20 Validate Master Schedules

This chapter contains these topics:

20.1 Validating Master Schedules

After you create the master schedule, validate it to ensure that you have sufficient work center capacity. Use the Rough Cut Capacity Planning (RCCP) batch program to generate capacity planning information.

In the JD Edwards World software, the same batch program generates capacity planning information for both RCCP and Capacity Requirements Planning (CRP). The only difference is in the work centers that you identified in the data selection.

The system uses the following inputs to RCCP:

  • Firm MPS work orders and routing instructions

  • Planned MPS work orders and routing instructions

If critical work centers appear in the routings of component work orders that are generated by Material Requirements Planning (MRP), then the system can also include MRP orders in RCCP, because both RCCP and CRP use the same batch program.

The system generates the following outputs from RCCP:

  • Over-capacity and under-capacity messages

  • Work center load

  • Work center load graph

  • Period summary

Rough Cut Capacity Planning consists of:

  • Identifying critical work centers

  • Identifying the pacing resource for critical work centers

  • Calculating the rated capacity for critical work centers

  • Calculating the MPS load for critical work centers

The pacing resource for critical work centers is either labor or machine, depending on which one would increase the work centers' capacity. A work center is paced by labor if adding additional employees to the work center increases capacity. A work center is paced by machine if adding machines adds capacity.

Validating the master schedule consists of the following tasks:

  • Generating Rough Cut Capacity Plans

  • Reviewing Work Schedules on Production Status

  • Reviewing Rate Schedule and Work Center Loads

20.1.1 What You Should Know About

Topic Description
Revising resource units The resource units indicate the hours that are associated with a work center for each workday on the Work Day Calendar. The system uses this information to backschedule work orders in the Shop Floor Control system and to calculate available hours for capacity planning. You can manually enter or revise resource unit information for each work center and for each workday using the Enter/Change Resource Units program.
Recalculating work center hours Use the Refresh Resource Units program to recalculate the work center hours. You can use this program only for processing data. It does not produce a printed report. However, you can view the results of the most recent refresh operation on Work Center Resource Units.

20.2 Generating Rough Cut Capacity Plans

Navigation

From Resource & Capacity Planning (G33), choose Periodic Rough Cut Capacity

From Periodic Resource/Capacity Planning (G3321), choose Rough Cut Capacity Planning

Use the Rough Cut Capacity Plan (RCCP) to compare prospective MPS resource requirements to the capacity available in critical work centers. RCCP indicates if you should revise the master schedule to create feasible work loads or improve use of limited resources.

20.2.1 Before You Begin

20.2.2 What You Should Know About

Topic Description
Reviewing RCCP After you generate RCCP, you can review the capacity load to determine if you need to change capacity or the scheduled load.
Reviewing work center load Use Review Work Center Load to display the loads and capacity information for the work center that you select. The information is dependent on the Prime Load code that you entered for the work center on Work Center Revisions.

Use the Work Center Load Graph program to view the load versus rated capacity (percent) bar chart for a work center. The numbers across the top are the percent of the rated capacity consumed by load during that period. The information is dependent on the Prime Load code that you entered for the work center on Work Center Revisions.
Reviewing period summary Use Review Period Summary to review specific items that make up the capacity load for a defined period for a work center. You can view the detail of all current and future orders that have been scheduled to enter a work center.

The system summarizes the load by period using the unit of measure that you select. The system also displays the percent of total load planned for that period for an item on an order.
Calculating rated capacity To calculate rated capacity for critical work centers, the system uses the following standard formula:

  • Number of employees (or machines) x hours per day x efficiency factor x utilization factor

You can manually calculate efficiency by dividing standard hours by actual hours. For example, if it takes a crew 10 hours to complete a job that has standard hours established at 8 hours, the crew is working at 80% efficiency (8 / 10 = .80).

For reference, the inverse (actual hours / standard hours) is called realization. The goal is to approach 1.0 realization.

