Production Scheduler

Transcription

1 Production Scheduler For Microsoft Dynamics NAV Introduction to the Basics of Production Scheduler Distributed by: Cost Control Software, Inc Old Meridian Street Carmel, IN Phone: (317) Page 1

2 Table of Contents Application Description... 3 Installation & Setup... 4 Sequence of Implementation... 5 Workflow... 6 Navigate in Production Scheduler... 8 New Fields & Views in NAV NAV Routing for Scheduling Visualization Bi-Directional Integration Manage Schedule and Exceptions Summary Test Your Knowledge Bonus Videos by PlannerOne Student Evaluation Course Evaluation Support This Training Material is designed for the following individuals: 1-2 trainees per company, that are experienced schedulers We are not teaching scheduling methodologies We are working on one company installation. Trainees will already be trained on setup, workflow and terminology of NAV Manufacturing and will be able to move about Microsoft Dynamics NAV fluidly. This Basics Training Manual is provided free of charge to companies that have purchased PlannerOne through Cost Control Software only. This manual should have come to you directly from Cost Control Software. Any other distribution of this manual is strictly prohibited. Any unreported distribution violation of this material is subject to a training material charge of $1,000. Please report violations of distribution to rick.baxter@costcontrolsoftware.com. Page 2

3 Application Description Objectives of this Class PlannerOne is a fully integrated and embedded scheduling tool within Microsoft Dynamics NAV Manufacturing. Basic training on PlannerOne will only take one (1) day to setup, and one (1) day for learning how to get started. PlannerOne Production Scheduler is designed to enhance your NAV Manufacturing with Optimized Scheduling; and it is localized to be used with basic NAV Manufacturing or Manufacturing Plus by Cost Control Software. Key Features Allows users to easily move orders around with Drag-and-Drop tool feature, and always respects constraints while automatically moving other work out of the way. Advanced scheduling features like overlap, storage constraints, and custom constraints. Provides the look-and-feel of Microsoft products for easy usage. Manages all constraints by taking in to account materials, machines, labor, and tooling. Infinitely customizes activity labels on our powerful Resource Gantt and Job Gantt. Shows resource utilization & availability by looking at organized Capacity Plan graph & grid. Highlights problems, like bottlenecks, in red so you ll never miss a scheduling conflict again. Color Coded Operation Stickers Benefits Improved customer service level Increased productivity through optimized capacity and set-up times Reduced cycle-time and inventory Improved responsiveness through the tight integration into Microsoft Dynamics NAV 2009 R2 and Microsoft Dynamics NAV Page 3

4 Installation & Setup Installation & Setup will be completed by Cost Control Software remotely. For the best possible scheduling results and to stay within a reasonable implementation budget we recommend the following: 1. Ensure your SQL Installation meets the Hardware Requirements specified during the sales process. 2. Ensure we are able to work with your IT Staff on a timely basis to expedite the installation. 3. Ensure we have the necessary credentials and instructions to work remotely on your server. (Install and Troubleshoot) 4. After Installation the application will be in the hands of your Production Scheduler. Be sure they have access to your Development Database and your live Production Database. 5. This class is designed for an experienced scheduler. It does not teach concepts of scheduling, it covers how to use Production Scheduler with Dynamics NAV. 6. We also assume the student of this class knows NAV Manufacturing. We have a separate Training DVD on how to use NAV Manufacturing. (Ask about it.) Page 4

