SHP Red Finished Frame is
summarized below.
SHP Red Finished Frame Plan
Seq
#
10 Finish SHP
20 Subassemble
Operation
Red Frame
SHP Frame
Work Cell
Finish 0.11 0.155 SHP Frame
Subassembly 0.19 0.083 Labor (1) Place in
Setup
Time
Process
Time
Additional
Resources
Notes
required
inventory
• • • • •
20
ASSEMBLE
FRAME
F
RAME
10
FINISH
FRAME
The process plans for a frame (SHP or SSD) contain four operations: cut, bend, machine,
and weld. The frame is then placed in inventory to be used by orders for finished frames.
The raw materials required at both the cut and weld operations have not been included in the
process plan as the material-planning replenishment process at the MRP level assures that
adequate materials will be available. The process plan for
SHP Frame
is summarized next.
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FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
SHP Frame Plan
Seq
#
10 Cut SHP Frame
20 Bend SHP Frame
30 Machine SHP
40 Weld SHP Frame Weld WD 0.234 Place in inventory
Operation
Tubing
Tubing
Frame Tubing
Setup
Work
Cell
Time
Process
Time
Additional
Resources
Notes
Cut 0.36 0.120
Bend BM 0.154
Machine MM 0.211
10
CUT FRAME
TUBING
H
ANDLEBAR ASSEMBLY
20
BEND FRAME
TUBING
30
MACHINE
FRAME
TUBING
40
WELD
FRAME
The process plans for the handlebar assembly contain a single subassembly operation. In this operation, the previously manufactured handlebars and neck posts are assembled. The subassembly is then placed in inventory where it is available for demand from a final assembly order. The component parts required for this subassembly are a handlebar and neck post for each subassembly to be produced. The process plan for Handlebar Assembly is summarized below.
Handlebar Assembly Plan
Seq
#
Operation Work Cell
10 Assemble
Handlebar
Subassembly 0.21 0.072 Labor (1) Handlebar and Neck
Setup
Time
Process
Time
Additional
Resources
Notes
Post required;
Place in inventory
10
ASSEMBLE
HANDLEBAR
H
ANDLEBAR
The process plans for a handlebar contain three operations: cut, bend, and finish. The
completed handle is then placed in inventory to be used by orders for handlebar
assemblies. The raw materials required at the cut operation have not been included in the
process plan as the material-planning replenishment process at the MRP level assures that
18
3 • THE FACTORY OVERVIEW
adequate materials will be available. The process plan for Handlebar is summarized
below.
Handlebar Plan
Setup
Seq
# Operation Work Cell
10 Cut
Cut 0.16 0.055
Time
Process
Time
Additional
Resources
Notes
Handlebar
Tubing
20 Bend
Bend BM 0.043
Handlebar
Tubing
30 Finish
Finish 0.14 0.088 Place in inventory
Handlebar
• • • • •
10
CUT
HANDLEBAR
TUBING
N
ECK POST
20
BEND
HANDLEBAR
TUBING
30
FINISH
HANDLEBAR
The process plans for a handlebar contain four operations: cut, machine, bend, and finish.
The completed neck post is then placed in inventory to be used by orders for handlebar
assemblies. The raw materials required at the cut operation have not been included in the
process plan as the material-planning replenishment process at the MRP level assures that
adequate materials will be available. The process plan for Neck Post is summarized below.
Neck Post Plan
Setup
Seq
# Operation Work Cell
10 Cut Neck
Cut 0.21 0.065
Time
Process
Time
Additional
Resources
Notes
Post
20 Machine
Machine MM 0.120
Neck Post
30 Bend Neck
Bend BM 0.072
Post
40 Finish Neck
Finish 0.14 0.074 Place in inventory
Post
10
CUT NECK
POST
20
MACHINE
NECK POST
30
BEND NECK
POST
40
FINISH NECK
POST
19
FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
S
EAT ASSEMBLY
The process plans for the seat assembly contain a single subassembly operation. In this operation, the previously manufactured seat post and purchased seat are assembled. The subassembly is then placed in inventory where it is available for demand from a final assembly order. The component parts required for this subassembly are a seat post and seat for each subassembly to be produced. The process plan for Seat Assembly is summarized below.
Seat Assembly Plan
Seq
# Operation Work Cell
10 Assemble
Seat and
Post
10
ASSEMBLE
SEAT AND
POST
S
EAT POST
The process plans for a seat post contain two operations: cut and machine. The completed
seat post is then placed in inventory to be used by orders for seat assemblies. The raw
materials required at the cut operation have not been included in the process plan as the
material-planning replenishment process at the MRP level assures that adequate materials
will be available. The process plan for Seat Post is summarized below.
Setup
Time
Process
Time
Additional
Resources
Notes
Subassembly 0.20 0.084 Labor (1) Seat and Seat Post
required;
Place in inventory
20
Seat Post Plan
Seq
# Operation Work Cell
10 Cut Seat
Cut 0.17 0.068
Post
20 Machine
Machine MM 0.130 Seat Post
Seat Post
10
CUT SEAT
POST
20
MACHINE
SEAT POST
Setup
Time
Process
Time
Additional
Resources
Material
Consumed
Material
Produced
3 • THE FACTORY OVERVIEW
Purchased components
In addition to the manufactured components, we also have purchased components that are
used in the assembly operations. Purchase orders for these components are automatically
generated by the MRP (based on the economic lot size and lead times) to meet the
manufacturing demands. The following table summarizes the purchased components for
this same sample ten-day production period.
