Labor Requirements Reschedule - Async - Calculations

SF106E

A. Housekeeping

1. All work fields are defined, and program constants are initialized.

2. Data is retrieved from the following records on the System Control file (CT100M):

a. The Shop Floor Control Record (SFCTL1) is accessed for the system post options. If this record is not found, processing terminates both for this program and for Manufacturing Order Generation (IC102E).

3. Data is retrieved from the following records on the Reference file (REFERP).

a. Category 446 is accessed for quantity field size for order quantities. If this record is not found, a message is sent to the system operator and the program aborts.

b. Category C14 is accessed for the last shop date. If this record is not found, a message is sent to the system operator and the program aborts.

4. The input parameter list from the Manufacturing Order Generation program (IC102E) is received:

Parameter		Use
Generate/Reschedule Flag (SHDRCH)		Input
Scheduling Direction Flag (CZFBSC)		Input
Order Number (LRORNO)		Input
Order Part (CZPPN)		Input
Order Quantity (CZORDQ)		Input
Date to Begin Schedule (STDAT)		Input/Output
Effectivity Checking Date (EFDAT)		Input
No L/R's Return Code (NOLRS)		Output
Critical Scheduling Error Return Code (SLERR)		Output
Warning Scheduling Error Return Code (ERRCDE)		Output
Abnormal Termination Return Code (LRGEN)		Output
General Error Indicator (ERROR)		Output
Plant (CZPLNT)		Input
Manufacturing Company (CZCO)		Input
Warehouse (CWHNO)		Input

B. Mainline

1. The input date, effectivity date and order quantity are converted to numeric fields. The scheduling direction (forward or backward) is retrieved from the input parameter list. Whether processing is for GENERATE or RESCHEDULE is also determined from the input parameter list.

2. The appropriate GENERATE or RESCHEDULE logic is performed.

3. In the event that no labor requirements records were processed from the master files, a warning message is returned to the Manufacturing Order Generation program (IC102E). Otherwise the program terminates normally and returns the parameter list to IC102E; this contains the due date of the last operation (if forward scheduling) or the start date of the first operation (if backward scheduling).

4. Any abort in the program is passed back to the Manufacturing Order Generation program (IC102E) in the parameter list.

C. Generate

1. Labor requirements records are generated from the operations listed on the Routing file for the parent part on order. Only those operations that are effective at the start date of the order are converted into labor requirements. Additionally, all routing steps which have neither a piece rate nor a lead time are ignored. JIT operations are ignored.

2. If the manufacturing order is configured, retrieve the labor requirements from the Generated Labor Requirements workfile (EC200AP). Delete the records after successfully reading them.

3. The inclusion of comments and alternates in the Labor Requirements file is determined by the system wide options to support comments and/or alternates.

4. As each operation record is read, data is transferred from the routing record to the corresponding new labor requirement record. This includes piece rate, setup hours, number of persons and machines required, permissible run time overlap (with the preceding operation), and descriptive data (tool and machine number).

5. If operation record read is a fixed time operation, the sensitivity flag is checked. If the operation is batch sensitive, the length of time to complete a batch is calculated. This will be used as the actual hours for that operation.

NUMBER OF BATCHES	=	ORDER QTY — (SENSITIVITY FACTOR * BATCH QUANTITY) BATCH QUANTITY
LENGTH OF TIME TO COMPLETE OPERATION	=	FIXED TIME LOAD * NUMBER OF BATCHES (ROUNDED UP) WORKCENTER HOURS PER DAY

6. The Workcenter file is accessed for the workcenter that will perform each operation. The working hours per day, move and queue times, and machine-or labor-paced flag are transferred to each labor requirements record.

7. Each primary routing operation is scheduled *sequentially (backwards or forwards) before being written to the IC102E workfile as an active labor requirement. Alternate operations (if selected) and comments (if selected) are written directly to the workfile as inactive labor requirements. Alternate operations for master operations are invalid and are rejected.

8. Master operations are validated before being written to the workfile. A master is only valid when it is preceded in the routing by active operations in a given workcenter that all have identical crew flags. Consecutive master operations, and master operations separated only by inactive labor requirements or comments, are also invalid.

D. Reschedule

1. If existing labor requirements are to be rescheduled, the Labor Requirements file is read sequentially for the order. Existing labor requirements are processed by the scheduling logic* before being written to the IC102E workfile.

2. Rescheduling may be caused by a change in order quantity, a change in scheduling direction, or a change to the order date on which scheduling was previously based.

3. Rescheduling as a consequence of a changed date is performed without reference to the existing labor requirements dates, and overwrites any dates previously entered. It is performed starting from the changed date, to the other end of the routing.

4. Rescheduling for a change in direction is treated identically to that for a changed date.

5. Rescheduling for a change in order quantity is performed in the direction indicated by the passed parameter. It is performed from the existing date of the first operation (for forward-scheduled orders) or last operation (for backward-scheduled orders). The order dates are not referenced.

* For a more detailed discussion of order scheduling, refer to the Shop Floor Control User Manual: Labor Requirements Generation and Order Scheduling key concept.

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Labor Requirements Reschedule - Async - Calculations

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