Master Scheduling

KMP 5903

Manufacturing Operation Management Weekly Presentation

Master Scheduling Group 7 1) Mohd Nasrull B. Abd Rahman (GS21504) 2) Edwin Chan (GS21416) KMP 5903 Manufacturing Operation Management

Content • • • • • • • • • • • • • • •

Scheduling Master Scheduling Axapta's Master Planning Software Master Schedule Types Scheduling Manufacturing Operations High-Volume Systems Gantt Load Chart Loading Sequencing Scheduling Difficulties Scheduling Service Operations Cyclical Scheduling Service Operation Problems Scheduling Workload United Airlines (Video) New process implementation, conversion schedule McDonald s (Video)

KMP 5903 Manufacturing Operation Management

Scheduling • Scheduling: Establishing the timing of the use of equipment, facilities and human activities in an organization • Effective scheduling can yield – Cost savings – Increases in productivity

KMP 5903 Manufacturing Operation Management

Master Scheduling • Master scheduling is used for: – demand management – scheduling production – validating the production schedule – managing the production schedule

• The schedules generated by master scheduling as input to other manufacturing functions, such as material requirements planning and rough-cut capacity planning. KMP 5903 Manufacturing Operation Management

Axapta's Master Planning Software Master scheduling helps to calculate what needs b) to be purchased and produced to fill a sales order: c) to deliver the amount ordered on the date scheduled, and to generate transfers between warehouses if needed. KMP 5903 Manufacturing Operation Management

Master Schedule Types Master Demand Schedule (MDS) • The MDS is a statement of demand and contains details of the anticipated shipment schedule • The master demand schedule provides an extra level of control that allows to view and modify statement of demand before creating a detailed production schedule. • Some of the demand types that the MDS considers are: – item forecasts – spares demand – sales orders – internal requisitions KMP 5903 Manufacturing Operation Management

Master Schedule Types Master Production Schedule (MPS) • The MPS is a statement of supply required to meet the demand for the items contained in the MDS. • The master production schedule defines the anticipated build schedule for critical items. • An effective master production schedule provides the basis for order promising and links the aggregate production plan to manufacturing by specific items, dates, and quantities.

KMP 5903 Manufacturing Operation Management

An example of a (very) simplified Master Production Schedule for 'Product A'.

KMP 5903 Manufacturing Operation Management

Scheduling Manufacturing Operations JAN

High-volume Intermediatevolume Low-volume Service operations

FEB

MAR

APR

MAY

JUN

Build A A Done Build B B Done Build C C Done Build D Ship

KMP 5903 Manufacturing Operation Management

On time!

High-Volume Systems • Flow system: High-volume system with Standardized equipment and activities

• Flow-shop scheduling: Scheduling for highvolume flow system Work Center #1

KMP 5903 Manufacturing Operation Management

Work Center #2

Output

High-Volume Success Factors • Process and product design • Preventive maintenance • Rapid repair when breakdown occurs • Optimal product mixes • Minimization of quality problems • Reliability and timing of supplies KMP 5903 Manufacturing Operation Management

Scheduling Low-Volume Systems • Loading - assignment of jobs to process centers • Sequencing - determining the order in which jobs will be processed • Job-shop scheduling – Scheduling for low-volume systems with many variations in requirements KMP 5903 Manufacturing Operation Management

Gantt Load Chart • Gantt chart - used as a visual aid for loading and scheduling Work Mon. Tues. Wed. Thurs. Fri. Center 1 Job 3 Job 4 2 Job 3 Job 7 3 Job 1 Job 6 Job 7 4 Job 10 KMP 5903 Manufacturing Operation Management

Loading • Infinite loading • Finite loading • Vertical loading • Horizontal loading • Forward scheduling • Backward scheduling • Schedule chart KMP 5903 Manufacturing Operation Management

Sequencing • Sequencing: Determine the order in which jobs at a work center will be processed. • Workstation: An area where one person works, usually with special equipment, on a specialized job.

KMP 5903 Manufacturing Operation Management

Sequencing • Priority rules: Simple heuristics used to select the order in which jobs will be processed. • Job time: Time needed for setup and processing of a job.

KMP 5903 Manufacturing Operation Management

Scheduling Difficulties • Variability in – Setup times – Processing times – Interruptions – Changes in the set of jobs

• No method for identifying optimal schedule • Scheduling is not an exact science • Ongoing task for a manager

KMP 5903 Manufacturing Operation Management

Minimizing Scheduling Difficulties • Set realistic due dates • Focus on bottleneck operations • Consider lot splitting of large jobs

KMP 5903 Manufacturing Operation Management

Scheduling Service Operations • Appointment systems –

Controls customer arrivals for service

• Reservation systems –

Estimates demand for service

• Scheduling the workforce –

Manages capacity for service

• Scheduling multiple resources –

Coordinates use of more than one resource

KMP 5903 Manufacturing Operation Management

Service Operation Problems • Cannot store or inventory services • Customer service requests are random • Scheduling service involves – – –

Customers Workforce Equipment

KMP 5903 Manufacturing Operation Management

Scheduling Workload United Airlines

KMP 5903 Manufacturing Operation Management

References •

Book of Operations Management, William J. Stevenson 8th edition

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http://www.mbsadvisor.com/axapta/masterscheduling.htm

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http://www.mcts.com/Master-Scheduling.html

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http://www.realtimesw.com/manufacturing/master_scheduling.htm

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http://www.master-scheduling.com/

KMP 5903 Manufacturing Operation Management

KMP 5903 Manufacturing Operation Management