Calendar - Master Production

The primary method for scheduling Jobs in Deacom is handled via either the Job Calendar, Job Inventory Calendar, or Master Production Calendar (MPC). The Master Production Calendar (MPC) allows schedulers to schedule production jobs based on inventory, resource availability, and due dates for jobs. It provides the flexibility to allow an experienced scheduler to manually manipulate the production schedule or for a user to quickly optimize the schedule using a number of different system driven inputs. The calendar was designed to schedule production jobs based on the availability of production resources, including Work Centers, Shop Areas and laborers. The link between the resource types and production jobs in Deacom is a Routing. 

Status color indicators

When scheduled, Routings for Jobs are split into two different color indicators (top row and bottom row). The top row indicates inventory availability and the bottom row indicates if it is finishing within the appropriate date range based on the Part's Lead Time, QC Lead Time, and Safety Days as defined on the Item Master MRP tab. The colors generate as follows:

• Inventory Guide (top row)
  • Green - Inventory is on hand based on the Finished Good Job's Planned Start date. The system will change the color from red/orange to green if the part is set to Allow Negative Inventory = "Always" or if the Facility is set to Allow Negative Inventory = "Always". These are the only two ways that the Job will display green when there is not enough inventory.
  • Yellow - Inventory is not on hand but valid plans exist for creating the necessary inventory by the Finished Good Job's Planned Start date.
  • Orange - Inventory is not on hand for the lower level Sub-Assemblies needed for the Job, and Jobs to produce them do not exist or exist and are scheduled after the Finished Good Job, but the Raw Materials needed to make the Sub-Assemblies are in stock for the Job's Planned Start date.
  • Red - Inventory is not on hand and no plan exists for creating the necessary inventory.
• Scheduling Guide (bottom row)
  • Green - The Job’s Planned Finish date is earlier than the Job’s due date.
  • Yellow - The Job’s Planned Finish date is on the same day as the Job’s due date. Yellow is the optimal color when just-in-time production scheduling is being used. It also is a clear indication to the scheduler that the job should not be pushed back.
  • Red - The Job’s Planned Finish date is after the Job’s due date or that there is no due date on the Job.

For example scenarios and descriptions of how the system color-codes scheduled Jobs, refer to the Job Inventory Calendar page.

• Note: An item's safety days are considered when the system determines the production box color scheme. For example, if a job contains a routing that starts/ends on the date which is the lead time minus the safety days, the routing will be displayed in yellow. If the start/end date of the routing is later then the lead time minus safety days, the routing will be read. If the start/end date of the routing is earlier then the lead time minus safety days, the routing will be green.

The information displayed on the routing sequence is user defined in Production > Options > Scheduling tab. Only two of these fields are displayed initially on the calendar, but the remaining five are shown by hovering over the sequence through the tool tip.

General form layout

Once generated via the Calendar Selection pre-filter, the Master Production Calendar form has three main sections.

• Toolbar - Contains buttons to change the view of the calendar, save changes made, print and view schedules, etc. These items are detailed in the Master Production Calendar form section below.
• List of Jobs available for scheduling - Including Job Number, Work Center, Operation, Hours required, and Facility.
  • Jobs display according to the "Routing Sort 1-3" pick list selections made in Production > Options > Scheduling tab.
  • Jobs may be dragged and dropped to the desired date/time for a Work Center. Note that users can also select the job and move the mouse to the left or right to have the calendar automatically scroll to the desired date/time.
  • Double clicking a Job in this section will open the detail in view mode.
• List of Work Centers, dates and times, and cross section used for scheduling - Work Centers are listed vertically while dates and times are listed horizontally.
  • The Facility and Facility Group pre-filter selections dictate which Work Centers are displayed. If no Facility or Facility Group is specified on the pre-filter, then all Work Centers, across all Facilities will be displayed.
  • Listed under each Work Center name are details regarding the hours and number of Jobs scheduled for the Work Center. These values will update depending on the calendar view (for example, if the user clicks "Next Week") and when Jobs are dropped onto or removed from the calendar.
  • The width of the hours columns may be adjusted via the "Pixels Per Hour" field in Production > Options > Scheduling tab.
  • All blackout times, whether from the Availability schedule, Availability Exceptions, or Maintenance, will display as black blocks of time with white text. The Availability schedule displays “Schedule”, Availability Exceptions display “Exception”, and finally Maintenance tasks display “Mtc. [Job Number] [Job Description]”.
  • Orders scheduled on the calendar will block off the time required for the Work Center chosen. This "block" displays up to five lines of text, dictated by the "Routing Field 1-5" pick list selections made in Production > Options > Scheduling tab.
  • Double clicking on a scheduled Job will open the Routing Calendar Detail form, detailed in the Routing Calendar Detail form section below.
  • Note: The assigned Work Center can also be changed if applicable via a Shop Scheduling report in Job Reporting, then selecting 'Edit Data' on the job.