5 Sequence of Implementation Install, Setup, and ensure Production Scheduler is operational 1. Cost Control will create a new Testing Database with Production Scheduler installed. This will be done at Cost Control Software. Note: New Dynamics NAV Manufacturing installations will take less time than an existing NAV customer with NAV Manufacturing fully operational. 2. After the Testing Database is operational at Cost Control, we will install the Testing Database on Client s Development Database. This Database will now be ready for the learning process to begin. Start the Learning Process with our Warm Up Self Study Manual. (This book) 3. Client will complete this Manual s pre-recorded Warm Up training on their Testing Database. This class begins on Page Client will attend 1 Web Training Sessions. (~ 2 hrs each). We will want to confirm that the Warm Up process is complete. We will be asking the Scheduler / Student to demonstrate what they have learned so far. 5. Client may continue to practice with software and develop a list of questions for the trainer. 6. Client will attend a 2 nd Web Meeting to get answers to their questions on the basics. Next is Level 2 training either on premise or via web meetings. 7. Now we start to Apply Production Scheduler to your business. With new NAV installations we setup Production Routers to optimize scheduling. With existing NAV installations we analyze your setup and make changes to optimize scheduling. Many use case scenarios are processed so you practice the real day in the life of a scheduler. Advanced Training Topics (optional) 8. This is optional: Our Trainer travels to the client s location for a minimum of 3 Days of onsite training and application configuration. This advanced training might also be provided through frequent web coaching sessions. We want to be sure you are properly applying Production Scheduler to solve your scheduling needs. On-Going support will always be available to you via web meeting and billed as needed. Page 5

6 Workflow The 3 Key Issues that we think you face every day: 1. Manually Scheduling - Whiteboard, Excel Spreadsheet, Paper - Can t take account of all the factors 2. How to Share the schedule - Print-outs, Post on Board, and Photo Copies 3. Duplicate Entry - Enter in both Excel and re-enter in NAV? In conclusion: This is not a productive way to spend your time! How we address your 3 Key Issues above: 1. Automated Scheduling - Just like MRP makes purchase recommendations, your Scheduling Software makes recommendations - The Master Scheduler accepts, rejects, or adjusts. 2. Make it Visual with Drag & Drop Adjustments - See you Schedule Graphically Displayed - Your monitor or Big Screen in the Shop 3. Fully Integrated in NAV - Just Accept the schedule or adjust if needed - Close work period, Move an Operation, Change a Due Date, - Move the What if to Live with Publish (Publish the Working Plan to the Published Plan ) Page 6

7 First think in terms of who will use the software: Scheduling Software is for your Scheduler This will let them Visualize the operations in a Graphical Format with Drag & Drop Options. Benefits of the software: Embedded in Dynamics NAV Designed to make your Scheduler s job more efficient (not accountant) A very interactive presentation of the ROUTER s date data Bonus: Sharing of the schedule - Post on a Big Screen in the Shop For use with NAV Manufacturing or Manufacturing Plus from Cost Control Software Page 7

8 Navigate in Production Scheduler Topics covered in this section: Production Scheduler Orientation o NAV Production Orders = PlannerOne Work Orders o NAV Operations on Routers are scheduled in PlannerOne (We are not scheduling inventory or BOM) o Views Resource Gantt, Work Order Gantt, Load, Resource Sequence o How to Save a View - ie: Filter for just Work Center 100 Operations o Ribbons Upper tabs Planning, Optimization, Display, Actions, Filter o Plans Working Plan, Published Plan Page 8

9 o Columns o Indicators & Details KPI, Work Center, Machine Center, Tools, Personnel, Multiple Types of User Access: o Planning User (probably you) o Collaborative User (Controlled by security) o Viewing User (Controlled by security) Steps of the Scheduling Process: o New NAV Production Order (SO, MPS, Forecast, Manual) o New Operation Stickers goes to Production Scheduler in Stand-By section (These new operations now need to be scheduled) o Planner runs Schedule Action o New Operations (Stickers) move to the Working plan o When satisfied with Working Plan you then Publish the plan Page 9

10 Status initially indicates o Scheduled o Unscheduled (In Stand-by Section) Subsequent operation statuses indicate o Not Started o In Progress (Indicator Bar) o Closed/completed (No longer shown on Scheduling Board) Test your knowledge: 1. What is a Work Order in NAV? 2. What does it mean when you run the Schedule function in PlannerOne? 3. Can you save filtered views of the Resource Sequence List? 4. Provide a real situation where filtered views of the Resource Sequence List would be used? 5. What can a Collaborative User do in PlannerOne? 6. When does Planner One get information from NAV? 7. When does NAV get information from PlannerOne? 8. How do you know when an operation is started in PlannerOne? Student Name: (required for evaluation) Page 10

