Galatians
Going “Live” With ERP LX Capacity Planning
ERP LX P
Prrograms – Capacity Planning (CAP)
Inquiry Programs
Maintenance Programs
Generally these are data entry
programs in which you enter
information into the database so it
can be used by the computer system,
as in Work Center Maintenance.
These are always on-line programs
that access information files. Use
these programs instead of reports
when you need to access limited
records in the file.
Numbered 100 – 199
Numbered 300 – 399
CAP100 – Work Center
Maintenance
CAP300 – Work Center Load
Inquiry
Report Programs
Transaction Programs
May be either on-line or batch
processed. These programs
manipulate data entered to them.
For example, CAP500 is an on-line
ERP LX program for generating rough
cut capacity requirements.
Numbered 500 – 699
Reports are on-line or batch programs
that print the data from the files in
report form. Information may be
sorted for logical sequence or limited
report parameters.
Numbered 200 – 299
CAP250 – Input / Output Report
CAP500 – Generate Rough
Cut Capacity
Requirements
CAP600 – Generate Detail
Capacity Requirements
Period Close Programs
These programs are batch-type
programs that process data at the end
of the month or year.
Numbered 900 – 999
CAP900 – Capacity Week End Close
Unbeaten Path
®
© 2008 Unbeaten Path International Ltd.
CAP. 4
Ephesians
System Flow
v
CAP “Live”
Detail Capacity Planning
†
Open Production Orders
from SFC / JIT / LMP;
Firm Planned & Planned
Orders from MPS and MRP
†
Corresponds to
Scheduled Receipts
What is
scheduled to be
produced?
Routings
What
resource
hours are
required?
Detail
Capacity
Planning
What
capacity
is
available?
Work Center
& Capacity
Information
Current Load
& Future Load
Projections
Detail capacity planning reviews current and planned load for all work centers.
∇ Uses item routings (primary and alternative)
◊ All manufactured items
◊ All work centers
∇ Material requirements planning tool
◊ Smooth the flow of planned production
◊ Performed after MPS and MRP generations
Unbeaten Path
®
CAP. 9
© 2008 Unbeaten Path International Ltd.
Ephesians
Overview
v
CAP “Live”
Capacity as a Planning T
ool
Tool
Planning
Level
Planning Function
Length of
Planning Horizon
Top
Management
Planning
Production Plan
Long Range
1–5 years
Operations
Management
Planning
MPS
MRP
CRP
Medium Range
1–6 months
Operations
Management
Execution
Shop Floor Control
Lean Manufacturing Process
JIT/Repetitive Process
Short Range
weeks / days / hours
Unbeaten Path
®
CAP. 17
© 2008 Unbeaten Path International Ltd.
Ephesians
Manufacturing Data Management
v
CAP “Live”
Work Centers: K
ey P
eatur
es
Key
Prrogram F
Featur
eatures
Work Center Maintenance .................................... CAP100
…continued from the previous page.
— CAP100 —
Significant Fields Affecting
Costing
Work Center
Maintenance
∇ Standard cost buckets 1–8
◊ relates a standard cost bucket 1–999
for rates 1–8 for cost updates
∇ Actual cost buckets 1–8
◊ relates an actual cost bucket 1–999
for rates 1–8 for cost updates
∇ Frozen cost buckets 1–8
◊ relates a frozen cost bucket 1–999 for
rates 1–8 for cost updates
∇ Going-to cost buckets 1–8
◊ relates a going-to cost bucket 1–999
for rates 1–8 for cost updates
∇ Outside operation 1–8 (or blank)
◊ indicates which rate is an outside
operation
Unbeaten Path
®
CAP. 37
© 2008 Unbeaten Path International Ltd.
Galatians
Going “Live” With ERP LX Capacity Planning
Routing – Basis Codes
Basis Codes
Blank ...
Hours P
er Unit
...Hours
Per
F ......
Hours P
er Fixed Duration Quantity
......Hours
Per
H ......
Hours P
er Standar
d Batch Size
......Hours
Per
Standard
P ......
Pieces P
er Hour
Per
......Pieces
1 ......
Hours P
......Hours
Per
er 10 Units
2 ......
Hours P
er 100 Units
......Hours
Per
Hours P
er 1,000 Units
3 ......
Per
......Hours
Hours P
er 10,000 Units
4 ......
......Hours
Per
5 ......
Hours P
er 100,000 Units
......Hours
Per
6 ......
Hours P
......Hours
Per
er 1,000,000 Units
Note: For outside operations, set the “Inside / Outside Operation” field to “1,”
and specify the cost in the “Outside Cost” field.
∇ Represent time in production
∇ Interpret machine and run hours as production rates
Example
∇ Basis code of 2 (hours per 100 units)
∇ Run hours of .75
∇ Production rate = 100 units are produced in .75 hours (or 45 minutes)
Unbeaten Path
®
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CAP. 40
Galatians
Going “Live” With ERP LX Capacity Planning
Finite F
or
war
d Scheduling
For
orwar
ward
Hours
Finite Forward Scheduled Loading
Overtime
scheduled
Rescheduled:
✦ Planned Orders
✦ Firm Planned Orders
✦ Shop Orders
Saturday
shift added
Modified
Plant
Capacity
? Capacity parameters
were adjusted
? Load characteristics
have been modified
Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr
Days
∇ Corrective action taken to increase available capacity
∇ Minimizes order rescheduling
— MRP640 —
∇ Modified using Finite Forward Scheduling (MRP640)
Finite
Forward
Scheduling
Unbeaten Path
®
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CAP. 76
Galatians
Going “Live” With ERP LX Capacity Planning
Reports and Listings: K
es
Key
Prrogram F
Featur
eatures
ey P
eatur
Resource Requirements Report ............................ CAP260
This Resource Requirements Report (CAP260D)
generates five capacity reports:
,
,
,
,
,
Labor Resource Requirements
Machine Resource Requirements
Setup Resource Requirements
Setup and Labor Resource Requirements
Setup and Machine Resource Requirements
— CAP260 —
Resource
Requirements
Report
These five separate reports contain similar
information in various formats to allow you to view
the data from different perspectives. They all
provide separate labor totals for each department.
The reports show detailed labor requirements at the
work center level by time frame.
Parameters
∇ Department
◊ select the department or range of departments
you wish to print
∇ Resource selection
◊ specify a code to indicate the resource
requirements you want to view. Choices are one of
the following:
1 .... machine
2 .... setup
3 .... setup and machine
4 .... labor
5 .... setup and labor
…continued on the next page
Unbeaten Path
®
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CAP. 106