Job Date fields supporting the MPC

The following are fields on the Date tab of the Job that support the MPC functionality:

• Schedule By - Determines how the Job will be scheduled. Note that Routing sequences may be scheduled across days on the calendar if necessary, which is useful in situations where processes such as the drying or setting of paint or adhesives will occur even when the plant is closed for normal production.
• Due - The due date for the production Job, this field automatically populates for Jobs created through MRP, but may be modified by the user.
• Planned Start - The planned start date for production on the Job.
  • For Jobs created via MRP, this field automatically populates as the "Due" date minus the "Lead Time" as defined on a Part's Item Master MRP tab.
  • For Jobs created manually, this field is user-specified for manually and not scheduled Jobs or calculated by the system for automatically scheduled Jobs.
• Planned Finish - The planned finish date for production on the Job
  • For Jobs scheduled via the MPC, this field automatically populates.
  • If the MPC is not used, this field will be left blank.
  • "Safety Days" as defined on a Part's Item Master MRP tab are also factored in when setting this date on the calendar.
• Started - Automatically populates once the first Routing sequence on a Job has begun.

The Edit Job form also contains a "Calc. Planned" button, which is used to recalculate the "Planned Start" date when the "Schedule By" or "Due Date" fields are modified by the user.

System Navigation

• Production > Calendar > Report Type of "Master Production"

Master Production Calendar form

Opened via the "View" button on the Calendar Selection pre-filter when the "Report Type" is set to "Master Production". The date used as the current date is displayed on the left side of the calendar.

Button	Description
Previous Week	Moves the view of the calendar to show the schedule for the previous week.
Previous Day	Moves the view of the calendar to show the schedule for the previous day.
Today	Moves the view of the calendar to show the schedule for the current day.
Go To	Opens a form that allows the user to jump to a particular date on the calendar. The fields are as follows: Type - Option between Date or Transaction to search by. Date - Enabled if Type = Date, user can type in or select on the calendar what date to jump to. Transaction Type - Disabled for the Master Production Calendar, always set to Purchase Order. Job Number - Enabled if Type = Transaction, search on the calendar to a particular job.
Next Day	Moves the view of the calendar to show the schedule for the next day.
Next Week	Moves the view of the calendar to show the schedule for the next week.
View	This button is enabled beginning in version 16.06.030, allowing users to switch between Day or Week view. The use of Week view allows users to see scheduling more easily for jobs across multiple days.
Save	Only available once at least one modification has been made to the schedule. If clicked, all modifications made are saved.
Undo	Reverts the previous modification made to the schedule. Only active if a change has been made to the schedule and the "Save" button has not yet been clicked.
Redo	Undoes the reverted action previously performed via the "Undo" button. Only active if clicking the "Undo" button was the last action and the "Save" button has not yet been clicked.
Undo All	Reverts the schedule back to the way it was as of the last save.
Refresh	Refreshes the data shown in the schedule.
Print	Opens the Print Schedule form, which allows users to print the schedule as is for a specified date frame. Users also have the option to include non-scheduled Jobs or omit them. When the Print Schedule form is accessed from the Master Production Calendar, the 'Report Type' field will be enabled; otherwise, the field will be disabled. Users can print out the 'routing' report layout for all routings.
Schedule	Opens the Routing Calendar Detail form, which provides additional details regarding the Jobs displayed and the abilities to print, issue/de-issue, close a Job, run MRP, etc.
Availability	Opens the Availability list, which define the schedule of available times for a Facility, Shop Area, or Work Center.
Availability Exceptions	Opens the list of Availability Exceptions, which define any availability exceptions for a Facility, Shop Area, or Work Center based on the defined Shop Schedule Basics.
Optimize	Opens the Schedule Optimizer form. The Optimizing wizard is a tool that can help update wide ranges of the production schedule automatically based on selections made by the user.
Mass Move	Opens the Mass Move form, which allows the user to shift all jobs on the Calendar depending on the previous pre-filter results. The system will keep jobs in the same sequence and reorder them when performing a Mass Move. Available fields are the following: Start/End Date - Select the date range for the move to take place in. Start Date is required, End Date is optional. If left empty, the End Date will be the last job available in the calendar. Days/Hours - Integer value that determines how many days/hours the selected jobs are moved back from their original dates respectively.

