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W/C Load Summary Report Print - Calculations
W/C Load Summary Report Print - Calculations
CP500E
A. Housekeeping
1. Workfields are defined, and program constants are initialized.
2. 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. Piece Rate Standard is retrieved from the Warehouse Description file (IC170ML2).*
*(This is all done in the plant validation subroutines).
6. Workday start time is plant specific and is found on IC170ML2.*
7. Last Capacity Planning L/R Generation Date (CZDATE) is found on CP080AP.*
B. Mainline
The report request is selected.
1. The logical Capacity Planning Report Request file (CP500AL) is read.
a. If there are no summary report requests (key equals R10) on the file, only the report headings and the message "No Report Requests" are printed. Then the program ends.
2. Each summary report request is selected.
3. The start and end dates are converted to the correct output format. The end date is checked to ensure that it is not greater than the last period end date.
a. If the end date is greater than the last period end date, the program terminates abnormally.
QCHECK is executed to send report(s) to the output queue on Request file.
Each report request is processed.
1. The user-defined report periods are set up. The Report Period Definition file (CP120M) is read to obtain the report period lengths. The report period lengths are used to calculate start and end dates for up to 100 report periods.
2. The report request is validated.
a. The Workcenter file (ME100M) is read.
b. If the request is for all workcenters and a report for all workcenters was already requested, the request is printed on the Exception report (CP500X).
*(This is all done in the plant validation subroutines).
c. If the request is for an outside processed workcenter, the request is not processed and the next request is read.
d. The workcenter is checked to ensure that it is active. If it is inactive, the message "Workcenter Inactive" is printed on the Load Summary report.
3. If Shop Floor Control is installed, the released load is calculated and allocated as follows.
a. The logical Labor Requirements file (IC125ML6) is read using the workcenter number as a key. If the request is for all workcenters, all labor requirements are read. If the request is for a single workcenter, labor requirements are read until the workcenter number changes. If no labor requirements before the requested horizon date exist, the message "No operations Within Horizon" is printed on the Load Summary report.
b. The piece rate is converted to hours per piece if the standard is pieces per hour.
c. The operation is validated to ensure that it is scheduled before the report request end date.
d. The workday end time is calculated.
e. Flags are set if some quantity has been completed, scrapped, or set up.
f. A flag is set if the operation is past due.
g. If the operation starts and ends on the same day and no activity has been reported, the setup load and run load are calculated.
(1) For labor-paced operations, the setup load equals the scheduled setup hours multiplied by the number of people. The run load equals any remaining workday hours multiplied by the number of people.
(2) For machine-paced operations, the setup load equals the scheduled setup hours multiplied by the number of machines. The run load equals any remaining workday hours multiplied by the number of machines.
h. If the operation starts and ends on the same day and activity has been reported, the setup load and run load are calculated, taking into account the quantity already setup, completed, and scrapped. The number of hours required to finish the quantity setup, completed, and scrapped is added to the time the operation should have begun. The resulting time is used in the following calculations.
(1) For labor-paced operations, the setup load equals the labor setup reported divided by the number of people. If there are any remaining setup hours, the additional setup load is calculated. It equals the remaining setup hours multiplied by the number of people. The run load equals any remaining hours (after all setup hours have been taken into account) multiplied by the number of people.
(2) For machine-paced operations, the setup load equals the machine setup reported divided by the number of machines. If there are any remaining setup hours, the additional setup load is calculated. It equals the remaining setup hours multiplied by the number of machines. The run load equals any remaining hours (after all setup hours have been taken into account) multiplied by the number of machines.
i. If the operation takes more than one day and has not begun, the setup load and run load are calculated. Load is calculated separately for each day.
(1) For labor-paced operations, the setup load equals the scheduled setup hours multiplied by the number of people. The run load equals any remaining hours multiplied by the number of people.
(2) For machine-paced operations, the setup load equals the scheduled run hours multiplied by the number of machines. The run load equals any remaining hours multiplied by the number of machines.
j. If the operation takes more than one day and activity has been reported, the setup load and run load are calculated, taking into account the quantity already setup, completed, and scrapped. The number of hours required to finish the quantity setup, completed, and scrapped is added to the time the operation should have begun. The resulting time is used in the following calculations. Load is calculated separately for each day.
(1) For labor-paced operations, the setup load equals the labor setup reported divided by the number of people. If there are any remaining setup hours, the additional setup load is calculated. It equals the remaining setup hours multiplied by the number of people. The run load equals any remaining hours (after all setup hours have been taken into account) multiplied by the number of people.
