Creating and Maintaining Flow Schedules

You can create schedules to produce items on a specific flow production line within a site. A flow schedule consists of a group of flow scheduled orders, each with a required quantity and a due date within the planning period associated with the schedule, as well as an optional reference to a demand order and existing work order.

• Enter them manually using Flow Schedule Maintenance (17.13.3). You can also use this program to update existing flow schedules—for example, to modify the sequence in which the production line completes its work on a given day or move orders from one day to another as priorities change. See Using Flow Schedule Maintenance.

• Create flow scheduled orders from MRP-generated planned work orders using Import MRP Orders to Schedule (17.13.9). See Importing MRP Planned Orders to a Flow Schedule.

• Copy existing orders from an existing flow schedule to a new date range using Flow Schedule Copy (17.13.5). See Copying Flow Schedules.

Use Flow Schedule Maintenance (17.13.3) to enter or update flow scheduled orders for a production line over a specified planning period.

You can optionally reference existing demand orders and work orders on flow scheduled orders. The system synchronizes due dates and quantities between the flow schedule and referenced work orders. If you do not reference a work order, the system automatically creates a type W (Flow) work order. Type W work orders cannot be updated or processed using any of the programs in the Work Orders module.

After you enter or update schedules, the system calculates production line resource usage based on setup data. Depending on records defined for the schedule code associated with the flow schedule, the system displays resource usage and flex fence data. Additionally, if you have defined one or more flow rate codes for items on the production line, the system optionally displays usage data based on different scenarios; for example, the effect of adding a machine or an extra worker to the production line. You can use these displays to determine how effectively your production line can meet the requirements of the schedule.

Important: To avoid locking a large number of records during flow schedule entry or maintenance and to provide a method of viewing a schedule before updating the database, the system uses temporary tables to record transactions. Data is not written to the database until you are finished and are ready to save the schedule. Since no records are locked, it is possible for two users to make conflicting changes to the same schedule. While the system in most cases can detect whether existing records have been modified, it is safer to implement a business process that prevents multiple users from maintaining schedules for the same production line at the same time.

• A header frame, which lets you specify which production line will use the flow schedule, the due date for which you want to enter or update orders, and information used to calculate usage data.

In the first frame, enter basic data to identify the flow schedule and determine how the system displays data while you are maintaining it.

This must be a valid site defined in Site Maintenance, and it must be a site for which the production line has been defined in Production Line Maintenance.

Enter the schedule code that applies to this flow scheduled order. This must be a valid schedule code defined in Schedule Code Maintenance.

If a default schedule code has been defined for this production line in Production Line Maintenance, that value defaults to this field. You can change it as needed.

Schedule codes determine basic information about the schedule that the system uses to calculate dates, determine production rates, and control which types of data display in Flow Schedule Maintenance.

Enter the date this flow schedule applies to. The field defaults to the current date. The system uses this date to determine the schedule to be created or modified.

You can change the field as needed, but it cannot be earlier than the starting date for the schedule specified in Schedule Code Maintenance.

After you complete the flow schedule header, the system uses the following setup data to calculate the date range in which this schedule falls:

Optionally enter the code representing the flow rate for the items on this schedule. If this is a new schedule, the field defaults from the production line, if it specifies a default rate code. Otherwise, the default for a new schedule is blank. On an existing schedule, the value defaults from when you entered or last modified the schedule.

To determine the effects of alternate production scenarios, such as adding or subtracting machines from the production line, associate flow rates with rate codes in Rate Code by Item Maintenance or Rate Code by Type/Group Maintenance. (See Defining Flow Rate Codes.) When you enter a valid value in Rate Code and Display Physical Usage Recap is Yes for the schedule code specified, the system displays the effects of each flow rate associated with items on the schedule.

Note: If you enter a value in this field and rate codes have not been defined for all the items on the schedule, the system displays an error message during processing.

After you complete these fields, the system lists the existing orders for the scheduling period. To update an order, select it and choose Go. You can then update many of the fields in the bottom frame.

To enter a new order, select any line and change the Date and Seq fields to a unique combination. The system clears the fields so you can enter a new order assigned to that date and sequence.

If the due date is later than the end of the period you are maintaining, the system displays a warning. Although information entered for such a date is stored, it is not used in usage calculations during the current session. Next time you access the schedule for this period, that detail record does not display. Instead, open the schedule that includes the specified date to view or modify that record.

You can enter the same due date for an item more than once on a schedule. However, each instance must have a different sequence number to indicate the production line’s priorities.

If you enter an existing date/sequence number combination, the system displays data for that record. You can update most of the fields. The Change to Due Date and Seq fields are also enabled so that you can update the due date and sequence for this record.

If you enter a valid value in Work Order, the system validates that this is the same as the work order due date. If it is not, a warning message displays. The system updates the work order to match the flow schedule due date.