Routing Calendar Detail form

Opened via the "Schedule" button on the Master Production Calendar form or by double clicking a scheduled Job, the Routing Calendar Detail form shows the detail for each Routing sequence in the selected set. The following fields from the dtjob2 (Job Routing) table are available to the grid on this form:

• j2_start = start
• j2_due = due
• j2_duetime = duetime
• j2_seq = seq
• j2_done = done
• j2_jlid = jl_id
• j2_worker = worker

In addition, the item Category (dmcats.ca_name) and item Sub-Category (dmcats2.c2_name) fields are available to the report grids on both the Master Production Calendar and the Routing Calendar Detail form. When adding Work Flow information to the grid, such as Work Flow type, name, and Sequence name, the Job Work Flow fields are prefixed with the word "job", so that tr_name would be jobtr_name.

Button/Field	Description
Previous Day	Moves the view of the form to show the Jobs scheduled for the previous day.
Next Day	Moves the view of the form to show the Jobs scheduled for the next day.
Modify	Opens the detail for the selected Job in modify mode.
View Detail	Opens the detail for the selected Job in view mode.
Print	Opens the Copies to Print form, which allows the user to print various production Report Layouts.
Print Schedule	Opens the Print To form, which allows the user to print the current details.
De-Issue	Opens the De-Issue/Un-Reserve Inventory form, which allows the user to de-issue any materials previously issued to the Job.
Issue	Opens the Issue/Reserve Inventory form, which allows the user to issue materials to the Job.
Inventory Detail	Opens the Calendar Color Detail form, which displays all Parts included on the Job(s) listed and their required and on hand amounts. This form also contains an "Availability" button, which runs basic item availability (displayed similarly to MRP) for the selected Part.
Edit Data	Opens the Edit Data form, which allows the user to modify some details of the Job.
Close Job	Opens the Close/Relieve Job form, which is used to relieve costs and materials, close Jobs, and print labels.
Job MRP	Shows an MRP report for the Job selected.
Date	Displays the calendar date that is currently being viewed on the form.
Display	Pick list used to display only Jobs that have not had any reports printed previously or all Jobs regardless of if reports were printed.

Edit Data form

Field/Flag	Description
Job For	Displays the part description from the Job.
Number	Displays the Job Number to which the selected Routing is attached.
Shop Area	Displays the Shop Area for the selected Routing step.
Work Center	Displays the Work Center for the selected Routing step.
Operation	Displays the Operation for the selected Routing step.
Worker	Search field that displays the Worker assigned to the selected Routing step and allows the user to select a new Worker if desired.
Start Date	Defines the start date for the selected Routing. If this date is changed (beginning in version 17.02.015) and linked jobs are associated with this routing, the user will be prompted if they want to move previous/subsequent jobs.
Start Time	Defines the start time for the selected Routing. If this time is changed (beginning in version 17.02.015) and linked jobs are associated with this routing, the user will be prompted if they want to move previous/subsequent jobs.
Remaining	Displays the remaining quantity for this Routing step
Finished	Used to enter the quantity that the Worker is "finishing" on the Routing.
Planned Hours	Displays the planned hours as defined on the Job Routing Sequence. This field is display only and may not be edited.
Hours	Defines the hours that the Routing sequence will take to complete. By default, when opening this form the value in this field will be the same as Planned Hours. If the value in this field is changed, the hours on the Routing will also be changed. The system will push subsequent Routings when increasing the Planned Hours and also push any Routings that result in a conflict (scheduled at the same time for the same Work Center). Changes to this field will impact the Job's Planned Finish date.
Work Crew	Search field used to assign a Crew to the selected Routing sequence.
Crew Size	Defines the size of the Crew for the selected Work Center/Routing sequence.
Lead Time	Defines the Lead Time for the sequence.
Notes	Memo field used to store notes regarding the sequence.
Done	If checked, this Routing sequence is considered complete and will be removed from the calendar.