11 New Field & Views in NAV Topics covered in this section: PlannerOne Additions to NAV On Item Card Page 11

12 Work Center Card Machine Center Card Page 12

13 Routing Lines Production Order Lines Page 13

14 Production Order Routing Page Page 14

15 NAV Routing for Scheduling Communication between Microsoft Dynamics NAV and PlannerOne Database See what you know: 1. TRUE or FALSE All Machine Centers are linked to All Work Centers? 2. TRUE or FALSE Machine Centers within the same Work Center should be interchangeable? 3. For Scheduling When do you attach a Machine Center to a Routing Operation? 4. TRUE or FALSE PlannerOne uses the Production Order Bill of Materials to schedule? Student Name: (required for evaluation) Page 15

16 Visualization Topics covered in this section: 1. How to access the Planner One Desktop from your Role Center. 2. The Display Tab (at the top) and how to move around. 3. The Resource Gantt Chart view is described - NAV Data displayed in left column - Timeline on top - Gantt Chart Body with Production Order Operations (Stickers) 4. Data available for display per Sticker/Operation - If you have 100 Production Orders with 5 operations each = 500 Operations/Stickers - Hover to see the Operation ScreenTips and how to define the tool tips. 5. Time scale Control - Adjust to your typical time frame. Page 16

17 6. Operation Bar Content - You control this content, but don t overload it. 7. Customization Row height 8. Setup Time Indicator Page 17

18 9. Double Click an operation to get more information: 10. From the operation ID, you can Drill Down to the NAV details. ESC will exit back to Production Scheduler. Page 18

19 11. Operation Colors We recommend you normally use the Advance/Delay view to spot late operations. However, you might want to set to Work Order/Production Order so all operation on the same production order are in the same color. Page 19

20 12. Filters, Highlight WO Shows all the operations within a Production Order 13. Add a new View. Work Order Gantt Page 20

21 14. Posting Time to an operation of a Production Order Page 21

22 Test your learning Try doing all of the following and record answers: 1. What functional area of NAV does the schedule use for the Gantt charts? 2. Access the scheduler from all 5 places. Did you have any trouble finding them? 3. In the Resource Gantt chart, what is the NAV term for the Group Code column? 4. On the Resource Gantt chart, what is the NAV term for the Resource Code column? 5. How do you adjust the time scale? 6. What is a Sticker? 7. What does a black and yellow striped indicator bar on a sticker mean? 8. If the sticker contains: What is ? What is 10000? What is 20? 9. How do you change the content of a Sticker s Help Tip? 10. What indicates a closed period? (Like a weekend or Down Machine) 11. What indicates the duration of an operation? 12. Draw how setup time is displayed on the Gantt Chart? Page 22

23 13. What happens if I double click a sticker? 14. How do I go from a Gantt Chart View into Dynamics NAV? 15. How do you change the colors of the operations? 16. What is the purpose of the Advance/Delay Colors? 17. What happens when I switch from the Advance/Delay Color mode to the Workorder color mode while on the Resource Gantt Chart? 18. Name two other Color modes? 19. Describe why you would use the Filter Tab? 20. Name all 4 of the Views available in Production Scheduler? (1) (2) (3) (4) 21. What does the + sign next to the view tabs do? 22. How do you adjust the row height? 23. What does the mean on the Gantt Chart? Student Name: (required for evaluation) Page 23

24 Bi-Directional Integration 1. Get Data (Real Time)(Stand-By Machine) 2. Schedule 3. Publish to NAV 1. New Production Orders immediately go into Stand-By for Scheduling Process. (Sources of Prod Orders) Notice the Frozen Period above. (Typically 2 or 3 Days) New Prod Orders are optimized outside of the Frozen Period. Page 24

25 2. Manually enter two (2) new Production Order and Refresh in Dynamics NAV. Exercise: Try this process in your Testing Database. Create 2 Production Orders and confirm that they show up in the Stand-By section of the Resource Gantt Chart. Do NOT Schedule yet. Page 25

26 3. Now run the Schedule from to move STAND-BY Prod Orders to the Schedule: Try this process in your Testing Database. Page 26

27 2.5 Either Accept the Schedule as presented, or MOVE the Operations as needed. The Plan is the scheduler s Working Plan until he/she Publishes. NAV will not know of any changes until he/she Publishes. Your viewers will also not know of any changes until he/she Publishes. Viewers only see the Published Plan. Let s see this in the live software. Try this process in your Testing Database. Page 27

