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W/C Load Detail Inquiry - Calculations
W/C Load Detail Inquiry - Calculations
CP810E
A. Housekeeping
1. Workfields are defined, and program constants are initialized.
2. Parameter lists and keylists are defined.
3. The company name is retrieved. Refer to Common Processing Routines for a description of this processing.
4. Category 049, Date Format, is retrieved from the Reference file.
5. The Reference File category 409 is read to determine if the user is authorized to all plants.
6. The Reference File category 428 is read to determine the workstations default plant.
7. A check is made to determine whether the program was entered via fast path.
a. Default plant is validated and plant information is accessed if plant is valid.
8. If the program was entered via fast path, the parameters passed are validated and processed as part of the Housekeeping subroutine.
a. The workcenter number is validated. For specific validation rules, refer to the Capacity Planning User Manual.
b. The Workcenter file (ME100M) is accessed to obtain the workcenter description, department number, machine/labor-paced flag, include setup in load flag, and hours per day.
c. The period start and end dates are validated and converted to shop date format for use in the load calculations. For specific validation rules, refer to the Capacity Planning User Manual.
d. The load option (labor or machine) is validated.
e. If the load option is labor, the program status code (PGMSTS) is set to labor (LAB). If the load option is machine, the program status code is set to machine (MCH).
B. Mainline
Load Inquiry Detail Function Select Screen
1. If the program is not entered via fast path, the Load Detail Inquiry Function Select screen is processed as part of the Mainline.
a. The workcenter number is validated. For specific validation rules, refer to the Capacity Planning User Manual.
b. The Workcenter file (ME100M) is accessed to obtain the workcenter description, department number, machine/labor-paced flag, include setup in load flag, and hours per day.
c. The period start and end dates are validated and converted to shop date format for use in the load calculations. For specific validation rules, refer to the Capacity Planning User Manual.
d. The load option (labor or machine) is validated.
e. Plant appears on the screen and may be changed and validated.
f. If the load option is labor, the program status code (PGMSTS) is set to labor (LAB). If the load option is machine, the program status code is set to machine (MCH). If the load option is blank, the program status code is set to labor or machine, depending on the pacing of the workcenter.
2. Command key processing is enabled.
a. If F3 - Exit is pressed, the program ends.
b. If F2 - Command is pressed, the command window is displayed.
c. If F17 - New Plant is pressed, a new plant may be input and validated.
d. If F4 - Prompt is pressed, valid values window defined for the prompted field is displayed.
3. If the Enter key is pressed and all the fields are valid, either the Load Detail Inquiry--Labor Detail or Load Detail Inquiry--Machine Detail is displayed, depending on the load option.
Load Detail Inquiry--Labor Detail Screen
1. The effective capacity for the workcenter is calculated for the requested period.
a. The Effective Capacity Definition file (CP110M) is read using the requested workcenter number and plant as the key.
b. The effective capacity is calculated for each day of the requested period.
c. The total labor period capacity (CZTLPC) equals the total of the effective capacities calculated for each day of the requested period.
2. If Shop Floor Control is installed, open and firm planned orders are processed as follows.
a. The logical Labor Requirements file (IC125ML6) is read using the workcenter number as the key.
b. Load is calculated for each open and firm planned order. Load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) Load calculations for open orders take into account any activity (setup time, quantity completed, and quantity scrapped) reported against the operation. Refer to Figure 1 for the specific equations used during load calculations.
3. If Shop Floor Control is not installed, open and firm planned orders are processed as follows.
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the workcenter number and order status (not equal to P) as the key.
b. Load is calculated for each open and firm planned order. Load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) Refer to Figure 1 for the specific equations used during load calculations.
4. Planned orders are processed as follows, if Shop Floor Control is installed or not installed.
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the workcenter number and order status (equals P) as the key.
b. Load is calculated for each planned order. Load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) Refer to Figure 1 for the specific equations used during load calculations.
5. Flow authorizations with a firmed or planned status are processed as follows:
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the workcenter number and the flow status (equal to P or F) as the keys.
b. Load is calculated for each JIT flow. The load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) See Figure 1 for the equations used during the load calculation.
