CONBON Analysis Generation - Calculations

CB100E

A. Housekeeping

1. Refer to the Housekeeping Section within Common Processing Routines for a general discussion of this subroutine. Processing specific to this program is described below.

2. A parameter list is set up to receive parameters from the System File Support Menu.

3. Key lists are defined for each keyed file the program retrieves.

4. Work fields are defined and program constants are initialized.

5. The default company name is retrieved from the company name record (COMNAM) on the System Control file (CT100M).

6. The following information is retrieved from the Reference file (REFERP):

a. The operating system's file status codes are retrieved from category 015. If this record is not found, a message is sent to the system operator, and the program aborts.

b. The date format is retrieved from category 049. If this record is not found, the date format defaults to MMDDYY, a message is sent to the system operator, and processing continues.

B. Read Request Record

1. Depending on whether the program was called from CFSPMENU or from the RP job stream, a read is performed to either CB310AP or RP110AP. The submit CONBON Analysis Field on either file (CZSCBA-CB310AP, CZRCBF-RP110AP) is checked for an "X" or a "Y", respectively, after the plant on either file is fully validated. If the plant is valid and the request field has been selected, a flag (CBFLAG) is set to YES to continue processing or NO to skip to the next record.

2. The next three steps (3, 4, and 5) are executed only if CBFLAG=Y.

3. The array containing the flow interval start dates (FIA) is loaded for the calendar code associated with the plant. This array is used to calculate the number of days each flow interval spans, and to retrieve the start and end dates of flow intervals. The parameter which specifies the flow interval type is the flow interval information category (C05). Flow intervals can span the following periods:

a. The flow interval spans weeks. The Flow Interval Start Date Array is loaded with valid week start dates, as identified on the Calendar Date file (CT140ML1).

b. The flow interval spans months. The Flow Interval Start Date Array is loaded with month start dates.

c. The flow interval spans user-defined periods. The Flow Interval Start Date Array is loaded with user-defined period start dates retrieved from the Flow Interval Start Date file (CT150M).

4. Depending on whether the program was called from the CFSPMENU or from the Requirements Planning module, the following processing occurs:

a. If called from the CFSPMENU, the begin date for processing is set to the processing start date from the CONBON Analysis Submit Request file. If the request date from the request file is less than the current date, the Processing Start Date defaults to the current date. If the current date is not a working day, the Processing Start Date defaults to the first working day following the current date. The number of flow intervals over which the analysis is to span is set to either the number of flow intervals from the CONBON Analysis Submit Request file, or the number of elements that were loaded into the Flow Interval Array (whichever number is less).

b. If called from the Requirements Planning module, the processing start date is set to the Requirements Planning run date, which is retrieved from the RP Generation Request File record. If the Requirements Planning run date is less than the current date, the processing start date will default to the current date or the first working day after the current date (if the current date is not a working day). The number of flow intervals over which the analysis is to span is defaulted to two.

5. The CON, BON, and single card records for the plant being processed are deleted to prepare new records to be written to CB100AP1, CB100AP2, and CB100AP3.

C. Mainline

1. CON analysis is performed for all valid records on the Part Master file where the CONBON Control Code is defined for a dual card system. If the CONBON Control Code is defined as single card, CON analysis is bypassed for those parts.

2. BON/single-card analysis is performed for all valid parts which have records on the Flow Requirements file. Depending on the CONBON Control Code, either the BON or Single-Card Analysis file will be written (dual or single card, respectively).

D. CON Analysis

1. The Part Production Center file (JT160M) is accessed and the part master record associated with the part production center record is retrieved from the Part Master file (DE100M). Validation is performed to ensure that the part is either a manufactured, build-thru, or transfer part, and that the part is active. If the part is valid, CON analysis is performed for every part/production center associated with the part which has a valid flow authorization. If there are no flow authorizations within a flow interval for a cell/part, a zeros record is written to the CON analysis file.

2. CON analysis consists of the following steps for each valid part with flow authorizations that fall within the requested processing period:

a. A check is performed to see if a flow authorization should be split. A flow authorization is split when the start and end dates of the flow authorization encompass the end date of one flow interval and the start date of another. This can only occur if the flow interval has been changed.

b. If a flow authorization does not need to be split, the rate and frequency tables are updated. These tables store the various rates and their corresponding frequencies that occur over the current flow interval. Production quantity, start and end dates for the flow authorization, and the revision level are stored in a multiple occurrence data structure. The highest and lowest daily production rates for the interval are stored in work fields which will later be written to the CON analysis record.

c. If a flow authorization needs to be split, CON analysis calculations for the flow interval are performed. If revision level breaks occur, a separate record is generated for each revision level. It should be noted that the MFO (most frequently occurring rate) is calculated over the entire flow interval, regardless of revision level breaks. The calculations are performed as follows. An asterisk preceding a field denotes that it is retrieved from the Part/Production center file. Two asterisks indicate that the field is retrieved from the Part Master file. All other fields are calculated in the course of the program.

