Understanding Volume Design
Demand at capacity (Dc) is the highest targeted volume of product, as defined by management, to be produced on a manufacturing line, typically in one day. You use Demand Flow techniques to create a line design that supports output to match demand at capacity.
The Volume Design and Product Synchronization program (PF30L201) enables you to:
Define demand for mixed model families and products within each family.
Define demand for subassemblies that are used to build products.
Assign a product synchronization to each product.
When you define a volume design, you associate it with one or more mixed model families and enter the volume for each mixed model family. The system stores this volume assignment in the FF30L202 table.
You can qualify the volume that you enter by assigning one of the following demand types:
Statistical/historical percent.
Target capacities.
User-defined.
After assigning a volume on the mixed-model family level, you specify the demand for products within mixed model families. The system provides two methods for entering demand for individual products:
Assign individual product volume as a percentage of the mixed-model family volume.
To assign volumes to individual products in a mixed model family, you must select the products that you want to include. The percentages that you assign to the selected items have to add up to 100 percent.
Enter independent demand as an absolute value for each individual item.
If you enter independent demand quantities for individual products, the system automatically calculates the percentages for the selected products within the mixed model family out of 100 percent and recalculates the mixed-model family volume.
In addition to specifying the independent demand for the products in a mixed model family, you can also use the Volume Design and Product Synchronization program to calculate the demand for the manufactured items that are required to build the products in the mixed model family. Running the bill-of-material explosion calculates the dependent demand for the subassemblies. The system stores the subassemblies and their dependent demand in the FF30L203 table, in addition to the independent product demand.
You can add independent demand to the dependent demand for subassemblies if you want to use subassemblies as field replacement units (FRU). For these subassemblies, the system calculates total demand by adding independent and dependent demand. If a parent item and its subassembly are included in the same process map, then the component is treated as a phantom item. To maintain the relationship between parent and subassembly, they need to be included in different process maps.
After defining a volume design, you assign product synchronizations to the products in the mixed model family. Having defined independent and dependent demand for subassemblies, you can assign product synchronizations to them as well. Subassemblies can have product synchronizations that are different from their parent items.
The system enables you to delete a volume design provided that it is not used by any process map.