Schedule Optimizer form

Opened via the "Optimize" button on the Master Production Calendar form, the Optimizing Wizard is a great tool that can help update wide ranges of the production schedule automatically based on selections made by the user. This will not affect jobs with the Include in Optimization flag unchecked in Routings.

Button/Field	Description
Continue	When clicked, runs the Optimizing Wizard with the selections made.
Start Date	Defines the start date the optimizing wizard will consider.
End Date	Defines the end date the optimizing wizard will consider. Defaults to today's date but may be changed. An End Date must be specified in order to run the Schedule Optimizer.
Schedule By	Pick list used to determine if scheduling will be based on Earliest Available, Latest Available, or Production Rate. If "Production Rate" is selected, the Production Rate Suggestions form will appear, which applies only to scheduled Jobs and allows users to modify production rate suggestions.
Sort By	Pick list used to determine how routings or jobs will sorted on the calendar when selecting Schedule By options of Earliest Available or Latest Available. Options are: Item Sequences Item Sequences Then Planned Start Date None Planned Start Date Then Item Sequences

Notes:

• Current functionality optimizes jobs based on the date range specified and the ‘Scheduled By’ value is Earliest/Latest Available within the range.
• If the 'Earliest Available' option is selected, jobs will appear at the earliest available time on the selected New Start Date. If the 'Latest Available' option is selected, jobs will appear ending at the latest time available on the New End Date.

Production Rate Suggestions form

Opened via selecting a "Schedule By" of "Production Rate" on the Schedule Optimizer form, the Production Rate Suggestions form applies only to scheduled Jobs, displays Job and Routing information, and allows users to modify production rate suggestions.

Button/Field	Description
Modify	Opens the Edit Production Rate Suggestions form for the selected Job Routing sequence, which is used to modify the Start Date and Suggested Hours.
Apply	Applies the changes made to Routings flagged as "Selected" via the Edit Production Rate Suggestions form and moves all Routings, after a Routing is shortened, to a prior start time by the amount of the Routing being shortened. Specifically, the system takes all Routings flagged as "Selected" by Work Center, sorts them by current Start Date and time, takes the current "Suggested Hours" values and calculates j2_hours as follows: If batch j2_hours = Suggested Hours. Else If 0 pieces, j2_hours = 0. Else, j2_hours = pieces * Suggested Hours / Quantity.

Edit Production Rate Suggestions form

Opened via the "Modify" button or by double clicking a Routing on the Production Rate Suggestions form. Calculations for the fields on this form are as follows:

• Start Time = j2_due + j2_duetime
• Percent Done = Elapsed Hours / Total Scheduled Hours (for this Routing step)
• Planned Finish (quantity that should have been done by now) = lj_quant * Percent Done
• Planned Hours (originally planned duration of this step):
  • If batch, Planned Hours = j2_planhours.
  • Else if pieces = 0, Planned Hours = 0
  • Else, Planned Hours = quantity * j2_planhours / pieces
• Scheduled Hours (currently planned duration of this step):
  • If batch, Scheduled Hours = j2_hours.
  • Else if pieces = 0, Scheduled Hours = 0
  • Else, Scheduled Hours = quantity * j2_hours / pieces
• Suggested Hours (modified hours being suggested to compensate):
  • Remaining Quantity = lj_quant - actual finished
  • Hourly Rate = lj_quant / scheduled hours
  • Remaining Hours = Remaining Qty / Hourly Rate