Utilization is calculated by finding the number of hours in a day that the work center is actually available for working load to standards. Therefore, 100% use is an unrealistic goal because preventative maintenance, employee breaks, and other typical needs affect utilization.
Calculating MPS load You calculate the MPS load for critical work centers by using either the routing table for planned work orders (+PLO) or the routing instruction table for firm work orders (+WO) with a routing attached. If the work order is firm (header created) but does not have a routing instruction attached, the system uses the routing table. The formulas for calculating MPS load are:

  • Planned orders x pacing hours from the routing table

  • Firm orders x pacing hours from the routing instruction table

The entry in the Prime Load Code field in the Work Center Master table determines the type of pacing at the work center.

Operations are backscheduled using the same logic in the Shop Floor Control system. This operation schedule places load into the proper time frame. You must enter the time basis code and order quantity into the equation for load calculation.

The system uses the following formula to calculate the load for an operation:

  • Work order quantity x number of packing hours on routing/time basis code

The system generates messages that indicate if your load is either over- or under-capacity.

See Also :

20.2.3 Processing Options

See Section 54.6, "Planning (P3382)."

20.3 Reviewing Work Schedules on Production Status

Navigation

From Resource & Capacity Planning (G33), choose Daily Rough Cut Capacity

From Daily Rough Cut Capacity Planning (G3312), choose Production Status

Use Production Status to locate and update work center scheduling information. This workbench environment serves as a starting point for work center scheduling and the release of work to the floor. Use this program to:

  • Access work order information, including the header, the parts list, and the routing instructions

  • Display work order information, such as work center, remaining labor, and machine and setup hours

  • Sort work orders by start date, requested date, or operations status codes

  • Change the work order status code, start date, or requested date

To review work schedules on production status

On Production Status

Figure 20-1 Production Status screen

Description of Figure 20-1 follows
Description of "Figure 20-1 Production Status screen"

  1. Complete the following fields:

    • Work Center

    • Operation Status

  2. Complete the following optional field:

    • Sequence

  3. For additional information for a work order, access the detail area (F4).

Figure 20-2 Production Status (Detail) screen

Description of Figure 20-2 follows
Description of "Figure 20-2 Production Status (Detail) screen"

Field Explanation
Thru Operation Status A user defined code (system 31, type OS) used as an end point to select work order information to display.
Sequence A code that determines the sequence in which transactions are displayed. You use the From and Thru Date ranges to select transactions according to the sequence. Valid codes are:

1 – Display work orders in start date order.

2 – Display work orders in requested date order.
Machine This is the actual machine time in hours recorded against the work order.
Setup The standard setup hours you expect to incur in the normal completion of this item.
Qty Remaining This is the remaining quantity for an operation. The remaining quantity is calculated by subtracting the quantity completed from the standard quantity.

20.3.1 Processing Options

See Section 54.8, "Production Status (P31226)."

20.4 Reviewing Rate Schedule and Work Center Loads

Navigation

From Resource & Capacity Planning (G33), choose Daily Rough Cut Capacity

From Daily Rough Cut Capacity Planning (G3312), choose Work Center Schedule Review

Use Work Center Schedule Review to review the work scheduled at either a work center or line for a day, week, or month. You can also select a specific date range for which to view the load for the work center. If you need to adjust the scheduled load at the work center, you can access several different screens to make adjustments.

You can use Work Center Schedule Review for rate scheduled items and as an alternative for viewing load on a work center. A processing option allows you to include work order-generated loads before or after rate loads.

To review rate schedule and work center loads

On Work Center Schedule Review

Figure 20-3 Work Center Schedule Review screen

Description of Figure 20-3 follows
Description of "Figure 20-3 Work Center Schedule Review screen"

To locate your work center schedule, complete the following fields:

  • Branch/Plant

  • Line/Cell

  • Date From

  • Thru

20.4.1 Processing Options

See Section 54.7, "Work Center Schedule Review (P31224)."