Rockwell-automation FactoryTalk Scheduler Users Guide Manual do Utilizador

USER’S GUIDESchedulerPUBLICATION SCHED-UM001F-EN-E–August 2007Supersedes Publication SCHED-UM001E-EN-PProduction ManagementINTEGRATED PRODUCTION &

FACTORYTALK SCHEDULER USER’S GUIDE4• • • • •Get phone supportThe Rockwell Automation support team of outstanding professionals provides top-notch

FACTORYTALK SCHEDULER USER’S GUIDE94• • • • •developed is a “2 by 5 Pool 4,” which is what we need. If we attach this time pattern to our Labor re

7 • SCHEDULE ANALYSIS95• • • • •One might conclude that Case 8 provides the best results. It also yields one of the better values for the latest e

FACTORYTALK SCHEDULER USER’S GUIDE96• • • • •would be the scheduling of a preventive maintenance activity or a breakdown, which only applies to on

97AGlossaryActivity Area—a generic term for sites, areas, or lines within a production enterprise. An enterprise may contain one or more sites, which

FACTORYTALK SCHEDULER USER’S GUIDE98• • • • •Composite Time Pattern—a base pattern with exceptions that is used to define a shift pattern for a re

A • GLOSSARY99• • • • •generated to produce components or subassemblies to-stock that are required for manufacturing orders for finished products.

FACTORYTALK SCHEDULER USER’S GUIDE100• • • • •Operation Constraint—a restriction placed on the duration, start, or end time of an operation. Opera

A • GLOSSARY101• • • • •Primary Resource—a resource that is specified as a primary resource at a work cell. Every work cell has a primary resource

FACTORYTALK SCHEDULER USER’S GUIDE102• • • • •Resource Efficiency—alters the rate at which work is performed using a resource. The actual work dur

A • GLOSSARY103• • • • •Time Pattern—a collection of calendar values, shift states, or other time patterns that have been assigned to specific blo

1 • WELCOME TO FACTORYTALK SCHEDULER5• • • • •Get on-site supportFor on-site support, Rockwell Automation field support engineers are located arou

FACTORYTALK SCHEDULER USER’S GUIDE104• • • • •

105BProcess PlansSHP RED BICYCLESHP BLUE BICYCLESeq # Operation Work Cell Setup Time Process Time Additional Resources Notes 10 Assemble and Pack S

FACTORYTALK SCHEDULER USER’S GUIDE106• • • • •SSD RED BICYCLESSD BLUE BICYCLESeq # Operation Work Cell Setup Time Process Time Additional Resour

B • PROCESS PLANS107• • • • •SHP RED FINISHED FRAMESHP BLUE FINISHED FRAMESSD RED FINISHED FRAMESeq # Operation Work Cell Setup Time Process Tim

FACTORYTALK SCHEDULER USER’S GUIDE108• • • • •SSD BLUE FINISHED FRAMESHP FRAMESeq # Operation Work Cell Setup Time Process Time Additional Resou

B • PROCESS PLANS109• • • • •SSD FRAMEHANDLEBAR ASSEMBLYHANDLEBARSeq # Operation Work Cell Setup Time Process Time Additional Resources Notes 1

FACTORYTALK SCHEDULER USER’S GUIDE110• • • • •NECK POSTSEAT ASSEMBLYSEAT POSTSeq # Operation Work Cell Setup Time Process Time Additional Resour

111CMRP ChartsSHP Red BicycleLEVEL: 0 LEAD TIME: 1SHP Blue BicycleLEVEL: 0 LEAD TIME: 1SSD Red BicycleLEVEL: 0 LEAD TIME: 1Period 2/10 2/11 2/12 2/13

FACTORYTALK SCHEDULER USER’S GUIDE112• • • • •SSD Blue BicycleLEVEL: 0 LEAD TIME: 1SHP Red Finished FrameLEVEL: 1 LEAD TIME: 1 LOT SIZE: 24SHP Blu

C • MRP CHARTS113• • • • •SSD Red Finished FrameLEVEL: 1 LEAD TIME: 1 LOT SIZE: 24SSD Blue Finished FrameLEVEL: 1 LEAD TIME: 1 LOT SIZE: 24Handleb

FACTORYTALK SCHEDULER USER’S GUIDE6• • • • •

FACTORYTALK SCHEDULER USER’S GUIDE114• • • • •Seat AssemblyLEVEL: 1 LEAD TIME: 1 LOT SIZE: 75Pedal and Chain AssemblyLEVEL: 1 LEAD TIME: 3 LOT SIZ

