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You can associate a production line with an individual item or a product family item, enabling you to perform rate-based RCCP on the item.
The following table illustrates the repetitive resource requirements generated by the bill of resource load assuming B and C are defined as repetitive assemblies in Oracle Work in Process. Cumulative resource requirements are shown in bold.
Item | Line | Setback Days | Usage Quantity | Source Item |
---|---|---|---|---|
A | Line 1 | 4 | 2 | B |
A | Line 1 | 4 | 3 | C |
B | Line 1 | 2 | 1 | B |
C | Line 1 | 2 | 1 | C |
Table 1 - 8. Bill of Resources for A, B, and C (Page 1 of 1) |
B and C are defined as repetitive assemblies and assigned to production lines in Oracle Work in Process.
Item | Line | Line Priority | Line Speed | Max Hourly Rate | Line Hours/Day | Line Days/ Week |
---|---|---|---|---|---|---|
B | Line 1 | 1 | 75 | 100 | 12 | 5 |
B | Line 2 | 2 | 50 | 100 | 6 | 5 |
C | Line 1 | 1 | 100 | 100 | 12 | 5 |
Table 1 - 9. Production Line Details for B and C (Page 1 of 1) |
Rate-based RCCP:
Item | Master Schedule Start Date | Master Schedule End Date | Master Schedule Quantity |
---|---|---|---|
A | 07-FEB | 07-FEB | 100 |
A | 10-FEB | 10-FEB | 100 |
A | 15-FEB | 15-FEB | 100 |
Table 1 - 10. Master Schedule for A (Page 1 of 1) |
Remember that setback days for B is 4 days, and that the usage quantity for B is 2. Setback days for C is 4 days, and the usage quantity is 3. 05-FEB and 06-FEB are non workdays.
Item3 | Rate Start Date | Rate End Date | Daily Rate |
---|---|---|---|
B | 01-FEB | 01-FEB | 200 |
C | 01-FEB | 01-FEB | 300 |
B | 04-FEB | 04-FEB | 200 |
C | 04-FEB | 04-FEB | 300 |
B | 09-FEB | 09-FEB | 200 |
C | 09-FEB | 09-FEB | 300 |
Table 1 - 11. Required Dates and Required Rates for B and C (Page 1 of 1) |
The following table illustrates how the repetitive schedule allocation process would allocate the two repetitive schedules across Lines 1 and 2 using the line priorities and line speeds specified earlier.
Item | Line | Required Rate | Max Hourly Rate | Line Speed | Load Factor | Load Rate |
---|---|---|---|---|---|---|
B | Line 1 | 200 | 100 | 75 | 1.33 | 267 |
C | Line 1 | 300 | 100 | 100 | 1 | 300 |
Table 1 - 12. Repetitive Schedule Allocation (Page 1 of 1) |
In this example, the maximum hourly rate for Line 1 is 100/hour, and the line speed for item B on Line 1 is 75/hour. Rate-based RCCP would calculate the load factor for item B on Line 1 as 100/75 = 1.33.
In this example, the required rate for item B on Line 1 is 200/hour, and the load factor for item B on Line 1 is 1.3. Rate-based RCCP would calculate the load rate as 200 x 1.33 = 267 units per hour.
The previous table illustrates the required rate for each item/line combination for one day. Rate-based RCCP aggregates the load rates by line and stores them as a required rate for the line for each day within the period defined by the rate start and end dates.
The following table illustrates the required rates and dates for Line 1.
Line | Required Date | Required Rate |
---|---|---|
Line 1 | 01-FEB | 567 |
Line 1 | 04-FEB | 567 |
Line 1 | 09-FEB | 567 |
Table 1 - 13. Required Dates and Required Rates for Line 1 (Page 1 of 1) |
The following table illustrates how rate-based RCCP uses required dates to bucket the required rates for Line 1 into weekly buckets. The example assumes that the first bucket starts on 31-JAN.
Week Start Date | Line | Required Rate |
---|---|---|
31-JAN | Line 1 | 1134 |
07-FEB | Line 1 | 567 |
Table 1 - 14. Bucketed Required Dates and Required Rates for Line 1 (Page 1 of 1) |
Rate-based RCCP calculates the available rate for a production line using the following formula:
available rate = max hourly rate X line hours per day X line days per week |
Line hours per day represents the start and stop times you specify for the line in the Production Line window in Oracle Work in Process. Line days per week reflect the number of workdays in the week based on the workday calendar you defined in Oracle Bills of Material.
The following table illustrates how rate-based RCCP would calculate the available rate for Line 1 assuming that you have defined the line to be available 12 hours per day, 5 days per week. In this example, rate-based RCCP would calculate the available rate for Line 1, for the week starting 31-JAN, as 100 x 12 x 5 = 6,000 units per week.
Line | Max Hourly Rate | Line Hours/Day | Line Days/Week | Available Rate |
---|---|---|---|---|
Line 1 | 100 | 12 | 5 | 6,000 |
Table 1 - 15. Available Rate for Line 1 (Page 1 of 1) |
The following table illustrates how rate-based RCCP would calculate capacity utilization for Line 1 for the weeks starting 31-JAN and 07-FEB. In this example, the capacity utilization of Line 1 for the week starting 31-JAN is 1134/6000 x 100% = 18.9%.
Week Start Date | Required Rate | Available Rate | Capacity Utilization |
---|---|---|---|
31-JAN | 1134 | 6000 | 18.9% |
07-FEB | 567 | 6000 | 9.4% |
Table 1 - 16. Capacity Utilization (Page 1 of 1) |
Notice that the rough cut analysis reveals that Line 1 is underloaded in both weeks. This information is illustrated in the following diagram.
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