Introduction to Rhythm Factory Planner(ppt)
Introduction to Rhythm Factory Planner
Agenda
What Is Rhythm Factory Planner (FP)
Rhythm FP Architecture
Rhythm Factory Planner (FP) Planning Concept
Rhythm FP features
What Is Rhythm Factory Planner (FP) ?
What Is Rhythm Factory Planner (FP)
Factory Planner uses the information from the existing transaction system (ERP) to provide intelligent decision support capability in Planning and Scheduling
Factory Planner provides a global integrated view
What Can Rhythm FP Do?
Factory Planner provides a systematic and constraint-based planning concept
Factory Planner can help to minimize the current ad-hoc planning process
Factory Planner can quickly reveal the production constraint, which is almost impossible for traditional planning process

Rhythm FP Architecture
Rhythm FP Architecture
Client-Server Architecture
Both server and client processes can run on Windows NT machines
May run server and client on separate machines
Use existing data (from Triton and SFCS)
Memory Resident
Multi-User capability
Rhythm FP Architecture (cont.)
Rhythm FP Framework (Input & Output)
Rhythm FP Framework (cont.)
FP requires ACCURATE and SUFFICIENT data input (garbage in & garbage out)
Open loop planning process in the first phase
Planners execute the production plan based on FP’s suggestion
Basic FP Data Objects
BOM data
Demand order data
Part number data
Unassigned inventory data
Supplier part data
Resource data
Routing data
More FP Data Objects
Wip data
Operation resource data
Resource calendar data
Vendor calendar data
Variable capacity bucket size data

FP Output Files
Critical delivery data
Purchase order EDC recommendations
Manufacturing order data
Planned start times
Procurement data
Procurement by part data
etc.
FP Data Objects Relationship
Rhythm FP Planning Concept
FP Planning Concept
BTO (Build-to-order) engine: use Demands as the driver to create plan
Consider both material and capacity constraints at the same time
Consider both Sales Orders and Forecasts as the demand input with different priorities
Start as an Infinite Capacity Plan and progress to a Finite Capacity Plan
FP Planning Concept (cont.)
Materials are assigned according to the BOM explosion from the finish good level
also consider Time factors
Raw Materials (Procured Parts) are supplied by on-hand inventory or P.O. from vendors.
Manufactured parts (finish goods and intermediate parts) are supplied by WIP or manufacturing orders (work orders).
Process Flow in FP
FP Infinite Capacity Planning (ICP)
Build factory model phase
Inventory Assignment phase
Planned start time phase
Capacity utilization phase
Presents plan through user interface (client)

ICP -- Build Factory Model
Read files into memory and create resident memory model
File formats in Spec Files
Do consistency checking

ICP -- Inventory Assignment
Explore Bill of Materials
Determines BOM configuration and routing assignments
Creates manufacturing orders to satisfy demands
Net requirements for raw materials and sub-assemblies against on-hand inventory and WIP (Work-In-Process)
Creates material requirements
ICP -- Inventory Assignment (cont.)
Backward Schedule
Definition: Latest Possible Start Time (LPST) - the latest date a manufacturing task can begin and still complete on time
LPST = Task Due Date - Task Processing time
Calculates the LPST for each manufacturing task
Each manufacturing task will have a LPST
Soft constraint: violate LPST constraint will deteriorate the order-fulfillment performance
ICP -- Inventory Assignment (cont.)
Backward Schedule
ICP -- Inventory Assignment (cont.)
Inventory Assignment
Prioritize demand orders (due date, priority, quantity)
Sort prioritized demand orders
Sort parts from end-item to raw materials
Calculate demands
Allocate supplies
ICP -- Inventory Assignment (cont.)
Forward Schedule
Definition: Earliest Possible Start Time (EPST) - the earliest date that a manufacturing task can begin (constrained by materials)
EPST = max (Server Start Time, Material Available Time)
Calculates the EPST for each manufacturing task
Each manufacturing task will have an EPST
Hard constraint: production cannot be started without materials available
ICP -- Inventory Assignment (cont.)
ICP -- Planned Start Time
Assign PST for each task
Definition: Planned Start Time (PST) is the expected start date that a task will begin taking material availability into consideration
Calculation: PST= max (EPST, LPST)
Each manufacturing task will have a PST
PST values may be overriden through the user interface
ICP -- Capacity Utilization
Determine bucket (operation time interval) configuration -- from variable capacity bucket size data
Calculate capacity for each bucket -- from resource calendar data
Calculate work load in each bucket based on PST and run time of each task

FP Finite Capacity Planning
Identify the constrained resources
Balance and offload loads for constrained resources in a GLOBAL view (Global optimization)
Plan based on flexible strategy options (e.g. Minimize WIP)
Respond quickly
FP Detail Scheduling
Schedule based on flexible strategy options (e.g. FIFO)
Able to specify the scheduling horizon
Able to generate a global optimized production schedule
Generate the dispatch list for execution
Intelligent scheduling algorithm and results
How to make it successful
User-own project
Trust and Cooperation
What are our game rules?
Forecast/Acceptance, S/O, P/O, etc.
Thinking of future, reasonable procedures
Data Clean-up
Should be started from the very beginning
Where, when, who, how, etc.
etc.
Rhythm FP Features
List of Some Features
Transfer Batching
Manufacturing Lot Sizing (CMO)
Procurement Lot Sizing
WIP Reporting
Advanced Scheduler (AS)
Due Date Quoting
Batch Client
Using Rhythm FP
Using FP -- Basic UI entities
Problem windows
Reports
Demand orders
Demand order plan
Mfg orders
Mfg order plan
Part buffer
Using FP -- Problem Windows
FP has the outstanding problem analytical capabilities
Short order problem
Late order problem
Capacity shortage problem
Material shortage problem
Late manufacturing parts problem
Using FP -- Problem Windows (cont.)
Using FP -- FP reports
Critical delivery report
Purchase order EDC report
Procurement report
Late material reservations
Master schedule
Resource load
Using FP -- Demand orders
Using FP -- Demand Order Plan
Using FP -- Mfg Orders
Using FP -- Mfg Order Plan
Using FP -- Part Buffer
Questions & Answers

Introduction to Rhythm Factory Planner(ppt)