C • MRP CHARTS115• • • • •WheelsLEVEL: 1 LEAD TIME: 3 LOT SIZE: 48Derailleur AssemblyLEVEL: 1 LEAD TIME: 4 LOT SIZE: 60Seat PostLEVEL: 2 LEAD TIME

FACTORYTALK SCHEDULER USER’S GUIDE116• • • • •HandlebarLEVEL: 2 LEAD TIME: 3 LOT SIZE: 100Neck PostLEVEL: 2 LEAD TIME: 3 LOT SIZE: 60SHP FrameLEVE

C • MRP CHARTS117• • • • •SSD FrameLEVEL: 2 LEAD TIME: 4 LOT SIZE: 50SeatLEVEL: 2 LEAD TIME: 2 LOT SIZE: 100Period 2/10 2/11 2/12 2/13 2/14 2/17 2

FACTORYTALK SCHEDULER USER’S GUIDE118• • • • •

119DTime Pattern EditorsIn this appendix, we’ll introduce the three available time pattern editors and show you how to use them in the context of Fact

FACTORYTALK SCHEDULER USER’S GUIDE120• • • • •3 hours, the machine would be available and processing at a 90% rate (capacity of 1 and efficiency o

D • TIME PATTERN EDITORS121• • • • •Now we’ll show you how to develop this time pattern under a different name. To do this, right-click in the Tim

FACTORYTALK SCHEDULER USER’S GUIDE122• • • • •

D • TIME PATTERN EDITORS123• • • • •We’ll leave the Default Value as the Unavailable state. Next click on the button to the right of the Duration

72The BizBikes Factory Introducing BizBikesThis chapter describes a sample company, BizBikes Inc., whose manufacturing system will be referred to in u

FACTORYTALK SCHEDULER USER’S GUIDE124• • • • •Accepting this dialog will populate the first row of the grid with your values. Note that the graph

D • TIME PATTERN EDITORS125• • • • •the time span grid and assign the new My Shift 1 time pattern to the hours from 7 to 15 for Monday, as shown b

FACTORYTALK SCHEDULER USER’S GUIDE126• • • • •The only difference between this new time pattern and the 2 By 5 Machine time pattern is that we did

D • TIME PATTERN EDITORS127• • • • •The resulting 2 By 5 Pool 3 time pattern looks very similar to the 2 By 5 Machine time pattern, except for the

FACTORYTALK SCHEDULER USER’S GUIDE128• • • • •Now let’s assume that one of your resources performs at a 90% level. Let’s develop a new efficiency

D • TIME PATTERN EDITORS129• • • • •be State and the Value to be the state Unavailable. Now use the drop-down arrows to open the calendar and set

FACTORYTALK SCHEDULER USER’S GUIDE130• • • • •would want to attach the 2 By 5 Pool 3 time pattern to the Capacity selection of the Labor resource

D • TIME PATTERN EDITORS131• • • • •

FACTORYTALK SCHEDULER USER’S GUIDE132• • • • •

133IndexAActiveX Data Objects (ADO)  1activity area  97activity-based costing  97additional resources  24, 97Adjust > Check Sequence menu o

FACTORYTALK SCHEDULER USER’S GUIDE8• • • • •BizBikes business problemsBizBikes has been losing market share to competitors due to both pricing pre

FACTORYTALK SCHEDULER USER’S GUIDE134• • • • •composite time pattern  98constrained system modeling  23material  23operation  23resource

INDEX135• • • • •GGantt chart  39good order  98HHandlebar  18Handlebar Assembly  18help online  3heuristic rules for sequencing  41Hi

FACTORYTALK SCHEDULER USER’S GUIDE136• • • • •Adjust > Validate Op On Drop  76Database  61, 65, 93Database > Time Pattern > Composite

INDEX137• • • • •predefined job preference rulesDynamic Highest Order Property Field  50Dynamic Lowest Order Property Field  50Highest Order

FACTORYTALK SCHEDULER USER’S GUIDE138• • • • •Schedule Analyzer  80Schedule Analyzer menu option  80schedule evaluation  76Schedule File Ord

INDEX139• • • • •Smallest Operation Slack Time  51Smallest Order Slack  56Smallest Order Slack Time  51Smallest Processing Time  52, 56Sm

FACTORYTALK SCHEDULER USER’S GUIDE140• • • • •Work-in-Process (WIP)  103www.rsbizware.com  9Zzero efficiency  27

2 • THE BIZBIKES FACTORY 9• • • • •Learn more about RSBizWareSee how RSBizWare solutions impact the BizBikes manufacturing system by visiting www.

