|JD Edwards EnterpriseOne Applications Demand Flow Manufacturing Implementation Guide
|PDF · Mobi · ePub|
This chapter contains the following topics:
Before you plan production and resources, you must:
Load sales orders that represent demand into the FF30L801 table for daily plans.
Create an active line design.
This section provides an overview of daily planning and sequencing and discusses how to:
Set processing options for Daily Planning and Sequencing (PF34S002).
Select daily plans.
Define daily plans.
Add finished good orders.
Sequence planned quantities for production.
Revise generated sequences.
Set processing options for DFM Sales Order Daily Plan Audit (RF34S801).
Compare sales orders and daily plans.
To help you meet firm demand (which is represented by unfulfilled sales orders within a given time frame), the Daily Planning and Sequencing program (PF34S002) enables you to create daily production plans and then sequence the planned quantity on the line.
You create a production plan based on sales orders for which the recommended start dates are within the planning date range that you define. By setting processing options, you can also include past-due sales orders that have not been planned, as well as past due plans. When you create a plan from a sales order, the system populates the sales order and customer information fields on the plan record—for example, the sales order number and quantity, and the customer name and number—from the sales order record. You cannot edit these fields on the Define Daily Plan form. However, you can access the DFM Demand Entry program (PF30L801) and the DFM Customer Master program (PF30L301) by using the links in the Sales Order Number field and the Customer Number field. As you create the plan, the system compares the daily rate to the demand at capacity to determine whether the plan is valid.
Note:In addition, you can create finished good orders to accommodate additional demand that is not based on sales orders. You use finished good orders to smooth demand or build to forecast, if necessary. If you create a finished good order, the sales order and customer fields remain blank in the grid on the Define Daily Plan form.
After creating a valid plan, you can sequence the planned quantity for the production line using the Daily Sequencing program (PF34S001). The system provides several methods for dividing the planned quantity for sequencing purposes—for example, dividing the planned quantity by maximum or minimum order quantity that you specified for the item. You can perform sequencing multiple times and make manual changes to create an optimal production sequence. If you change the planned quantity, you have to generate new sequence records. Generating a sequence populates the Sequenced Quantity field in the grid on the Define Daily Plan form and serves as an indicator that sequencing has already been performed at least once. You can also review the result of sequencing online in the View Daily Sequence program (PF34S005).
When you complete a quantity against a plan using the Item Completions program (PF31011), the completions process populates the Completed Quantity field and the Scrapped Quantity field (if scrap exists). You can close a plan manually if you are not using JD Edwards EnterpriseOne Shop Floor Management to perform item completions.
Note:If you have created a daily plan from sales orders with related work orders, you must complete the quantities on these work orders using the Work Order Completions program (P31114). You access the Work Order Completions program from the Demand Flow Plans program (PF31013). This completion populates the Completed Quantity field and the Scrapped Quantity field on the daily plan as well.
You delete a plan by selecting it on the grid and clicking the Remove button. You can delete multiple plans at a time. Deleting a plan also deletes the corresponding sequence records. You can delete a plan only if no quantity has been reported against the plan.
Changing the planned quantity splits the plan. For example, if the planned quantity is 100 and you change it to 35, the system creates a new plan for a planned quantity of 65. If the new plan that was created from the original plan has the same planned start date, the system issues an error message, forcing the planner to enter a different planned start date. This does not apply to a finished good order.
If you modify the planned start date of a plan and if sequence records exist for the original planned start date, these sequence records are deleted. You have to generate a sequence for the new date. However, if the planned quantity and the sequenced quantity do not match for a planned start date, the system issues a warning.
|Category Codes (F34S/CC)||You can select category codes to be displayed as item attributes on the daily sequence.|
|Dividing Method for Sequencing (F34S/DQ)||These codes determine how the system divides the planned quantity into sequence quantities.|
|Order Category (F34S/OC)||These codes indicate what type of order the daily plan is based on.|
|Daily Plan Status (F34S/ST)||These codes indicate whether a plan is open or closed.|
You can print both the daily production plan and the daily sequence. You print the production plan in the Daily Plan report (RF34S003) by clicking the Print button on the Define Daily Plan form. You print the daily sequences in the Daily Sequence report (RF34S004) by clicking the Print button on the Define Daily Sequence form. Set the versions for both reports in the processing options for the Daily Planning and Sequencing program (PF34S002). You can also access both reports from the Demand Flow Daily Management menu (GF30L11).