6. The total load for the workcenter is calculated.
a. If the include setup in load flag (WCINC1) is Y, the total labor load equals the workcenter's labor setup load (CZWLSL) plus the workcenter's labor run load (CZWLRL).
b. If the include setup in load flag (WCINC1) is N, the total labor load equals the workcenter's labor run load (CZWLRL).
7. The load percentage for the workcenter for the requested period is calculated. The total labor load is divided by the total labor period capacity (CZTLPC), and the result is multiplied by 100.
8. Screen fields are formatted and the screen is displayed.
9. Command key processing is enabled.
a. If F3 - Exit is pressed, the program ends.
b. If F2 - Command is pressed, the command window is displayed.
c. If F11 - Machine Detail is pressed, the program status code (PGMSTS) is set to machine (MCH). The Load Detail Inquiry-- Machine Detail screen is displayed. If there is no machine load in the requested period, the Labor Detail screen is redisplayed with the appropriate error message.
d. If F12 - Summary Inquiry is pressed, the Load Summary Inquiry-- Labor Detail screen (CP800S03) is displayed for the workcenter under review with the dates specified on the Function Select screen.
e. If an operation is selected with an X and F13 - Alternate Opers is pressed, the Load Detail Inquiry Alternates screen is displayed for that operation if alternate operations exist. Otherwise, the Labor Detail screen is displayed with the appropriate error message.
f. If an operation is selected with an X and F14 - LR Inquiry is pressed, the Labor Requirements Inquiry program (SF810E) is called and the Operation Status screen is displayed for either open or firm planned orders. If the order is planned, the appropriate error message is displayed. This command key is enabled only if the Shop Floor Control module is installed.
10. If the Enter key is pressed and Fast Path was not called, the Function Select screen is displayed for the entry of new values.
Load Detail Inquiry--Machine Detail Screen
1. The effective capacity for the workcenter is calculated for the requested period.
a. The Effective Capacity Definition file (CP110M) is read using the requested workcenter number as the key.
b. The effective capacity is calculated for each day of the requested period.
c. The total machine period capacity (CZTMPC) equals the total of the effective capacities calculated for each day of the requested period.
2. If Shop Floor Control is installed, open and firm planned orders are processed as follows.
a. The logical Labor Requirements file (IC125ML6) is read using the workcenter number as the key.
b. Load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) Load calculations for open orders take into account any activity (setup time, quantity completed, and quantity scrapped) reported against the operation. Refer to Figure 1 for the specific equations used during load calculations.
3. If Shop Floor Control is not installed, open and firm planned orders are processed as follows.
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the workcenter number and order status (not equal to P) as the key.
b. Load is calculated for each open and firm planned order. Load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) Refer to Figure 1 for the specific equations used during load calculations.
4. Planned orders are processed as follows, if Shop Floor Control is installed or not installed.
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the workcenter number and order status (equal to P) as the key.
b. Load is calculated for each planned order. Load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) Refer to Figure 1 for the specific equations used during load calculations.
5. Flow authorizations with a firmed or planned status are processed as follows:
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the workcenter number and the flow status (equal to P or F) as the keys.
b. Load is calculated for each JIT flow. The load is calculated only for that part of an operation that takes place during the requested period. (Refer to the Capacity Planning User Manual for more information.) See Figure 1 for the equations used during the load calculation.
6. The total load for the workcenter is calculated.
a. If the include setup in load flag (WCINC1) is Y, the total machine load equals the workcenter's machine setup load (CZWMSL) plus the workcenter's machine run load (CZWMRL).
b. If the include setup in load flag (WCINC1) is N, the total machine load equals the workcenter's machine run load (CZWMRL).
7. The load percentage for the workcenter for the requested period is calculated. The total machine load is divided by the total machine period capacity (CZTMPC), and the result is multiplied by 100.