FACTORYTALK SCHEDULER USER’S GUIDE10• • • • •

113The Factory OverviewThe BizBikes manufacturing systemTo begin our assessment of the BizBikes factory, we’ll first examine their manufacturing syste

FACTORYTALK SCHEDULER USER’S GUIDE12• • • • •(frames, handlebars, etc.) as well as final assemblies. The components are produced to-stock and are

3 • THE FACTORY OVERVIEW13• • • • •Order # Product Name Order Quantity Release Date Due Date SHP Red 1 SHP Red Bicycle 15 2/11/03 11 PM 2/12/

iiContact RockwellCustomer Support Telephone — 1.440.646.3434Online Support — http://www.rockwellautomation.com/supportCopyright Notice© 2007 Rockwell

FACTORYTALK SCHEDULER USER’S GUIDE14• • • • •The BizBikes manufacturing resourcesThe BizBikes manufacturing plant contains seven work cells (Cut,

3 • THE FACTORY OVERVIEW15• • • • •ASSEMBLY AND PACKThese work cells are used to assemble and pack the finished BizBikes. The setup and process (p

FACTORYTALK SCHEDULER USER’S GUIDE16• • • • •This matrix shows the setup time for an operation based on the previous production lot that was proce

3 • THE FACTORY OVERVIEW17• • • • •The components required before this operation can be started are the manufactured parts SHP Red Finished Frame,

FACTORYTALK SCHEDULER USER’S GUIDE18• • • • •SHP Frame PlanHANDLEBAR ASSEMBLYThe process plans for the handlebar assembly contain a single subasse

3 • THE FACTORY OVERVIEW19• • • • •adequate materials will be available. The process plan for Handlebar is summarized below.Handlebar PlanNECK POS

FACTORYTALK SCHEDULER USER’S GUIDE20• • • • •SEAT ASSEMBLYThe process plans for the seat assembly contain a single subassembly operation. In this

3 • THE FACTORY OVERVIEW21• • • • •Purchased componentsIn addition to the manufactured components, we also have purchased components that are used

FACTORYTALK SCHEDULER USER’S GUIDE22• • • • •InventoriesWe have a starting inventory level for both the manufactured and the purchased material. T

234Scheduling FeaturesFactoryTalk Scheduler provides a wide range of features for modeling constrained scheduling systems. There are four basic catego

iii1 • Welcome to FactoryTalk Scheduler 1What is FactoryTalk Scheduler?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACTORYTALK SCHEDULER USER’S GUIDE24• • • • •also restrict what operations can be processed at the same time by requiring that certain operation a

4 • SCHEDULING FEATURES25• • • • •called Assembly and Pack Area 1 and Assembly and Pack Area 2. We will associate a 1/5-shift pattern with all the

FACTORYTALK SCHEDULER USER’S GUIDE26• • • • • Let us assume that FactoryTalk Scheduler is going to schedule an operation that requires a primary r

4 • SCHEDULING FEATURES27• • • • •as shown below. Although this operation time is six hours, this particular process spans a nine-hour period beca

FACTORYTALK SCHEDULER USER’S GUIDE28• • • • •Although the operation could start at 4 PM, there is only one unit of labor available from 3PM to 9 P

4 • SCHEDULING FEATURES29• • • • •Sequencing constraintsSequencing constraints are normally a part of the product or job routing and determine the

FACTORYTALK SCHEDULER USER’S GUIDE30• • • • • all operations with lower root numbers and a fewer number of suffixes must precede that operation,

4 • SCHEDULING FEATURES31• • • • •The second example extends the previous one by allowing two sets of parallel operations. In this example, the fi

FACTORYTALK SCHEDULER USER’S GUIDE32• • • • •The third example illustrates how to use the numbering schemes to allow a series of operations to be

4 • SCHEDULING FEATURES33• • • • • 10.1.1.1(10)20.1.1.1(20)30.1.1(40)10.1.1.2(30)10.1.2(50)20.1.2(60)20.1.3.1(80)20.1.3.2(90)10.1.3(70)30.1.3(100)

FACTORYTALK SCHEDULER USER’S GUIDEiv• • • • •Primary and additional resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACTORYTALK SCHEDULER USER’S GUIDE34• • • • •The final example illustrates a non-traditional network routing structure. Project management and mai

4 • SCHEDULING FEATURES35• • • • •product bill of materials and indicates the amount of each material item required and where in the routing it is

FACTORYTALK SCHEDULER USER’S GUIDE36• • • • •attempt to allow the scheduling of the initial item. If there are insufficient material-replenish ord

