• Calculate the volume of all parts that must be run each day, based on the time available and the takt time.

• Determine the mix of the various items produced in the process. The past mix is determined by analyzing historical demand to find what percentage the item represented of the total volume of items sold. Additionally, the system looks at forecasts and customer orders to calculate the percentage this item represents in terms of anticipated future volume. You can override the future mix percent of the items based on the total demand volume for the process.

• Calculate a suggested daily level schedule by shift for each item based on the established process volume, mix, pitch, EPEI, and the sequence in which items are produced by a process. This level schedule can be manipulated and modified based upon management decisions and other factors or it can be accepted as calculated. One of the factors that may influence whether the level schedule is accepted or modified is an evaluation of future inventory performance based on calculations in Supermarket Workbench.

• Update the master production schedule (MPS). Once you are satisfied that the leveled mix is within the level volume and the buffer performance is acceptable, you can send the new schedule back to the MPS in the form of updated flow schedules.

• Kanban base data including:

• Pacemaker processes and the items they produce using Kanban Process Maintenance. See Define Processes.

• Supermarkets using Supermarket Maintenance. See Setting Up Kanban Supermarkets.

• Kanban loops for the items produced at the pacemaker processes using Kanban Master Maintenance. See Setting Up Kanban Loops.

• The time available at the process for each shift using Process Shift Maintenance. See Set Up Process Shifts.

• Optionally, depending on how process items have been defined, item total setup and run times using Process Item Operation Rollup. See Roll Up Item Data.

• Flow schedule base data, including adding the items to the production line referenced in the process record, using programs on the Flow Menu (17.21). Flow schedules may or may not already be set up for the item on the production line. See Setting Up Flow Scheduling.

• Save: Click Save when you are finished analyzing the effects of changes and want to update the database.

• Refresh: Replace the workbench data with the original values from the database. If you modified any fields, the system prompts you to continue. If you continue the refresh without clicking Save, any changes you made in the workbench are lost.

• Recalculate Totals Only: Update calculated fields based on changes you have made without creating a level schedule.

• Recalculate: Update calculated fields based on changes you have made. This updates the workbench and calculates the level schedule, but no changes are made to the database until you click Save.

• Audit Report: View a report comparing the baseline data with updates that will take place when you click Save. The report also shows the level schedule that will be generated using the current workbench values. Use this feature to analyze the effects of your changes before modifying the database.

• Calculate Audit: After clicking Update, view a report showing the basis for the level mix calculations, including an interval-by-interval summary of how quantities were allocated to shifts.

• Mix Analysis: This tab is selected when you launch the program. Initially, it displays the average historical mix percent of items produced by the process.

• Individual shifts: Use these tabs to adjust quantities per item on each shift.

• All Shifts: The system displays updated per-item summaries of the total schedule for the day.

• Level Volume and Calendar: Click to display shift subtabs, which let you view calendar and volume information. Optionally, you can enter or update time adjustments for each shift.