Material Name Quantity Date
Pedal and Chain Assembly 60 6/10/02 6:00 PM
Pedal and Chain Assembly 60 6/13/02 6:00 PM
Pedal and Chain Assembly 60 6/19/02 6:00 PM
Brakes 75 6/12/02 6:00 PM
Brakes 75 6/18/02 6:00 PM
Wheels 48 6/12/02 6:00 PM
Wheels 48 6/17/02 6:00 PM
Wheels 48 6/19/02 6:00 PM
Derailleur Assembly 60 6/12/02 6:00 PM
Derailleur Assembly 60 6/17/02 6:00 PM
Derailleur Assembly 60 6/20/02 6:00 PM
Seat 100 6/10/02 6:00 PM
• • • • •
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FACTORYTALK SCHEDULER USER’S GUIDE
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Inventories
We have a starting inventory level for both the manufactured and the purchased material.
The following table summarizes the starting inventory of these items.
Material Type Initial Quantity
SHP Red Bicycle Make 0
SHP Blue Bicycle Make 0
SSD Red Bicycle Make 0
SSD Blue Bicycle Make 0
SHP Red Finished Frame Make 8
SHP Blue Finished Frame Make 16
SSD Red Finished Frame Make 17
SSD Blue Finished Frame Make 6
Handlebar Assembly Make 27
Seat Assembly Make 36
SHP Frame Make 97
SSD Frame Make 54
Seat Post Make 127
Handlebar Make 155
Neck Post Make 118
Pedal and Chain Assembly Buy 15
Brakes Buy 50
Wheels Buy 54
Derailleur Assembly Buy 54
Seat Buy 54
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Previously scheduled orders
Finally, we have previously scheduled orders planned for completion. These orders are
shown below.
Material Name Quantity Date
Seat Post 100 2/12/03 6:00 PM
Neck Post 60 2/12/03 6:00 PM
SSD Frame 50 2/12/03 6:00 PM
Summary
Now that we have described the BizBikes manufacturing process, we’ll use the
information in the tutorial to illustrate the features of FactoryTalk Scheduler in Chapter 4.
4
Scheduling Features
FactoryTalk Scheduler provides a wide range of features for modeling constrained
scheduling systems. There are four basic categories of modeling constraints available—
resource, sequencing, material, fixture, and operation. We will discuss the major
features for each of them and use the BizBikes tutorial from Chapter 3 to demonstrate
examples.
Resource constraints
FactoryTalk Scheduler provides full support for the scheduling of constrained resources
with four distinct resource types:
Singular
Infinite
Simultaneous
Adjustable Pooled
The resource types differ in the functionality that they provide in modeling a wide variety
of production environments.
The Singular resource is the most commonly used type. It represents a single machine,
person, device, jig, fixture, or any resource that is constrained and has a capacity of one.
Tuto rial
Bend, Cut, Finish, Machine, Weld, Subassembly, and Assembly and Pack, as each
resource can only perform one operation at a time.
The Infinite resource type provides the ability to represent resources that have an
unlimited capacity. The most common example is a subcontractor or a drying area.
Although a subcontractor has a theoretical infinite capacity, it still requires time to
complete the task and may work only a single shift.
Tuto rial
The Simultaneous resource type represents resources that may have the ability to handle
multiple activities. It is further restricted in that if a Simultaneous resource processes
multiple activities at the same time, all the activities must be synchronized. This means
that they must all start and end at the same time. The significance of this feature is best
described by considering a kiln with a capacity measured in cubic feet. The kiln can be
used to process any number of parts, as long as the volume of the parts does not exceed
the kiln capacity. The synchronized restriction means that once you load and start the kiln,
you must finish that process before it can be used to process any additional parts. You can
: For our tutorial system, we will model the resources as Singular in work cells
: We will not use this resource type in our tutorial system.
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FACTORYTALK SCHEDULER USER’S GUIDE
• • • • •
also restrict what operations can be processed at the same time by requiring that certain
operation attributes match before they can be processed together.
Tuto rial
The Adjustable Pooled resource type is most often used to represent pools of like
resources, any one of which fulfills the requirement of the task or operation being
performed. Typical examples are labor pools, totes, fixtures, or space. The number of
units of an Adjustable Pooled resource can vary during the operation span. We will
elaborate on this difference shortly.
Tuto rial
: We will not use this resource type in our tutorial system.
: The labor pool in our tutorial will be modeled as an Adjustable Pooled resource.
Primary and additional resources
Each operation to be scheduled must have a single primary resource for the entire duration
of the operation. Operation durations can be separated into three phases. Normally, these
are referred to as setup, process, and teardown. Additional resources can be specified for
the entire operation or for an individual phase of the operation. There is no limit on the
number of additional resources that an operation may require. However, as the number of
additional resources increases, the scheduling problem becomes more complex. This will
result in more time being required to develop a solution.
Shift patterns and efficiency
You can associate shift patterns, preventive maintenance, downtimes, etc., with any
resource. In addition to shift patterns, you can also associate an efficiency, expressed as a
fraction, with Singular, Infinite, and Simultaneous resources. Typically, this efficiency
would be defaulted to 1.0. By changing the efficiency, you can speed up or slow down
those operations that use the resource.
24
Resource sets
FactoryTalk Scheduler schedules to either a resource or a resource set. A resource set
contains one or more resources. When a resource set contains multiple resources, the
resources are typically of the same type, although it is not required. Likewise, it is not
required that the names used for resource sets differ from those of resources, but this is the
most common naming convention. Furthermore, a resource may be included in more than
one set.
Tuto rial
Machiner, Welder, and Labor. You might note that although Labor is a single resource, it
will have a capacity greater than one. We also have two resource sets, Subassembly Areas
and Assembly and Pack Areas, each with two resources. The two subassembly resources
are called Subassembly Area 1 and Subassembly Area 2. The two assembly resources are
: In our tutorial system, we will have six resources: Bender, Cutter, Finisher,
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