28 Machine Center Task List/Sequence per Machine Or from PlannerOne Desktop Page 28

29 You can Revert (Un-do) any changes you have made during the day. You can not un-do your last change, only revert to the start of the last Published Plan. You can also Swith to the current published plan, and back to the Working Plan. (This acts as a toggle) Page 29

30 3. Once you are satisfied with the schedule, it is time to Publish the plan back to Dynamics NAV and to your Viewers. Question: How frequently should you Publish? Answer: As often as you want to - Typically 1 to 10 X per day. Hence you are Re-scheduling and Adjusting as needed. Page 30

31 It s time to see what you learned. 1. Where is the Stand-By area in PlannerOne? 2. What data is in the Stand-By area? 3. How does data get into the Stand-By area? 4. Name three(3) ways that data moves out of the Stand-By area? (a) (b) (c) 5. What is meant by a Frozen Period? Would you use a Frozen Period in your Business? be? If so, what would that period length 6. Name two(2) new things you see on the Prod. Order Card that are there now that PlannerOne has been integrated into NAV? (a) (b) 7. What Choices are found on the Upper Optimization Tab? 8. What Choices are found on the Upper Actions Tab? 9. How do I do a Resource Re-sequencing in NAV? Page 31

32 10. What happens when you Publish a schedule? How frequently do you think you will Publish a schedule in your business? And Why? 11. What does the following symbol mean? 12. Describe how to set the above symbol on a sticker? 13. Why would you use the above feature in PlannerOne? 14. What does the following mean? 15. How do you get that line to appear? 16. What effect will this line have on the schedule? Student Name: (required for evaluation) Page 32

33 Manage Schedule and Exceptions What happens during a typical Day: - Customer changes a Ship Date PlannerOne Adjusts the Schedule - Customer chages a Quantity PlannerOne Adjusts the Schedule Page 33

34 - Machine Breaks Down - Close the Period - Resource (Employee) does not show up for work (Sick/Vacation) - New Order is received, run Schedule from Make the Change in NAV; Planner one will adjust Make the Change in PlannerOne (ie Machine Breakdown), Publish will push to NAV (What if) Page 34

35 Summary Real Time Uses web services Interacts with NAV functionalities, enabling real-time communications. Ease of Use Quick and Easy It s more about Re-Scheduling than Scheduling Make the schedule to accommodate real life Graphical planning is easy to understand. Fully Integrated Works right out of the box Simple integration and no data replication Developed using the latest Microsoft technology (Visual Studio 2010,.Net4) Fully integrated into Microsoft Dynamics NAV Key Functionality Visualization for Scheduler and Viewers Bi-Directional Integration Manage Schedule & Exceptions. Page 35

36 Test Your Knowledge: 1. Change the shipment date on a released production order. Go to PlannerOne to see the changes. Do you have PlannerOne set to Auto or Manual Refresh? 2. Change the quantity being made on a production order in NAV. Go to PlannerOne to see the changes and note here: 3. Try Closing the Period on a Machine Center in Planner One. Describe how you did it? 4. Why would you Close the Period on a Machine Center? 5. How would you make the same change in NAV? 6. The reference to a Resource in PlannerOne is equivalent to what term in NAV? 7. How are Employees setup in NAV to indicate their usage on a Production Order? 8. If an Employee calls in sick, what two choices do you have to adjust the schedule? Try them in the live software and then record what you did and where, and record the results below. (a) Action taken: Results on the Gantt Chart: (b) Action taken: Results on the Gantt Chart: 9. Where do you find Add Calendar Exceptions? Student Name: (required for evaluation) Page 36