You can also create the DFM Sales Order Daily Plan Audit report (RF34S801),which enables you to compare sales orders and daily plans. This report enables the planner to identify sales orders for which no plans have been created or daily plans for which no sales orders exist. The report also lists differences between sales orders and daily plans.
|Manage Daily Plan||WF34S002A||Demand Flow Daily Management (GF30L11), Daily Planning and Sequencing||Select daily plans by Demand Flow line, plan dates, and plan status.|
|Define Daily Plan||WF34S002B||Demand Flow Daily Management (GF30L11), Daily Planning and Sequencing
Complete the Line Name field and the planned start and end date fields on the Manage Daily Plan form. Click the Define Plan button.
|Define daily production plans based on demand.
Sequence planned quantities for production.
|Add Finished Good Order||WF34S002C||Click the Add Finished Good Order button on the Define Daily Plan form.||Add a finished good order that becomes the demand for the daily plan. You do not use this form to edit the finished good order.|
|Define Daily Sequence||WF34S001A||Click the Sequence Plan button on the Define Daily Plan form.||Revise generated sequences.|
These processing options control default processing for the Daily Planning and Sequencing program.
These processing options control whether the program displays past due plans and sales orders and whether it performs sequencing.
Specify whether the system displays past due plans. Values are:
Blank: Do not display.
Specify how many days prior to the current date you want to use to determine past due plans.
Specify whether you want to display past due sales orders. Values are:
Blank: Do not display.
Specify how many prior to the current date you want to use to determine past due sales orders.
Specify whether to sequence the plan. Values are:
Blank: Do not perform sequencing.
1: Sequence the plan.
This processing option determines whether the system displays the Sequencing group box on the Define Daily Plan form.
These processing options control which category codes the system displays in the daily sequence.
Specify the category codes from the Item Branch/Plant information that you want to display as item attributes on the daily sequence. You can use these attributes to sort sequence records.
These processing options control the version that the system uses when it calls the following programs:
If you leave either of these processing options blank, the system uses the default version, XJDE0001.
If you leave either of these processing options blank, the system uses the default version, ZJDE0001.
Enter the Demand Flow line for which you want to create a daily plan. If you have selected the integration constants for the scenario, you can select only a line that has been defined as a work center.
Enter the date range for retrieving the plans.
Enter a plan status as a search criterion.
Enter the date range for downloading sales orders. The system provides the planned start and end dates as default values, but you can override these default values.
Click to load into the grid all the sales orders with the recommended start dates that are within the specified date range. The system calculates the recommended start date for each sales order by subtracting the lean flow leadtime from the recommended completion date. The system calculates the recommended completion date by subtracting the shipment preparation time from the promised ship date of the sales order.
Note:After you have loaded the sales orders to the grid, the system displays a text message next to the Sort By field that indicates how many new records have been added to the plan
If you set the processing options to include past-due sales orders and plans, this option loads them into the grid as well. A sales order is considered past due if the promised ship date of the sales order is before the current date. A plan is considered past due if the planned start date of the plan is after the current date. If a sales order is loaded into the grid that is already planned partially, the remaining, unplanned quantity on the sales order is combined with an existing plan if the recommended start date of the sales order matches the planned start date of the plan. If no match occurs, the system creates a new plan for the remaining sales order quantity.
When you load records to the grid, the system automatically saves them.
Click to access the Select Orders form. This form displays all sales orders with recommended start dates that are within the specified planning date range. If you have set the processing options to include past due sales orders and past due plans, the form displays them as well. Pick the current and past-due sales orders, as well as past due plans that you want to plan.
Note:After you have loaded the sales orders into the grid, the system displays a text message that indicates how many new records were added to the plan.
Select to access the Add Finished Good Order form. Use this form to create a plan without a sales order. You can use this option only to add a plan. You edit the plan on the Define Daily Plan form.
You can enter a planned start date and press the Tab key to move out of the field to calculate the load summary for the production line. If you select a line in the grid, the system overwrites any date that was previously entered with the planned start date of the selected row.
Displays the total capacity of all the products that are planned to be manufactured each day on the line. This value is based on the volume for the mixed model family that you enter in the Volume Design and Product Synchronization program (PF30L201).
Displays the total planned quantity that is calculated for all the records with the planned start date displayed. You can compare this value with the daily capacity to determine the validity of the plan.
Displays the difference between the demand at capacity and the daily rate.
Displays the load percentage for the line. For example, if the calculated daily rate is greater than the demand at capacity, the line is overloaded by the difference between the two values. For example, if the demand at capacity is 100 and the daily rate is 120, the line is loaded at 120 percent.
Sort the plans by planned start date, product number, or sales order.