(1) Current Quantity = *Number of CON Cards x *Container Quantity

(2) Card Print Quantity = MFO x (*Queue Days + **Lead Time) +

Container Quantity

*Safety Quantity + *Authorized Quantity

*Container Quantity *Container Quantity

where:

· MFO is the most frequently occurring rate in the flow interval.

· Queue Days is the number of days production in the outbound queue of the producing cell.

· Safety Quantity is the BON safety stock quantity.

· Authorized Quantity is the quantity needed to begin production.

· Container Quantity is the number of units found in a container.

(3) Net Change in Number of Cards = *Number of CON Cards - Card Print Quantity

d. Processing of flow authorizations is handled in two different ways. First, if the user requests a number of flow intervals that are greater than or equal to the number of flow intervals that are stored in the Flow Interval Array, all flow authorizations will be processed. Second, if the user requests a number of intervals that are less than the number of flow intervals stored in the Flow Interval Array, processing continues until the start date of the (n + 1) interval. Where n is the requested number of flow intervals.

e. If a part's production includes fixed lead time, the MFO is calculated over the flow interval, which is offset by leadtime days. In this way, the CON start and end dates take into account the start date specified for the part. The part is produced in time to meet the production schedule due date.

E. BON/Single-Card Analysis

1. The Flow Requirements file is read until all requirements have been processed. Flow requirements are retrieved in production center sequence. Processing breaks occur when any of the following conditions occur:

a. If another flow interval becomes effective, the information for the part currently being processed is written to either the BON Analysis file or the Single-Card Analysis file depending on whether it is a dual or single card system.

b. If another revision level becomes effective, the information for the part at its previous revision level is written out to the appropriate file and processing continues at the new revision level.

c. If the part number changes, the information for the part is written to the appropriate file and processing continues for the new part within the same production center.

d. If the production center changes, the information for the last part within the previous production center is written to the appropriate file and processing continues for the new production center.

e. If the flow requirement's part type is non-stock or its usage code is produced (by-product, etc.), then the flow requirement is ignored and the next record is read. BON cards are therefore not created for non-stock parts or components in which the usage code is produced.

2. Each time a processing break occurs the following calculations are performed before the record is written to the appropriate file. An asterisk preceding a field denotes that it is derived from the Part/Production center file. Two asterisks indicate that the field is retrieved from the Product Structure file (DE120ML4). All other fields are calculated in the course of the program.

a. If the CONBON Control Code indicates that it is a dual card system, the current quantity is calculated as follows:

Current Quantity = *Number of BON Cards x *Container Quantity

Otherwise, current quantity is calculated for a single card system:

Current Quantity = *Number of CON Cards x *Container Quantity

where:

· Number of BON/CON Cards is the number of BON/CON Cards currently on the shop floor, and

· Container Quantity is the number of parts that are stored in one container.

b. Net change in number of cards is calculated as follows:

Net Change in Number of Cards = *Current Number of Cards - (Cycle Cards + Safety Cards)

Each of the above variables is derived by performing these preliminary calculations:

Cycle Cards =

Bon Analysis: MFO / **Delivery Frequency / *Container Quantity

Single-Card Analysis: MFO / **Delivery Frequency / *Container Quantity x 2

Note: If the analysis is for a single card system, the number of cycle cards is multiplied by two. In a single card system, twice the number of cards are needed compared to a dual card system.

Safety Cards = *Safety Quantity / *Container Quantity

Current Number of Cards = *Current Quantity / *Container Quantity

3. When a component part is used by more than one parent part in the same using cell, the delivery frequency is taken from the product structure with the smallest non/zero delivery frequency. However, the BON Safety Stock is accumulated for all the parent parts. A warning message is written to the exception report if the parent parts have different relief locations.

F. Windup

1. If an exceptions report was generated for the given plant, it is closed and routed to the output queue defined on either request by subroutine QCHECK.

2. The CONBON Analysis Submit Request field (CZSCBA on CB310AP) is reset for the given plant and the file is updated.

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CONBON Analysis Generation - Calculations

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