QAD 2017 Enterprise Edition > User Guides > Lean Manufacturing > Using External Applications > Level Mix Workbench > Exporting Level Mix Workbench Data
  
Exporting Level Mix Workbench Data
Use Level Mix Workbench Export (17.14.19) to generate a data file containing records that you can use with an external application to analyze the historical and projected product mix required in your pacemaker processes. You can use the exported data to generate level schedules based on the product mix as well as to create or update flow schedules to support the level schedules.

Level Mix Workbench Export (17.14.19)
Use Site and Process to identify a unique kanban process. Both fields are required.
Note: The system exports data for a process only when the following are true for the process record in Kanban Process Maintenance:
Process Function is set to PACE. See Process Function.
Pitch Quantity is greater than 0. See Pitch Quantity.
If one of these conditions is not met, the system displays an error message.
Several fields in the program are the same as in Kanban Workbench Export. See Exporting Kanban Workbench Data.
Unique fields include the following:
Historical Days
Enter the number of days of historical data the system should use in average mix percentage calculations.
Future Days
Enter the number of days the system should use in selecting future demand records for export.
This value must be greater than 0 (zero) and greater than the value entered in Time Fence Days.
Time Fence Days
Enter the number of calendar days into the future, starting from today, when flow scheduled orders are considered frozen. This value defaults from Kanban Control. It is included in the export file.
This must be less than the value entered in Future Days.
Tolerance Percent
Specify the allowable tolerance percentage between the total amount planned to be scheduled and the total amount actually scheduled. This value defaults from Kanban Control. It is included in the export file.
Schedule Time Adjustments
Optionally enter up to five reference codes related to calendar adjustments specified in Process Calendar Except Maint (17.1.14). The system validates entries against that program. See Set Up Process Shifts.
These fields default from Kanban Control.
The reference codes and the associated time adjustments are included in the export file.
Time adjustments are typically used to identify such exceptions to the standard shift calendar as holidays or irregularly scheduled meetings that cannot be accounted for by shortening the shift hours.
Record Selection
The system uses the following rules in determining data to be included in the export file:
If no future forecast data is found for any items in the form of mrp_det records, average demand is used to determine future demand values. The current date is used to determine the past and future amounts. See Daily Demand.
Flow orders entered using Flow Schedule Maintenance (17.13.3) are analyzed to find orders matching the site, production line, and item with a due date within the Future Days range. The export file includes data from matching flow schedule detail (flsd_det) records. See Using Flow Schedule Maintenance.
Note: The production line specified in Kanban Process Maintenance must match the flow schedule.
If the item in the flow schedule has a different unit of measure than the pitch UM defined in Kanban Process Maintenance, the system converts quantities to the pitch UM before creating the export file.
When you use both Kanban and Flow Scheduling, you should ensure that flow orders are in kanban quantity increments. The actual flow order quantity amount (converted to the process UM if needed) is included in the export file. If this is not in the correct pitch increment, the system displays an error message.
The system does not select the following flow orders:
Orders posted to repetitive
Closed orders
Fully completed orders
Orders that have a work order number specified in Flow Schedule Maintenance
Level Mix Workbench Export and Import File Definition shows the structure of the export file created by Level Mix Workbench Export, as well as the structure needed when you return revised data to the system using an import file. The values in the fields are the same as those the system loads into Level Mix Workbench. See here for information on Level Mix Workbench.
The file includes four different record types:
H: A header record
P: Records to hold mix analysis data by item
D: Records to hold date and shift
Q: Records to hold order quantity data by date, shift, and item
The record type is in the first position of each record.
The export file includes placeholders for updated fields that will be returned to the system for import after processing by the external application. The table shows those fields in italics.

Level Mix Workbench Export and Import File Definition
 
Field Name
Format
Description
RECORD TYPE “H”
 
record_type
character
H
zero_constant
integer
0
site
character
Site of the process
process_id
character
Process
production_line
character
Production line for process. Any flow orders imported or exported must reference this production line.
hist_work_days
integer
Number of historical days to use to determine average demand
fut_work_days
integer
Number of future days used to calculate average demand
time_fence
integer
Number of days (from today) considered frozen. Flow orders in frozen dates can be changed, but will not be replanned by the workbench recalculation logic.
pitch_quantity
decimal
Pitch size for the process
pitch_um
character
Pitch unit of measure
tolerance_pct
decimal
Difference between total modified orders and total planned orders that will generate a warning message
epei_disp
integer
Indicates how EPEI displays (weeks, days, hours, minutes, etc.)
cycle_time_sec
integer
Cycle time in seconds for the process
time_adj1
character
Shift adjustment reference code
time_adj2
character
Shift adjustment reference code
time_adj3
character
Shift adjustment reference code
time_adj4
character
Shift adjustment reference code
time_adj5
character
Shift adjustment reference code
days_per_period
integer
For future use. Currently always set to 1.
takt_time_revised
decimal
New takt time as a result of order modifications (to be posted to process record)
RECORD TYPE “P”
 
record_type
character
P
zero_constant
integer
0
part
character
Item number
epei_disp_amt
decimal
EPEI converted to the desired display format
hist_demand
decimal
Total historical demand
fut_demand
decimal
Total future demand
kanban_quantity
decimal
Kanban quantity
cycle_time_sec
integer
Cycle time for item in seconds
epei_sec
integer
EPEI for item in seconds
seq_nbr
integer
Used to determine the order in which items are to be considered when being planned
seq_work
integer
Work field used to determine sequence number
mfg_seq
integer
User-defined manufacturing sequence number for this item
req_operators
decimal
User-defined required number of operators
knb_keyid
decimal
Kanban Loop ID: Internal keyid of knb_mstr record exported from the system
max_buffer
decimal
Maximum buffer size for loop
buf_adj_revised
decimal
User-entered change to maximum buffer size (can be positive or negative number)
RECORD TYPE “D”
 
record_type
character
D
shift
integer
Shift
date
date
Date
day_of_week
character
Monday, Tuesday, etc.
days_in_period
integer
Number of days in period
total_hours
decimal
Total work hours available in shift
time_adj_amt1
decimal
Time adjustments for adj category 1
time_adj_amt2
decimal
Time adjustments for adj category 2
time_adj_amt3
decimal
Time adjustments for adj category 3
time_adj_amt4
decimal
Time adjustments for adj category 4
time_adj_amt5
decimal
Time adjustments for adj category 5
time_adj_amt_other
decimal
Time adjustments for all other adj categories
avail_hours
decimal
Total hours in shift less all adjustments
frozen
Yes/No
Indicates if this is a date within the time fence horizon
time_adj_amt1_revised
decimal
User-entered amount for adjustment category 1
time_adj_amt2_revised
decimal
User-entered amount for adjustment category 2
time_adj_amt3_revised
decimal
User-entered amount for adjustment category 3
time_adj_amt4_revised
decimal
User-entered amount for adjustment category 4
time_adj_amt5_revised
decimal
User-entered amount for adjustment category 5
RECORD TYPE “Q”
 
record_type
character
Q
shift
integer
Shift (1 through 4)
date
date
Flow order date
part
character
Flow order item
ord_qty
decimal
Flow original order quantity
comp_qty
decimal
Flow quantity completed so far
wb_qty
decimal
Calculated value of ord_qty – comp_qty
frozen
Yes/No
Indicates if flow order is within the time fence horizon
seq_nbr
integer
Flow order sequence number
order_qty_revised
decimal
Revised quantity entered by user. If zero found and flow order exists, it will be deleted.