Shop Control

+ Transcript

MRP generates a coordinated master schedule that properly aligns jobs and POs so that materials, components, and subassemblies are time-phased to be available when needed so that jobs can be started and finished on time. See the Job Planning and PO Planning videos for details.

Once MRP generates the master schedule, the system provides two screens that enable the master schedule to be executed as planned out in the shop - the Job Control Panel and the Shop Control Panel, which are covered in this video.

Jobs are released to the shop floor through the Job Control Panel, here on the Jobs menu.

Jobs are only released when the scheduled start date comes due and an item's first work center has open capacity, which prevents the shop from getting overloaded. The First-Q field lets you know if the first work center is accepting new job sequences. You can also click this icon as a final check that required materials are on hand. Select the Release checkbox against each job that is ready for release. You can then batch print job travelers, which are covered in the next segment, and then click the Update button to release the selected jobs.

Job Travelers are printed concurrent with releasing jobs to the shop floor.

Job travelers can be batch printed against all jobs selected for release. The job traveler accompanies the job on the shop floor and provides workers with complete manufacturing specifications.

The traveler can be customized by selecting or clearing the printing options listed on this screen. You can save your selections against a layout name so that you can create multiple custom layouts, if needed.

Here we are looking at a sample printout.

The Shop Control Panel is used to create a daily schedule within each work center so that all jobs are prioritized in a coordinated fashion to meet their planned finish dates.

This tab provides an overall view of the shop, including work center capacity settings. Here you can compare the Buffer Days, which is the expected queue time or waiting time in each work center, with its Queue Days, which is the actual waiting time. This enables you to quickly identify bottlenecks that can help you decide where to deploy workers and other resources.

This tab is used by shop supervisors for daily scheduling of each work center. Work center capacity settings are maintained here. You can optionally activate Queue Control, which enables a work center to stop accepting new job sequences once its expected queue time has been exceeded.

Job sequences are scheduled such that sequences already in progress are listed first, and sequences with a status of 'Ready', which means that the job is physically waiting in the work center queue and is ready for production, are sorted in On-Time ratio order.

The on time ratio measures whether a job is running behind or ahead of schedule. Jobs running behind schedule are given priority over jobs running ahead of schedule.

If you follow the suggested schedule, you will avoid needlessly working on job sequences that have plenty of time to be done later and you will be focusing on the job sequences that need attention the most. Follow the suggested schedules throughout the shop and your work centers will function in harmony instead of at cross-purposes. The result is that more jobs will get completed on time with fewer bottlenecks and less expediting.

Shop control is the means by which jobs are completed on time, while keeping costly expediting to a minimum. Instead of clogging the open job schedule with jobs that cannot be started until later, you keep the shop lean and efficient by only releasing jobs when they are scheduled and when open capacity exists. Instead of expediting favored jobs at the expense of other jobs, work centers can be scheduled in in a coordinated fashion by running job sequences on time ratio order.