After a work order is linked to a flow schedule, the system synchronizes the schedule due date. You can update it here, and changes are reflected in Work Order Maintenance. However, you cannot update it in that program.

Enter a sequence number indicating the order in which this production line will perform the scheduled activities on this day. You can update these numbers when priorities change; for example, in response to a rush sales order from a key customer.

The field accepts a decimal value, which you can use to insert a new schedule between two existing entries. For example, if you already have entries for item A on 5/25 with sequence numbers 1 and 2, but you want to resequence the schedule by adding another item A order before the current sequence 2, enter 1.5 in Sequence. After you complete the schedule, the system updates the sequence numbers in the middle frame to 1, 2, and 3.

Enter the number of the item to be produced. This must be valid item for this site and production line, already defined in Production Line Item Maintenance.

An item number can be included on a flow schedule more than once, as long as each instance has a different due date/sequence combination.

If you enter a valid value in Work Order, the system verifies that this is the item on the work order. If you enter a sales order and line, the system also validates the item number.

The scheduled quantity must be expressed in the stocking unit of measure for the item. If this is different from the unit of measure, weight, or volume specified in Schedule Code Maintenance for the schedule code referenced on this flow scheduled order, a conversion factor must exist in Unit of Measure Maintenance. Otherwise, the system displays an error message.

If you enter a valid value in Work Order, the system validates that this is the same as the work order quantity. If it is not, a warning message displays. The system updates the work order to match the flow schedule quantity.

After a work order is linked to a flow schedule, the system synchronizes the schedule quantity. You can update it either here or in Work Order Maintenance.

This system-maintained field displays the quantity received for this flow scheduled order. See Receiving Completed Flow Scheduled Orders.

The work order must be for the same item or the system displays an error. In addition, if the work order due date and quantity are not the same as the flow schedule due date and quantity, warning messages display. The system then updates the work order record to match the due date and quantity on the flow schedule.

Additionally, the system automatically references a work order when you use Import MRP Orders to Schedule to add a scheduled order for an item with a purchase/manufacture code other than W (Flow manufactured) or L (Line manufactured). You cannot update the displayed values.

When you enter both work order and sales order numbers, the system determines whether the sales order is for a configured item that has been released to a type F (final assembly) work order using Sales Order Release to Work Order (8.13). If so, the work order must be the one associated with the sales order. Otherwise, an error message displays.

When you reference a work order on a flow schedule, the system synchronizes data between the Flow Scheduling and Work Orders modules. For example, you can receive completed orders using Work Order Receipt (16.11), Work Order Receipt Backflush (16.12), or Flow Schedule Receipts (17.13.7). Each program updates the Completed field in both Flow Schedule Maintenance and Work Order Maintenance.

Optionally enter the number of the demand order that created the demand to be filled by this flow scheduled order. This can be a sales order, a return material authorization (RMA) issue, a customer scheduled order, or a material order.

If you enter a value in this field, the system validates it against existing values in the sales order master table. It confirms that the specified item is included on the demand order only if you also specify a line number. Otherwise, it just validates that the order exists.

When you enter both work order and sales order numbers, the system determines whether the sales order is for a configured item that has been released to a type F (final assembly) work order. If so, the work order must be the one associated with the sales order. Otherwise, an error message displays.

This field is for reference. It appears on some reports and inquiries, and can be used to introduce a greater level of detail into the sequence of activities on a production line.

When this field is Yes, the system displays a standard transaction comments screen when you click Next. You can enter unlimited comments, with each comment up to 99 pages long.

This system-maintained field indicates whether an order has been exported for scheduling with the Repetitive or Advanced Repetitive module using Export Schedule to Repetitive (17.13.10). When it is Yes, you can no longer process this flow scheduled order using programs on the Flow menu. See Exporting Flow Schedules to Repetitive.

If the date you enter is later than the period you are maintaining, the system displays a warning. Although information entered for such a date is stored, it is not used in usage calculations during the current session. Next time you access the schedule for this period, that flow schedule does not display. Instead, open the schedule for the appropriate period to view or modify it.

The sequence number can be a decimal. For example, to resequence an order to fall between existing order sequence numbers 1 and 2, set this field to 1.5. After you click Next, the system renumbers the order lines as 1, 2, and 3.

When you finish entering or updating data, click Back when the cursor is in the Due Date field to return to the second frame, and then click Back again. Based on setup data and settings in Schedule Code Maintenance, you can use these frames to analyze how well the production line can meet the requirements shown in the schedule before you write the schedule to the database. See Defining Schedule Codes.

If the setup data is not available for a recap frame, the system does not display the frame regardless of the setting in Schedule Code Maintenance. For example, if you have not set up appropriate flex fence parameters in Flex Fence Maintenance, the recap frame and warning messages do not display.