37 Videos from PlannerOne Videos of Production Scheduler are provided by the PlannerOne Development Staff: These videos were produced by PlannerOne. They go very fast. We recommend you use the pause button and try some of the things they show on your Development Database. Ctrl + Click PlannerOne Video, Part #1 (4:20 min) Review of the Visualization of PlannerOne Ctrl + Click PlannerOne Video, Part #2 (4:30 min) Indicators & Details Windows (statistics of overall schedule) What if Machine Breakdown (Adjust Resource Calendar, Operations using this Resource are Postponed, Move Operations, and Suggest Schedule). What if Component Stock Out (View Gantt Chart in Item Color Mode, Fix start date of operation needing the component, subsequent operations postponed, Re-Schedule). Ctrl + Click PlannerOne Video, Part #3 (4:06 min) Real time Dynamic Integration of PlannerOne with NAV What if Quantity of a scheduled Production Order changes (Make changes in NAV, see changes on schedule, Adding a new Production Order in NAV, Real time scheduling, assign color for new order, See immediately in the Stand-By area in PlannerOne, Schedule, Using the Advance/Delay Color mode, check the new production order s effect on the schedule, if good, confirm orders due date). Ctrl + Click PlannerOne Video, Part #4 (2:53 min) Looking at other views in PlannerOne Work order Gantt Chart (one order per line, see markers like green triangle for Start date, and red triangle for due date, Waiting time displayed, Highlight a Work order, show network chaining, and fix date). Load Chart Resource Sequence Page 37

38 Student Evaluation Congratulations. You have completed the first step toward learning about Production Scheduler by PlannerOne, a great new scheduling tool for your business. Step 1 is the Self Study program providing basic knowledge on PlannerOne Production Scheduler and getting you prepared for the Level 2 training where you will discuss how you will use PlannerOne with a PlannerOne instructor. As a prerequisite to beginning Level 2 training we need you to send us pages 10, 15, 22, 23, 31, 32 and 36 with your responses. Shortly after receiving the Test your knowledge pages we will setup a 2-hour web meeting to review the self study topics and your responses, to make sure you have a firm grasp of PlannerOne basics. Please sign and return the Question & Responses pages to: FAX - (317) or rick.baxter@costcontrolsoftware.com Page 38

39 Course Evaluation It is very important to us to know what you thought about the self-study program. We feel that there is a certain amount of basic training that individuals can gather on their own time and pace as well as saving the implementation budget for more in depth application topics for instructor lead training. But, we really need to hear from you. Please, take the time to fill out this short questionnaire and fax or it back to us. Sincerely, Julia Baxter, CEO Cost Control Software, Inc. 1. Approximately how much time did it take to go through the program? 2. Did you learn something? YES or NO 3. Was it worth your time? YES or NO 4. Did you like this form of training? YES or NO Please explain: 5. Would you recommend this form of training to others? YES or NO 6. How can we improve on this training? Student Name Date Please return evaluation to: FAX (317) or rick.baxter@costcontrolsoftware.co m Page 39

40 Support Congratulations on your purchase of PlannerOne! We couldn t be more thrilled for you. Soon, you will be on your way to enjoying and utilizing the features and functionality of this product. This training manual is just the beginning. After completing this self study program you should feel like you can move around in PlannerOne Production Scheduler, understand basic terminology, the integration with NAV, changing visualization modes and actually doing some simple scheduling. Your next step will to work with a PlannerOne special trainer to discuss how you will use this product in your business. Contact us to schedule the next step, Level 2 training. On behalf of NAV Software, NAV Solution Centers and NAV Service Providers, we thank you for your business. Most importantly, Cost Control Software sincerely appreciates your trust in our products. Should you have any questions or comments regarding our product, we encourage you to contact your local NAV Solution Center (NSC). Please also contact your NSC if you are considering modifications or seeking new software functionality. Cost Control Software provides many add-on products that may be just the solution you were looking for. Your NSC can provide you with our complete list of add-ons. You may also check out our website to see available add-on products as well. Visit: for more information. Distributed by: Cost Control Software, Inc Old Meridian Street Carmel, IN Phone: (317) Page 40

41 Addendum Here are some bonus tips and Ideas to help you along the way. Some tips to analyze a Work Order Delay: 1. Check the WO Network. See if the Start Date is constrained by a previous WO. 2. Check the Earliest Start Date (Router Line, P1 Field) - Check the Planner One Setup for Earliest Work Date. - See Below The above setting will fix the start date in the Stand By Area to exactly 4 weeks before the end of the requested Ship Date (Due Date). Exception: The Item Card has a longer period. (Usually set based on the typical build time of the item with consideration to other work in the shop). Exception #2: TODAY. A production order can t start earlier than today! Note: You may get an indicator line to the left showing the calculated Earliest Start, but it just can t start before TODAY. Page 41