4 • SCHEDULING FEATURES37• • • • •A similar feature allows an operation process time to have a resource product dependency.FactoryTalk Scheduler a

FACTORYTALK SCHEDULER USER’S GUIDE38• • • • •

395Scheduling ConceptsFactoryTalk Scheduler incorporates both an algorithmic and a simulation-based scheduler. This chapter describes finite-capacity

FACTORYTALK SCHEDULER USER’S GUIDE40• • • • •In this simple example, Job A consists of two operations that are defined by sequence numbers 10 and

5 • SCHEDULING CONCEPTS41• • • • •repeats this process until all jobs (and therefore, all operations) have been loaded. Each operation is loaded o

FACTORYTALK SCHEDULER USER’S GUIDE42• • • • •(due date and slack time) focus on reducing the number of late jobs, whereas the priority-based rule

5 • SCHEDULING CONCEPTS43• • • • •Although the idea of constructing a schedule that has no late jobs is appealing, backward sequencing has some pr

CONTENTSv• • • • •Set the planning horizon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Attach

FACTORYTALK SCHEDULER USER’S GUIDE44• • • • •as an available ranking order property. FactoryTalk Scheduler will automatically list all specified o

5 • SCHEDULING CONCEPTS45• • • • •SCHEDULING EXAMPLE 4The following sets of figures illustrate the simulation-based construction process. In each

FACTORYTALK SCHEDULER USER’S GUIDE46• • • • •STEP 4: LOAD OPERATION B-20STEP 5: LOAD OPERATION C-20The first step in the simulation-based sequence

5 • SCHEDULING CONCEPTS47• • • • •Selection rulesIn a simulation-based sequencer, there are two types of selection rules that can be applied each

FACTORYTALK SCHEDULER USER’S GUIDE48• • • • •determines which operation to load. This rule is the key factor that determines the quality of the re

5 • SCHEDULING CONCEPTS49• • • • •and selects the desired operation using any appropriate logic. This type of rule gives complete flexibility in t

FACTORYTALK SCHEDULER USER’S GUIDE50• • • • •Tardiness, Minimum Job Flow Times, and Maximum Facility Capacity. We will discuss each of these core

5 • SCHEDULING CONCEPTS51• • • • •The predefined job preference rules are generally used in situations where the characteris-tic of the job (e.g.,

FACTORYTALK SCHEDULER USER’S GUIDE52• • • • •work (rather than number of operations) to be done. The basic premise is that the remaining slack tim

5 • SCHEDULING CONCEPTS53• • • • •Maximum Facility Capacity category ignore the job due date and are focused on generating a schedule that is effi

FACTORYTALK SCHEDULER USER’S GUIDEvi• • • • •SHP Blue Finished Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACTORYTALK SCHEDULER USER’S GUIDE54• • • • •increase until no orders remain with the same or larger campaign value. When this occurs, the rule th

5 • SCHEDULING CONCEPTS55• • • • • The Non-Bottleneck Earliest End Time rule selects the non-bottleneck resource that will complete the operation

FACTORYTALK SCHEDULER USER’S GUIDE56• • • • • Fewest Remaining Operations (static): The operation whose job has the fewest remaining operations i

5 • SCHEDULING CONCEPTS57• • • • • Campaign Sequence Cycle: The operation with the same or next highest (lowest) campaign value is selected. The

FACTORYTALK SCHEDULER USER’S GUIDE58• • • • • Timed Least Setup With Campaign: The operation with the least setup time and the closest campaign v

596Using FactoryTalk SchedulerIn Chapter 3 we introduced our tutorial system, and in Chapter 4 we discussed the basic FactoryTalk Scheduler modeling f

FACTORYTALK SCHEDULER USER’S GUIDE60• • • • •Thus, the first time you load a new FactoryTalk Scheduler application, you will have to set up your p

6 • USING FACTORYTALK SCHEDULER61• • • • •Attach a databaseSelect the Database > Attach menu option to open the Connect To Database dialog that

FACTORYTALK SCHEDULER USER’S GUIDE62• • • • •Select the database from the drop-down list (BizBikes) and click the Next button. The last dialog req

6 • USING FACTORYTALK SCHEDULER63• • • • •Once all the data is read in, our resource names will be displayed down the left side of the Sequence Ov

11Welcome to FactoryTalk SchedulerWelcome to FactoryTalk Scheduler, the state-of-the-art finite-capacity system that will help you gain control of you

FACTORYTALK SCHEDULER USER’S GUIDE64• • • • •Now we’ll open the Unallocated Jobs window by using the View > Unallocated Orders/Operations windo

