Calculating Operation Durations

Operation durations are calculated as follows:
Tkbs1 = t (k-1)bt
Tkbs2 = operation duration * ceil (k * transport batch / operation batch)
Tkbs = max (tkbş1; tkbs2)
Tkbt = tkbş + ts
The end time of the last operation is processed if tkbs is greater than the end time of the last operation.
Calculating Material quantities to be used in production
Calculation of factors for BOM:
a= Product quantity to be used in Production Order / BOM product quantity
b= Product unit to be used in Production Order / BOM product unit
Factor = a * b
If Scalable option is selected for any material, the formula is defined as: Planned quantity in main unit to be used in Production Order= Factor * BOM Quantity including Scrap * Unit / Main Unit on BOM
Example
The following example can be examined to further explain the planning process:
Material Definitions
CodeDescriptionUnitProcurement TypeMaterial Withdrawal
Mshm1 Black leather footpurchaseWhen order starts
Mshm2Brown leather foot purchaseWhen order starts
Mshm3Solepair purchaseWhen order starts
Mshm4Thick leatherpair purchaseWhen order starts
Mshm5Shoelace pairpurchaseWhen order starts
Mshm7Brown insole pair purchaseWhen order starts
Mshm8Velcropair purchaseWhen order starts
Msmm1Black shoepair productionWhen order starts
Msmm2Brown shoepair productionWhen order starts
Msym1Black insolepair productionWhen order starts
Msym2Brown insolepair productionWhen order starts
Ms2Insole classpair productionWhen order starts

Ms1Shoe material class
msmm1Black shoe product
msmm2Brown shoe product
Shoes ms 1 pair







Insole ms 1 pair
Shoelace hm 1 pairSole hm 1 pair
Insole hm 1 pair
Thick leather hm 1 pair






Leather hm
25 shoes




Shoe Routing

Ms2Insole material class
msym1Semi finished insole with black leather
msym2Semi finished insole with brown leather
Insole Routing

Assuming that routes are not overlapped, line information of operations would be as follows:

In cutting and stitching machines, raw material warehouses are used as raw material warehouses, while in assembly and polishing machines raw material warehouses are used as semi finished product warehouses and semi finished product warehouses are used as product warehouses.
The plant in our example does not work on Saturdays and Sundays. Working hours for Employees and Work Stations are from 08:00 to 18:00. BOM definition of shoe material class is as follows:
Shoelace material should be processed with polishing operation. Salpa is not displayed on Production Order lines if the related Production box is not checked.
The BOM definition of semi finished insole product class would be as follows. The following BOM is selected on two Pseudo Semi Finished Good lines of the shoe material class BOM:
It is assumed that Velcro can be used instead of shoelace and that one Velcro is the alternative of one shoelace. It is known that 50 pairs of lacing are available in the Central warehouse, 30 pairs of Velcro are available in the raw material warehouse and 10 pairs of Velcro in the Central warehouse. Assuming that "Enable Lot Tracking" option is selected for leather raw materials and FIFO option is checked as the Lot Determination Method in usage, the following quantities are available in the Central warehouse:
Material Lot NumberEntry Date
Black leather 1500 feetl0101012002
Brown leather 1500 feet l0101012002
Black leather 1000 feetl0206082002
Brown leather 1000 feet l0206082002
Assuming that a Production Order for 100 pairs of black shoes is issued with an end date of September 5, 18:00 o'clock and that the scheduling method is selected as Backwards, Production Order lines can be checked using "Calculate" option located in the right mouse button menu.



When Production Order is recorded, Release operation, in other words, the calculation of planned dates is also performed.
The planned start and end dates of the Production Order are calculated as 02/09 at 08:00 and 05/09 at 18:00 respectively. Planned slips generated in accordance with this order are:
Black leather Usage Slip dated 02/09 from the raw material warehouse,
Black insole Input from Production Slip dated 03/09 to semi finished product warehouse,
Sole and insole Usage Slip dated 04/09 from raw material warehouse,
Black insole Usage Slip dated 04/09 to semi finished product warehouse,
Shoelace Usage Slip dated 05/09 from raw material warehouse,
Black shoe Input from Production Slip dated 05/09 to product warehouse.
When a Material Procurement operation is performed for this Production Order,
30 pairs are displayed on the Fulfilling from Stock field of the shoelace material line. When the Fulfilled from Stock window is opened, it can be seen that 30 pairs of Velcro present in the raw material warehouse are used as the alternative of shoelace. A Warehouse Slip is generated for raw material warehouse in the Procurement Transactions section for 50 pairs of shoelace and 10 pairs of Velcro available in the central warehouse. An Order Slip is suggested for the remaining 10 pairs. The material to be ordered is the one used the most in this order. In other words, since 50 pairs of shoelace and 40 pairs of Velcro are used in the Production Order, 10 pairs of shoelaces should be ordered. If the quantity of Velcro used was more than the shoelace, Velcro would have been the material to be ordered.