Understanding Line Design Calculations
Based on the product synchronization, volume design, and process map that you have defined and calculated, you can perform the line design calculations using the Mixed Model Line Design program (PF30L910). These calculations support building the actual Demand Flow manufacturing line on the shop floor. You can perform the calculations multiple times until you are satisfied with the results. You must designate as the active line design the line design that you want to use for further processing.
Before creating a line design, you must set up the line for which you want to create the line design. When you set up the line, you also define an associated JD Edwards EnterpriseOne work center. If you integrate JD Edwards EnterpriseOne Flow® Manufacturing with other JD Edwards EnterpriseOne Manufacturing systems, you must specify a work center name.
After you have set up a line, you define the line design. You can have multiple line designs for a line. When you define the line design, you associate it with a process map and retrieve the processes and their associated information from the process map. If the process map includes only one product, the line is automatically set up as a dedicated line. If the process map contains a product mix, the line is defined as a mixed model line.
After you have loaded the processes from the process map into the line design, you can change the following data:
Number of shifts per day.
Effective hours per shift.
After you have run the calculations, you can adjust the number of labor and machine operations for the process, based on the calculated values. You can override any of these fields and save the changes to the data base. The system retains these values until you recalculate the line design. At that point, the system issues a warning that the recalculation will delete the overrides.
When you run line design, the system calculates the following values:
Takt time.
Actual work content time weighted for machine and labor.
Number of required labor and machine operations per process or cell based on the data from the process map.
Takt time is the targeted amount of time that is required for machines and labor to meet the production capacity that the Demand Flow line is designed to achieve. The system calculates Takt time for each process using the effective hours per shift (HE), number of shifts (S), and demand at capacity (Dc) per process. The system retrieves the effective hours from the branch/plant. If you have not defined shifts and hours for the branch/plant, the system retrieves these values from the line-design control parameters of the default scenario. The system calculates demand at capacity by item and process like this: Total targeted volume for the product synchronization for the item × process consumption quantity (for each process in the product synchronization) + scrap add-ons + rework input + option input.
The system sums the demand at capacity for all products that share a particular process resulting in the throughput for this process. Based on these values, the system calculates Takt like this:
Takt = (HE × S) ÷ Σ (Dc)
Actual time weighted is based on the actual time that is required to complete a process, as stated on the process map. The design selection on the process map determines whether this calculation uses the actual machine or labor times from the standard sequence of events or the sequence of events, or resource times that are entered directly into the process map. The calculation is weighted by the volume of product flowing through the line. The system calculates actual time weighted for machines and labor like this:
ATW = Σ (Dc × AT) ÷ (ΣDc)
As part of line design processing, the system also calculates how many labor and machine operations are required to perform a process. This calculation assumes that actual time weighted and Takt have been calculated. The system calculates the number of labor or machine operations like this:
NumOper = ATW ÷ Takt