6 • USING FACTORYTALK SCHEDULER65• • • • •and save the fcs file, these changes will automatically be used when you recall an application using the

FACTORYTALK SCHEDULER USER’S GUIDE66• • • • •Unallocated Jobs Window and places them on the planning board. The resulting schedule is shown next.E

6 • USING FACTORYTALK SCHEDULER67• • • • •The Attributes windowYou can get more information about each operation by placing your mouse cursor on a

FACTORYTALK SCHEDULER USER’S GUIDE68• • • • •If you want to view the schedule of the Handlebar 1 order in the context of the entire schedule, you

6 • USING FACTORYTALK SCHEDULER69• • • • •When you activate this option, all operations that are not a part of the Handlebar 1 order are grayed ou

FACTORYTALK SCHEDULER USER’S GUIDE70• • • • •Labor resource and overlay the time patterns for the Labor and Cutter resources, your overview should

6 • USING FACTORYTALK SCHEDULER71• • • • •use this procedure, your resulting Sequence Overview window, or the default Gantt view, should resemble

FACTORYTALK SCHEDULER USER’S GUIDE72• • • • •This results in a new view being created and assigned the name “Fabrication.” Note that this is basic

6 • USING FACTORYTALK SCHEDULER73• • • • •If you accidentally hide a resource that should be visible, simply right-click in the resource area of t

FACTORYTALK SCHEDULER USER’S GUIDE2• • • • •you to check the schedule performance against the defined objectives and adjust the schedule if necess

FACTORYTALK SCHEDULER USER’S GUIDE74• • • • •Manually edit a scheduleOnce you develop a partial or complete schedule, you can also use the drag-an

6 • USING FACTORYTALK SCHEDULER75• • • • •resource—the “Cut Neck Post” operation. Move it to the right and note the change in the window. A plus “

FACTORYTALK SCHEDULER USER’S GUIDE76• • • • •If you have these other types of constraints, you can get information on their validity by selecting

6 • USING FACTORYTALK SCHEDULER77• • • • •Orders are considered to be on time by comparing their order end dates/times to the order due date times

FACTORYTALK SCHEDULER USER’S GUIDE78• • • • •Holding your cursor over the chart will display the legend. In this case, the bars represent the idle

6 • USING FACTORYTALK SCHEDULER79• • • • •February 17 to midnight Saturday, February 22, we’ll get a more representative utilization chart. The n

FACTORYTALK SCHEDULER USER’S GUIDE80• • • • •typical information that is included in most applications. These include two activity-based costing r

6 • USING FACTORYTALK SCHEDULER81• • • • •Clicking on the Neck Post 2 order causes the operations of the order to be displayed in the operations s

FACTORYTALK SCHEDULER USER’S GUIDE82• • • • •This window provides additional information on the selected operation. The upper-left part of the win

6 • USING FACTORYTALK SCHEDULER83• • • • •Close the Operation Constraints window and scroll down the on-time orders until you find the SHP Red 6 o

1 • WELCOME TO FACTORYTALK SCHEDULER3• • • • •technical support group. Additionally, electronic copies of the FactoryTalk Scheduler Customization

FACTORYTALK SCHEDULER USER’S GUIDE84• • • • •Now let’s turn our attention to the Material Prerequisites. This section lists all the materials requ

6 • USING FACTORYTALK SCHEDULER85• • • • •A section of the Scheduled Orders report showing the orders due on 2/11/03 is shown below. In the actual

FACTORYTALK SCHEDULER USER’S GUIDE86• • • • •Where desirable, the information in a report also can be displayed in a graphical format. For example

877Schedule AnalysisIn Chapter 6, we covered the basic procedures for using the FactoryTalk Scheduler system. In this chapter, we will show you how to

FACTORYTALK SCHEDULER USER’S GUIDE88• • • • •This filter option uses the data in the last auxiliary Boolean attribute field for orders to determin

7 • SCHEDULE ANALYSIS89• • • • •This portion of the Baseline Comparison provides summary performance measures, much like the Performance Metrics w

FACTORYTALK SCHEDULER USER’S GUIDE90• • • • •the third column show the relative percent of change between the two schedules using the base schedul

7 • SCHEDULE ANALYSIS91• • • • •to the database. Thus, they will be lost when you exit the FactoryTalk Scheduler session. This method is best used

FACTORYTALK SCHEDULER USER’S GUIDE92• • • • •Now if we develop a schedule using simulation, it will use these new rules. This results in a schedul

7 • SCHEDULE ANALYSIS93• • • • •Now, use the Sequence > Forward > By Release Date menu option to schedule the remaining orders.Reviewing the