Indicates the end item from the sales order for which you create the plan.
Displays a quantity after you have sequenced the planned quantity.
Displays as the default value the open quantity of the sales order if you create the plan by using the Load All Orders option or the Load Selected Orders option. If you create a finished good order, the quantity from the finished good order becomes the planned quantity. You can override this quantity.
If you change the quantity to a value that is lower than the original quantity on a sales order, the system splits the line. For finished good orders, the line is not split. You can change the planned quantity to a value that is greater than the original quantity.
Displays the quantity that has not yet been planned.
Displays a value after you have completed a quantity against the plan.
Displays a value if scrap occurred during completions.
Display the values from the sales order that you downloaded.
Display as default values the recommended start and completion dates of the sales order. You can override them.
Indicates whether the plan is based on a sales order or a finished good order.
Designate the sales order as a high priority order.
Appears by default from the sales order. You can override it in the context of the daily plan without affecting the setting in the Sales Order Master table.
Indicates whether the plan is open or closed. After you complete a quantity that is equal to or greater than the planned quantity, the system sets the plan status to closed. You can also manually close a plan. If no completion against the plan exists, the system sets the planned quantity to 0. If a completion quantity has been reported, you receive an error message if you attempt to close the plan.
Indicates whether a plan is available for editing. The plan may be locked because another planner is working with it or because the planned quantity is being completed.
Select a plan record, and click this button to remove the record from the grid.
Click to re-sort the grid based on the selected sort field. This option also recalculates the open quantity of the sales order if you change the planned quantity.
Click to print the Daily Plan report (RF34S003) for all the plans with the selected line name, scenario name, and planned start date range.
Enter the planned start date for the finished good order.
Appears by default from the planned start date.
Enter the product for which you are creating a finished good order, or use the search button to select the number from the Select Primary Item form. The system validates the product number against the active line design.
If you use the Search button to select the product from the Select Primary Item form, the branch/plant appears by default in this field. If you enter the product number manually, you have to complete this field manually as well.
Enter the quantity of units that needs to be planned on a line for a given day.
Displays the scenario unit of measure for the item.
Displays by default the planned start date of the plan that you select for sequencing. If you enter a sequence date that does not match any planned start date of the listed plans, the system issues an error message.
Select the method by which the program divides the planned quantity into sequence records from the DFM Production Sequencing user-defined code table (F34S/DQ). Values are:
1: Full quantity (default)
2: Minimum order quantity
3: Maximum order quantity
4: User-specified quantity
You define the minimum and maximum order quantity for the item in the DFM Item Definition Master program (PF30L501).
This field become input-capable when you select sequencing method 4. In this case, you enter the quantity that you want the system to use when dividing the planned quantity into sequence records. This value cannot be a negative number or 0.
Click to generate the sequence records. If you created sequence records for this plan previously, clicking this button deletes the sequence and creates new sequence records. After creating new sequence records, the system calls the Define Daily Sequence form.
Click to access the Define Daily Sequence form to make manual changes to generated sequence records. If you click this button without having generated sequence records for the selected plan, the system displays a warning prompting you to generate the sequence.
To review only existing sequence records, click this button without defining a dividing method and quantity.
If you have changed the planned quantity and then want to edit sequence records, the systems prompts you to apply the net change. Click Save Changes or Save and Close to save the net change.
Note:For net change, you have to complete the Sequencing Method and Sequencing Quantity fields.
Select a value to use for sorting the sequence records. In addition to the sequence number, sales order, and product number, you can also use the item attributes that are defined in the processing options to sort the records.
(Optional) Change the sequence numbers of the generated sequence records. If you create a duplicate sequence number, the system issues an error message. This field cannot be blank.
(Optional) Increase or decrease the sequenced quantity. If you decrease the sequenced quantity, the system splits the sequence record into two lines.
When you change the quantities in the sequence records for the plan, the total sequenced quantity still has to match the planned quantity of the plan from which you generate the sequence; otherwise, the system issues an error message.
Select a sequence record, and click to remove the record from the grid.
Click to reverse any changes that you made to sequence records after you entered the Define Daily Sequence form.
Select a sequence record, and use any of the arrows below the grid to move the sequence record as desired. You can reorder the grid by:
Moving the selected records up one row.
Moving the selected records down one row.
Moving the selected records to the top of the grid.
Moving the selected records to the bottom of the grid.
Click to print the Daily Sequence report (RF34S004). This button is enabled after you generate and save sequence records or apply and save net change.
These processing options control default processing for the DFM Sales Order Daily Plan Audit program.
These processing options control which information you want to include in the audit report.