• Takt time, also known as operational cycle time, for the current schedule on the production line. In this frame, Takt time is always displayed as the number of minutes needed to make one unit. This indicates the pace at which the production line operates to meet the current schedule. See Takt Time.

Flex fences are tools for determining whether the total required quantity to be produced on the schedule you are entering is within a specified percentage of the current period’s requirements. See Flex Fences.

When production requirements are outside the percentage specified in Flex Fence Maintenance, the system also displays a warning message in addition to the flex fence data summary.

The system displays a frame of physical usage data, expressed as the percentage of target and maximum production line capacity represented by total requirements for the planning period, under the following circumstances:

• You have associated target and maximum rates either with the applicable schedule code in Production Line Maintenance, or with the production line in Schedule Code Maintenance.

You can use time usage calculations to determine the effects of alternate resource scenarios on the production line’s ability to meet schedule requirements effectively. See Checking Time Usage in a Schedule.

The system displays time usage data in two formats—for the entire schedule period or for each individual day in the period—only under the following circumstances:

• The appropriate field—Display Time Usage Recap or Display Daily Time Usage Recap—is Yes for the applicable schedule code record in Schedule Code Maintenance.

After displaying the appropriate data summaries, the system prompts you to take an action regarding the flow schedule by entering one of following values:

1: Accept new flow schedules and changes to existing schedules. The system displays a status screen during processing, followed by a summary of the number of schedules processed for each day of the period. Updated records are written to the database from the temporary table used during data entry.

2: Edit the schedule. The system returns to the summary frame so you can continue to enter or update records. Changes made or new records entered during this session are not yet saved in the database.

3: Cancel. The system clears the temporary table created during this session, and the program returns to the header frame. No changes are saved in the database. Any new or modified data you entered in the program is discarded; existing schedules saved during earlier sessions are not affected.

Use Import MRP Orders to Schedule (17.13.9) to select planned work orders for specified items and add them to flow schedules for the appropriate production lines.

Enter selection criteria for the items that will have planned orders added to flow schedules. To limit the selection to items that are usually produced on a flow line, set Include Flow Items Only to Yes. Set Update to No to review a report on the effects of running this program before updating the database.

When you click Next, the system looks for MRP-planned (status P) work orders for the items matching the selection criteria. If the item is not assigned to a production line in Production Line Item Maintenance, it is skipped. If it is assigned to multiple production lines, the system uses the Preference value from Production Line Item Maintenance to determine the production line where the order will be scheduled. See Associating Items with Production Lines.

Based on the planned order due date, the system assigns each work order to the production line flow schedule for the appropriate period. If a schedule already exists for that date, the system assigns the next available sequence number. After importing the orders to flow schedules, you can update sequence and date information using Flow Schedule Maintenance.

If the item on an imported schedule has a purchase/manufacture code of W (flow), the system changes the work order type to W. (See Purchase/Manufacture Codes.) Otherwise, the work order type is left blank. In either case, the system sets the work order status to E (exploded). It then follows standard work order processing: Bill of material (BOM) and routing records are created based on item master data, and the product structure is re-exploded using the latest BOM and routing information available. The release date is calculated based on the due date.

The copied order includes much of the same data as the original, such as site, production line, item number, and schedule quantity. The due date is modified based on the specified target date range. Other values in the new record are blank even if the source order included values in the corresponding fields; for example, the system does not copy references to sales orders or work orders, and the Completed field is set to 0 (zero).

For each flow scheduled order copied, the system creates a new type W (flow) work order just as it does when you enter a new order using Flow Schedule Maintenance.

Enter the range of dates you want schedules to be copied from, as well as the target start date for the newly created schedules. Using the specified selection criteria and a calculated target date range based on due dates for existing schedules, the system copies existing flow schedules to the corresponding dates in the target date range.

For example, you enter a source date range of 5/15/02 to 5/22/02 and a target date of 6/15/02. The systems finds schedules with due dates of
5/16, 5/19 and 5/20 that match the selection criteria. It copies the data from those schedules into new schedules with due dates of 6/16, 6/19, and 6/20.

To see the effects of this program without actually copying orders, set Update to No. Then review the output report, adjust selection criteria as required, and run the program again with Update set to Yes.

No: The system does not create a new schedule for that order. On the output report line for that order, Source From Due Date is blank and Existing Schedule displays Yes.

Yes: The system adds the quantity from the copied order to the existing flow scheduled order. On the output report line for that order, the same due date displays in both Source From Due Date and Schedule Due Date. Additionally, Existing Schedule displays Yes.

The system also adds the quantity to the associated work order for the target date. This can be either the system-generated type W work order or the standard work order referenced in the Work Order field. See Work Orders.