42 Some tips to analyze a Work Order Delay: This field on the Item Card will Trump the Global Setting in the setup area. Page 42

43 Also here is a screen shot that shows how Earliest Start Date is used: So, this was the best tip to understand or trouble shoot delays: Page 43

44 Final Results or Optimization/Schedule: The Earliest Start Date held true and all work got scheduled after that based on availability in the other Machine Centers. Tip: Before you run the Schedule, Set color to WO. Then it is easier to follow your production order. Tip: When you run Schedule from the Production Order Card, the results are easier to follow too. (see above) Dynamics NAV schedules from the Due Date backwards based on the duration of each operation. It is Infinite capacity, hence no consideration to other production orders. Production Scheduler Users Forward Scheduling Logic and Finite Capacity If there is another operation on the scheduling board, it moves the new operation forward on the time line. Suggestion: Learn by scheduling just One Production Order to begin with. Draw on paper a 30 Day time line. Plot: Due Date, NAV End Date, NAV Start Date Look at the NAV Dates and plot them. Page 44

45 Now View the PlannerOne Stand-By from the Production Order Card! Production Scheduler in Stand-by puts the start of the Prod Order on Earliest Start Date. When you select Schedule Production Scheduler places the 1 st Operation as close to the Earliest Start Date as possible. The remaining tasks fall in line when a W/C or M/C is available. This means you will get a more realistic calculation of WO completion Date. (Promise Delivery Date) Optimization Tip: If you want to always ship early, set your Earliest Start Date Calc to -6W. If you want to ship JIT, set your Earliest Start Date on the Item Card to aprox duration to make that items when there are other jobs on the shop floor. (-12D if it normally takes 10 Days to make) Publish Tip: On PlannerOne Setup set the Overwrite option to NO! (No change to NAV Prod Header Dates) When you publish, only the Router Start and End Dates are updated with more accurate values. (You might want to create a Scheduling Report based on these published Dates) Page 45

46 Next Operation Link Type Field Next Operation Links are constraints that can be added to the Routing steps in a Production Order. They can either be added to the Master Router for an item or even added on the fly when editing a Production Order s Router. SS for Start-Start Synchronization Links Both operations start together (example: 20:SS) Page 46

47 ES for End-Start Synchronization Links next operation starts as soon as the previous one finishes (example: 20:ES) EE for End-End Synchronization Links Both operations end together (example: 20:EE) Page 47

48 FU for Full Synchronization Links Both Operations start and end together (example 20:FU) NP for Non-Parallel Links A nonparallel link between two operations means these operations must not overlap. Yet, they have no precedence constraint with one another; any of them can be performed first. Page 48

49 RR for Resource Reservation Links A planning constraint between two operations. Both operations must be assigned the same resource, and no other operation can be planned between them on that resource. SR for Same Resource Links - A planning constraint between two operations. Both operations must be assigned the same resource. Still, other operations can be planned between them on that resource. Page 49

50 Linking 2 Production Orders that Produce the Same Item to Run Together In this demonstration we will be linking 2 Production Orders together that produce the same item to run as a batch. Their operations need to be linked so that they run back to back for both Production Orders. In this example I created 2 Production Orders for Item DOOR100 Steel Door & Frame, one for a Qty. of 35 and the other for 50. The Routing for this item has 2 operations, so we would like to link them so that the operations for the two Production Orders run together as a batch since they are for the same item. Page 50

51 Go to Links between Production Orders to set up the Links and click New. Next you will need to set up the Links. We need to Link both OP #10 s together as well as both OP #20 s. We also need to the 2 nd Op #10 to the 1 st OP #20 so that they run in order. We will use the same Link Code for all 3 links, which is the ES (End-Start) Link code. This means when one operation ends, the next linked one starts right after. Example: Page 51

52 After you have created these links, open Production Scheduler to view the linked Production Orders along with their Linked Operations. Video - Linking Production Orders & Operations using Links to Production Orders Page 52