(2) For machine-paced operations, the setup load equals the machine setup reported divided by the number of machines. If there are any remaining setup hours, the additional setup load is calculated. It equals the remaining setup hours multiplied by the number of machines. The run load equals any remaining hours (after all setup hours have been taken into account) multiplied by the number of machines.
k. Past due load is added to the past due accumulator.
4. If Shop Floor Control is not installed, the released load is calculated and allocated as follows.
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the keylist made up of workcenter number and order status. If the request is for all workcenters, all labor requirements are read. If the request is for a single workcenter, labor requirements are read until the workcenter number changes. If no labor requirements before the requested horizon date exist, the message "No Operations Within Horizon" is printed on the Load Summary report.
b. The piece rate is converted to hours per piece if the standard is pieces per hour.
c. The workday end time is calculated.
d. The operation is validated to ensure that it is scheduled before the requested end date.
e. The requested start date is checked to ensure that it is greater than the operation start date.
f. A flag is set if the operation is past due.
g. If the operation starts and ends on the same day, the setup load and run load are calculated.
(1) For labor-paced operations, the setup load equals the labor setup reported divided by the number of people. The run load equals any remaining hours multiplied by the number of people.
(2) For machine-paced operations, the setup load equals the machine setup reported divided by the number of machines. The run load equals any remaining hours multiplied by the number of machines.
h. If the operation takes more than one day, the setup load and run load are calculated. Load is calculated separately for each day.
(1) For labor-paced operations, the setup load equals the labor setup reported divided by the number of people. The run load equals any remaining hours multiplied by the number of people.
(2) For machine-paced operations, the setup load equals the machine setup reported divided by the number of machines. The run load equals any remaining hours multiplied by the number of machines.
i. Past due load is added to the past due accumulator.
5. Planned load is calculated and allocated as follows.
a. The Capacity Planning Labor Requirements file (CP100AP) is read using the keylist made up of order status and workcenter number. If the request is for all workcenters, all labor requirements are read. If the request is for a single workcenter, all labor requirements are read for that workcenter. If no labor requirements before the requested horizon date exist, the message "No Operations Within Horizon" is printed on the Load Summary report.
b. For JIT flows, the setup load is set to zero. Run load is calculated as the daily load multiplied by the number of working days within the requested period.
c. For MRP orders, setup and run load are calculated as follows:
(1) The MRP operation is validated to ensure that it is scheduled before the requested end date.
(2) The requested start date is checked to ensure that it is greater than the operation start date.
(3) A flag is set if the operation is past due.
(4) If the operation starts and ends on the same day, the setup load and run load are calculated.
(a) For labor-paced operations, the setup load equals the labor setup reported divided by the number of people. The run load equals any remaining hours multiplied by the number of people.
(b) For machine-paced operations, the setup load equals the machine setup reported divided by the number of machines. The run load equals any remaining hours multiplied by the number of machines.
6. If the operation takes more than one day, the setup load and run load are calculated. Load is calculated separately for each day.
(a) For labor-paced operations, the setup load equals the labor setup reported divided by the number of people. The run load equals any remaining hours multiplied by the number of people.
(b) For machine-paced operations, the setup load equals the machine setup reported divided by the number of machines. The run load equals any remaining hours multiplied by the number of machines.
7. Past due load is added to the past due accumulator.
8. If any planned or released load has been calculated, report period detail lines are printed.
9. The total capacity for the period is calculated.
a. The Effective Capacity file (CP110M) is read.
b. The number of days is multiplied by the daily machine or labor capacity.
c. Excess or under-used capacities, if any, are calculated.
10. The total load for the period is calculated.
a. If the setup included flag (WCINCS) is yes, the total load equals the sum of the released run load, released setup load, planned run load, and planned setup load.
b. If the setup included flag is no, the total load equals the released run load plus the planned run load.
11. The load as a percentage of total capacity is calculated. It equals:
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X
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100
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Effective Capacity
Per Period
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a. If the total capacity is zero, the message "No Capacity Defined" is printed.
b. If the load is greater (or less) than the capacity for the period, and the overload (or underload) percentage is greater than a user-defined percentage, the Exception report is printed.
c. If the load is greater (or less) than the capacity for the period, the overload (or underload) percentage is greater than a user-defined percentage, and the reporting option equals the pacing of the workcenter, the Detail report for the period is requested.
d. If any calculation causes a field to overflow, the calculation fields on the report for that period are filled with nines, the message "Overflow Has Occurred" is printed, and processing ends for the period.
12. Past due detail lines are printed.
13. Report period detail lines are printed for the Labor Load Summary (CP500A).
14. Report period detail lines are printed for the Machine Load Summary (CP500B).
Wrap-up processing
1. After each report request is processed, it is deleted from the Capacity Planning Report Request file.