8. Screen fields are formatted and the screen is displayed.
9. Command key processing is enabled.
a. If F3 - Exit is pressed, the program ends.
b. If F2 - Command is pressed, the command window is displayed.
c. If F11 - Labor Detail is pressed, the program status code (PGMSTS) is set to labor (LAB). The Load Detail Inquiry--Labor Detail is displayed. If there is not labor load in the requested period, the Machine Detail screen is redisplayed with the appropriate error message.
d. If F12 - Summary Inquiry is pressed, the Load Summary Inquiry-- Machine Detail (CP800S03) screen is displayed for the workcenter under review with the dates specified on the Function Select screen.
e. If an operation is selected with an X and F13 - Alternate Opers is pressed, the Load Detail Inquiry Alternates screen is displayed for that operation if alternate operations exist. Otherwise, the Machine Detail screen is redisplayed with the appropriate error message.
f. If an operation is selected with an X and F14 - LR Inquiry is pressed, the Labor Requirements Inquiry program (SF810E) is called and the Operation Status screen is displayed for either open or firm planned orders. If the order is planned, the appropriate error message is displayed. This command key is enabled only if the Shop Floor Control module is installed.
10. If ENTER is pressed and Fast Path was not called, the Function Select screen is displayed for the entry of new values.
Load Detail Inquiry Alternates Screen
1. The logical Manufacturing Order Header file (IC100ML1) is read to obtain the order quantity of the selected order.
2. The Routing file (ME120M) is read. The alternate operations for the selected operation will be retrieved and the labor/machine setup and run load with be calculated for each alternate.
3. The following fields are written to the detail line: operation number, operation line number, workcenter number, operation type, crew operation flag, number of persons required, number of machines required, overlap, labor/machine setup load, and labor/machine run load.
4. Command key processing is enabled.
a. If F3 - Exit is pressed, the program ends.
b. If F2 - Command is pressed, the command window is displayed.
c. If an alternate is selected and CA12 - Summary Inquiry is pressed, the Load Summary Inquiry--Labor Detail or Machine Detail screen is displayed for the selected alternate's workcenter using the period start and end dates specified on the Function Select screen. If the alternate is an outside processed operation, the Alternates screen is redisplayed with the appropriate error message.
d. If F16 - LR Maintenance is pressed, the Shop Floor Labor Requirements Maintenance program (SF100E) is entered. If the order is planned, or if Shop Floor Control is not installed, this command key is not available.
5. If the Enter key is pressed, the Labor Detail or Machine Detail screen is redisplayed.
For MRP operations:
Operation Setup Load for Labor Load Report Request =
Number of Setup Hours Remaining x Number of People in Requested Period
Operation Run Load for Labor Load Report Request =
Number of Elapsed Run Hours x Number of People Remaining in Requested Period
Operation Setup Load for Machine Load Report Request =
Number of Setup Hours Remaining x Number of Machines in Requested Period
Operation Run Load for Machine Load Report Request =
Number of Elapsed Run Hours x Number of Machines Remaining in Requested Period
Operation Total Load (if include setup in load flag = Y) =
Operation Setup Load + Operation Run Load
Operation Total Load (if include setup in load flag = N) =
Operation Run Load
Operation Percentage Load =
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x
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100
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Workcenter's Effective Capacity
for Requested Period
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Workcenter Setup Load =
Cumulative Total of Operation Setup Loads
Workcenter Run Load =
Cumulative Total of Operation Run Loads
Workcenter Total Load (if include setup in load flag = Y) =
Workcenter Setup Load + Workcenter Run Load
Workcenter Total Load (if include setup in load flag = N) =
Workcenter Run Load
Workcenter Percentage Load =
|
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x
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100
|
|
Workcenter's Effective Capacity
for Requested Period
|
|
|
For JIT operations:
The daily load for each day covered by the JIT operation is added directly to the load bucket.
The setup is always zero.
2.1 Common Processing Routines
Company Name Retrieval
The System Control file is accessed to obtain the company name record (COMNAM) for output on the System Error report. If this record is not available, a message is sent to the system operator and the program continues.
Date Format Retrieval
Category 049, Date Format, is retrieved from the Reference file. This record is used to determine the date format. If this record is not available, a message is sent to the system operator, the date format defaults to MMDDYY and the program continues.
User Authorization Retrieval
Category 409, User Authorization, is retrieved from the Reference file. This is used to determine which plants the user is authorized to. If the user is authorized to the manufacturing company warehouse for a plant, then they are authorized to that plant.
Workstation Default Retrieval
Category 428, Workstation Default, is read to determine which plant a particular workstation defaults to.