Specify the scenario for which you want to run the audit report.
Specify whether the report should include a section that lists sales orders for which no daily plans exist. If you leave this processing option blank, the system does not create this section when you run the report.
Specify whether the report should include a section that lists daily plans that do not have sales orders. The report does not include finished good orders. If you leave this processing option blank, the system does not create this section when you run the report.
Specify whether the report should include a section that shows differences between daily plans and matching sales orders. If you leave this processing option blank, the system does not create this section when you run the report.
Select Demand Flow Advanced Processing GF30L31), Sales Order Daily Plan Audit.
Run this report to compare the sales orders that you imported into JD Edwards EnterpriseOne Demand Flow Manufacturing with the daily plans that you have created. Depending on how you set the processing options, the report can have three sections:
Sales orders without daily plans.
Daily plans without sales orders.
Differences between sales orders and matching daily plans.
Note:You can run the report for any or all of these data sets.
The system can retrieve sales orders without daily plans if you have imported sales orders into JD Edwards EnterpriseOne Demand Flow Manufacturing but have not created daily production plans for any of these sales orders.
You might see daily plans without matching sales orders on the report if the sales orders for which you have created daily plans since the previous sales order import were canceled or closed and the status change was updated on the sales orders in the FF30L801 table. In this case, the report displays daily plans that are now invalid.
Use the third section on the report to list changes to the sales orders that have occurred since the previous import. This section shows differences for the following information:
Plan dates that are later than the request date.
Plan quantities that are greater than the order quantities.
Plan quantities that are less than the order quantities.
The planner should review the differences and resolve them to ensure that the production plans can fulfill the demand that was created by the sales orders.
This section provides an overview of resource management, lists prerequisites and common fields, and discusses how to:
Create a resource design.
Set up effectivity dates for the resource design.
Perform a resource simulation.
Resource management enables you to accommodate fluctuating demand. You use the resource management programs to obtain an up-to-date estimate of the number of required labor and machine resources that are needed on the line. Resource management enables you to adjust the number of available resources as well as productivity percentages to optimize the use of resources. You can also adjust the demand to determine how to use the resources most effectively.
After you define a daily plan for an item, you must determine the resource requirements and compare the requirements with available resources. To perform this analysis, you use the Resource Design program (PF34R010) to retrieve the processes that are required for creating a product. The process map determines which work content selection the resource design uses: sequence of events, standard sequence of events, or actual work content. The resource design stores the resources that are used for a given process by cell.
After you determine the resources that are required for the processes of a particular line design, you can review and revise the number of resources and their productivity. The system retrieves the labor and machine number of operations from the Mixed Model Line Design Detail table (FF30L911) and displays it in the Design Quantity field, but you can revise this value in the Current Quantity field to reflect accurately the pool of actual machine and labor resources. The system enables you to define a resource as shared by the line so that you have some flexibility when determining the number of available resources on a line. The default value for the productivity percentage is 100 percent, but you can modify it based on the experience level of the labor pools or the amount of machine uptime on the line.
Note:For shared resources, the simulation aggregates the current quantity by resource type to reflect a larger pool of available resources.
Resource designs eventually become obsolete, for example, when resources that are assigned to a particular process become unavailable. To accommodate change, you can assign effectivity dates to a resource design. Using the DFM Resource Effectivity program (PF34R011), you can maintain multiple resource designs with different effectivity dates. However, the program does not allow gaps between the effectivity date ranges of the different resource designs for a line design. The program also does not allow overlap of the effectivity date ranges of subsequent resource designs.
You can use the resource design to simulate the deployment of resources in various scenarios, based on different demand patterns. The simulation enables you to determine whether you have sufficient resources to make the daily plan feasible. You run the DFM Resource Simulation program (PF34R012) to determine the use of resources based on a given day's demand. The program calculates the required time and quantity as well as the available time and quantity of each resource. It calculates the utilization percentage by dividing the time that is required by the time that is available. A plan is not feasible if the calculation shows that any process or cell requires a capacity of more than 100 percent. In this case, the program generates an error message.
You can create a realistic production scenario either by revising the resources or by adjusting the planned demand for a product. The two sources of demand are the demand at capacity, as specified by the process map, and the production plan. Adjusting the demand of items affects the required time and resource quantity of a simulation. Adjusting the resources of a line affects the available time and quantity of a simulation. If the results are not satisfactory when you run the simulation, revise the demand or available resources until you achieve a satisfactory resource utilization.
Note:You can run the simulation only for a single day, but you can define the time horizon differently.
