I wonder if someone can point me in the right direction on scheduling planning as the way we have the system setup is not reflecting what we do – we may consider using some consultancy but at a high level I need to understand if E10 can do planning the way we would like to.
We make to order, discrete customer parts, some of these will be simple route and boms, some of these will be complex routes and bom’s with multiple levels of sub assembly. Each saleable part, including all of it’s sub-assemblies will be manufactured via one production order. To try to give this some context we may make a steel tank, so we would have a separate part for the right hand, left hand, top, bottom etc that come together as one saleable part which then may have other smaller part assembled onto it – foam kits etc
A customer may issue us with an order for 16, requiring delivery of 4 a week over 4 weeks – to optimise machine setup time etc we would run this as one production job with quantity of 16.
At our front end operations, for example cutting and bending operations, we will work on a full batch – so for example for an order of 16, we would cut and fold 16 left hand sides, 16 right hand sides etc all together. At subsequent operations, which may take several hours/days to complete for each unit, we would work on these one at a time and move them onto subsequent processes one at a time. For example it may take one day to weld all the sides together, once one is welded, we can paint that one and so on.
As our ops, routes, resources etc are currently setup, when I schedule this job, each operation is scheduled so that the preceding operation/sub assembly requires to be completed before you can start working on the next operation/assembly so it means that in the example above the painting op is only scheduled to start when all 16 have been welded – in our cases this could be a gap of days/weeks.
Effectively we are looking to be able to schedule a job as batch for some initial operations and for later operations switch to one piece flow. It is not Takt time as the demand is highly variable within a relative short window of time and indeed we are trying to establish where load exceeds capacity so as we can take action. Also not really level loading, as we would like the ability to flex capacity.
I’ve read the 170 page plus Tech RefGuide for scheduling and tried playing about with things like start to start, start to finish (we are currently finish to finish, with an 8 hours (shift) queue time between operations), production consumption rate, daily production capacity and also the scheduling factors like send ahead type and send ahead factor but I don’t get what I need which is the load spread smoothly across some/all operations during the life cycle of the job.
I appreciate this is a complex issue and question, but assuming anyone understands the above , has anyone setup Epicor 10 scheduling to be able to operate in this manner – please feel free to reply requesting more information.