Scheduling Production Jobs Using the Optimization Function

The Optimization wizard, located on the DEACOM Master Production Calendar toolbar, is used to automatically prioritize the order in which Production Jobs are scheduled, based on all necessary inputs and resources. Scheduling Sequencers, used in the Scheduling a Changeover process and by the optimization wizard, provide planners with an option to prioritize how items on active production jobs should be scheduled. Two sequence levels are available and each item may be assigned to one schedule sequence 1 and one schedule sequence 2. The optimization wizard will search for items assigned to level 1 sequences first, then assign jobs containing these items to the appropriate work center or shop area. Next, the optimization wizard will search for items assigned to level 2 sequences (after items with level 1 sequences have been assigned) and then assign jobs containing these items to the appropriate work center or shop area.

Configuration

Options for the Schedule Sequencers 1 and 2 need to be created prior to using the Changeover and Optimization functions.The setup steps are detailed in the beginning of the Scheduling a Changeover process below.

Process

Configuring Schedule Sequencers

Prior to scheduling a Changeover, Sequences must be added and assigned to Parts.

  1. Navigate to Inventory > Maintenance > Schedule Sequencer 1.
  2. Click "New" to open the Edit Schedule Sequencer 1 form.
  3. Enter a Name for the Sequence. A basic example for our purposes might be oil-based and water-based paints. In this case, two sequences would be created, "Oil Based" and "Water Based".
    1. Note: The Schedule Changeover function currently works only with Schedule Sequencer 1). Ensure the "Active" box is checked then save.
  4. Repeat steps 2 and 3 for any other Sequences that need to be defined.
  5. Navigate to Inventory > Item Master, select the desired Part, then click "Modify".
  6. On the General 1 tab, select the Sequence from the pick list. In our example, the "Oil Based” Sequence will be assigned to the "1 Gallon Waterproof Outdoor" Item Master. The "Water Based" sequencer will be assigned to the "1 Gallon White Interior Latex" Item Master.
  7. Save and close the Edit Item Master form.
  8. Repeat steps 5-7 for any other Parts that need Sequences assigned.

Scheduling a Changeover

Once Sequences have been defined and assigned to Parts (refer to the section above), the process for scheduling a basic Changeover is as follows:

  1. Identify or create the Operation(s) in DEACOM that, when performed and listed on a Job, will require a Maintenance or Changeover process. For our example, the "Mixing" operation will be used.
    1. Notes:
      1. Operations are assigned to Routings which in turn are added to an item's Bill of Materials. Users will need to ensure that the operation identified in the Changeover rule is attached the appropriate Routings in the system. In our example, we are using two parts: 1 Gallon Waterproof Outdoor and 1 Gallon White Interior Latex. Both of these Parts must have a Routing with the "Mixing" operation identified.
      2. Users may modify a Routing once a Job has been created via the "Routings" button on the Job header. The system will evaluate the Routing on the Job order when using the Scheduling Changeover option.
  2. This step involves deciding when Maintenance or Changeover steps will occur: (1) after the current Job/item is finished or (2) before the next Job/item is started. Users have the option to choose here. In our case, we are going to setup a Changeover rule that indicates the cleaning process that will be performed after a Job containing an oil-based Sequence/item is finished and before a Job containing a water-based Sequence/item is started.
  3. Identify or create a non-stocked, active, manufactured Item Master that represents the Changeover/Maintenance work that will be performed. Item Master records are created via Inventory > Item Master. Our example uses a part entitled "Clean Mixer".
  4. Navigate to Production > Maintenance > Changeover. Click the "Add New" button to display Edit Schedule Changeover form. In the "Previous Sequence 1" field, use the search box to pick the "Oil Based" option. In the "Next Sequence 1" field, select the "Water Based" option. In the "Operation" field, select the "Mixing" operation. In the "Part Number" field, select the "Clean Mixer" part that was created previously. Finally, ensure the "Active" checkbox is selected and click the "Save" button to save the Changeover rule.
  5. Navigate to Production > Job Entry. Create a job for the "1 Gallon Waterproof Outdoor" part. Ensure the job has "Earliest Available” selected on the Dates tab of the job. Once all the appropriate information has been entered, save the job.
  6. Create another Production Job for the "1 Gallon White Interior latex" part. Ensure the Job is also scheduled by selecting an option in the "Schedule By" field on the Dates tab. For our example, the "Earliest Available" has been chosen. Once all the appropriate information has been entered, save the Job.
  7. Navigate to Production > Job Calendar. Select a Report Type of "Master Production” and click the "View" button.
  8. Notice that three separate Jobs will be visible in the following order: One Job for the "1 Gallon Waterproof Outdoor" part , One Job for the "Clean Mixer" part, and one Job for the "1 Gallon White Interior Latex" part. When Jobs for the "1 Gallon Waterproof Outdoor" and "1 Gallon White Interior Latex" parts were schedule, the system evaluated the Changeover table and found the entry which was created earlier. This entry indicated that if a Job containing an "Oil Based" Sequence and a "Mixing" Operation is scheduled before a Job containing a "Water Based" Sequence and a "Mixing" Operation is scheduled, then the system needs to create a Job with the "Clean Mixer" part scheduled in between these two Jobs.

Note: Multiple Changeovers may be created. A Changeover Job will be created for every Operation on the Job's Routing that has a corresponding Operation and subsequent Sequences identified on this form. In the example used on this page, only one Changeover, using the "Mixing" operation was identified. If two Changeovers were created with a Previous Sequence of "Oil Based", a Next Sequence of "Water Based" and two different Operations, then the system would have created two separate Changeover Jobs between the 1 Gallon Waterproof Outdoor and the 1 Gallon White Interior Latex Jobs on the MPC.

Using the Optimization Wizard

The wizard can be used in a number of situations including:

  • When a job is canceled and space becomes available on the calendar.
  • When a job is moved to a later date and space becomes available on the calendar.
  • When a rush job is scheduled and other jobs must be pushed to a later date on the schedule.

Note that the optimizer will not schedule a job starting in a blackout time. Once the user clicks the "Optimize" button the schedule optimizer form will be displayed.

  1. Once the MPC has been loaded, click the "Optimize" button on the toolbar.
  2. Enter the start and end date that the Optimizer should use for its' considerations.
  3. Make a selection in the "Schedule by" and "Sort by" fields to provide the tool with direction.
  4. Click "Continue" to run the Optimizing function.