Before you create a resource design and perform resource simulations, you must set up the following data:
Mixed-model line design with design quantities for labor and machine resources.
Required processes and work content selection for a line design's process map.
Planned quantity from the daily production plan.
Work content for each process, as specified by standard sequence of events, sequence of events, or actual work content records.
Select the line design that provides the basis for the resource design that you are creating. Associate effectivity dates and the resource simulation with the same line design.
Enter a unique, scenario-specific name to identify a resource design. You define effectivity dates for the resource design
|Add Resource Design Detail||WF34R010C||Demand Flow Daily Management (GF30L11), Resource Design
Click the Add button on the Search for Resource Design form.
Complete the Resource Design Name and Line Design Name fields, and click the Continue button on the Add Resource Design form.
|Create a resource design.|
|Add Resource Effectivity Detail||WF34R011C||Demand Flow Daily Management (GF30L11), Resource Design Effectivity
Click the Add button on the Search for Resource Effectivity form.
Complete the Resource Effectivity Name and Line Design Name fields, and click the Continue button on the Add Resource Effectivity Header form.
|Set up the effectivity date ranges for a resource design.|
|Execute Resource Simulation||WF34R012B||Demand Flow Daily Management (GF30L11), Resource Simulation
Click the Add button on the Search for Resource Simulation form.
|Perform a resource simulation by creating resource planning scenarios iteratively to determine the most effective use of resources to carry out a plan.|
|Revise Demand||WF34R012D||Click the Revise Demand button on the Execute Resource Simulation form.||Adjust demand to eliminate overuse of resources.|
|Revise Resources||WF34R012F||Click the Revise Resource button on the Execute Resource Simulation form.||Change resource design values, such as the current quantity and the productivity percentage, to adjust the simulation.|
Displays the process that is required to produce the item.
Displays the type of resource, labor or machine, that is assigned to each process.
Indicates whether a resource is shared or dedicated. If the resource is shared, the resource simulation calculates available resources by resource type, based on the aggregated current quantities of all resources of this resource type. The default value is Shared. The values for this field are stored in the Utilization Type user-defined code table (F34R/UT).
Defines the actual number of resources that are available for a process. This number appears by default from the design quantity. You can change this value to reflect the actual resource situation for labor or machines for the processes on the line.
You define this quantity by resource type in the Designed Machines or Designed Labor Operations field in the Mixed Model Line Design program (PF30L910).
Adjust this value to reflect the actual productivity of the resources. The default value is 100%.
Enter an effectivity date range. You can enter multiple date ranges. Date ranges cannot have gaps between them, and they cannot overlap.
Enter a unique scenario-specific name to identify the resource simulation.
Select the set of effectivity date ranges of the resource design that you are using for the simulation.
Select either demand at capacity or the daily rate as the demand source to use for the simulation.
Click to complete parameter fields for the resource simulation.
Enter the start and end dates for the simulation.
Adjust this value to further adjust the efficiency estimate of the resources. The system applies this factor to the available resource calculation for all processes on the line.
Click to access the Revise Resources form.
Click to access the Revise Demand form.
Click to run the resource simulation for the time frame between the start and end dates. When the simulation is complete, the system displays the results in a grid by process. If you make changes to resources or demand, repeat the simulation to account for the changes.
Displays the available time after you run the resource simulation. The resource simulation calculates the available time based on the following formula:
Current Quantity × Productivity %× EfficiencyFactor × HE (effective hours per shift)
If the resource is shared, this value reflects the aggregate number of shared resources by resource type. The system displays the time in the work content unit of measure for the scenario.
Displays the required time. The resource simulation calculates the required time based on the selected work content type on the process map. The system retrieves the work content for the process for the item and the resource from the standard sequence of events, the sequence of events, or the actual work content record. To calculate the required time, the system multiplies this value with the quantity of planned-for products, either demand at capacity or the daily rate from the daily plan.
Displays the percentage of utilization. The simulation calculates the utilization percentage by dividing the required time by the available time. If the result of this calculation for a process is greater than 100 percent, the system generates an error message for that process.
Displays the number of available resources by process according to the associated resource design. This is the current quantity multiplied by the productivity percentage. If the resource is shared, this value is the sum of all shared resources by resource type. If the resource is dedicated, this field displays the value for that specific resource only.
The simulation calculates the required time by taking the sum of the required time divided by the sum of the demand. The result is the weighted average of the required time. Then the effective hours for that resource as stated by the line design are divided by the sum of the demand as well. The result is the weighted average of the available operation hours. The weighted average of the required time is then divided by the weighted average of the available hours to determine the required resource.