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| ATC Capacity Input for
Customer Order Scheduling |
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Available to Capacity (ATC)
will be defined in more detail later in this section of the
book; however, it is important to link the S&OP output for
cell capacity planning to ATC. As will be explained in the ATC
section, cell capacity as determined at S&OP will be used
in customer order booking to match capacity to demand. This
process prevents unintentional over booking of capacity in the
production final assembly cells.
We know from the S&OP planning example above that we are
forecasting to sell 2737 Widgets per day for May 2004 and that
we have committed to produce that quantity per day. Capacity
for the Widget final assembly cell has been established as 2737/day,
or for a 5-day working week, 13685/week. The 13685 units/week
is the Widget final assembly cell capacity for a planned 5 day
work week. This capacity is used by ATC for scheduling of customer
orders.
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The supplier 1 line per item
report is used to reduce the lead time from a supplier by giving
the supplier sufficient information to plan production and reduce
their lead time to that of packaging and shipping time once
a release has been triggered.
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| The supplier 1 line report
contains |
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- Contact information from the ordering contact
- The supplier contact information
- The date of the report
- Part #s being ordered and the kanban quantity
- The planned quantity for the next few weeks, and for the
next few months.
This report is sent to suppliers weekly, or when a major
change in the business occurs that affects the suppliers.
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| Building Block 8,
ATC Customer Order Scheduling |
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| ATC, Available to Capacity,
is a primary route of the overall Lean Roadmap process. ATC
is the capacity management process at order entry that allows
for: |
• Scheduling
of customer orders to final assembly cell capacity for
repetitive products
• Full lead-time scheduling of cells for non-repetitive
items
• Prevention of over-scheduling of cells at the time of
order booking. Scheduling that exceeds capacity is done
when a known on-time delivery will occur. |
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| ATC Process Flow |
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| ATC is a final assembly capacity
matching process. As orders are received, capacity is reduced
in the cell for the week the product is requested. |
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| A more detailed description
of the process is |
- As customer orders are received,
- Orders are compared against a capacity table for available
capacity. (Note that all line items on an order are considered
and the longest lead-time date for the order is used for
the delivery date.)
- Should an order promise date exceed the customer requested
date, a best date is determined by the scheduler and the
customer is notified.
- Customers receive an immediate order confirmation for
those orders that meet or are less than promised lead-time,
and a confirmation is given for dates that are greater than
the customer requested date.
- A daily customer build schedule is used by each cell leader
to macro-schedule the cell for that day or week, and plan
staffing levels based on calculated Takt time.
- Customer orders are assembled and labeled for delivery
to a specific order consolidation point.
- Assembled products are delivered multiple times per day
to a specific customer order consolidation point for shipment.
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Customer
Orders Scheduling
ATC Available to capacity |
Each
bucket represents one production in week,
Each Bucket of capacity = a weekly capacity of 13865
units of product. |
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| Notes of Clarification |
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- The ATC module is a macro-scheduling tool and is divided
into weekly capacity buckets for each final assembly cell.
Each bucket contains a quantity of units that can be produced
per day times the number of working days scheduled for that
week.
- A weighted average cycle time at the constraint operation,
based on sales and operations planning logic, is used to
calculate unit capacity.
- The final cell is where the micro-scheduling takes place.
At ATC, a promise date for the last workday of the week
the product is scheduled is promised. (This is variable.)
Therefore the cell has not been overscheduled. The cell
leader then groups work together based on assembly logic,
and by customer request date all customer orders are grouped
on the customer build schedule by date and part number.
- Takt times are calculated each week and/or day for each
cell, providing the cell leader an indication of staffing
required to meet the customer demand. Standardized work
sheets are then used to assign work within the cell.
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| In the Lean Roadmap process,
material for assembly of repetitive products is not considered
as a constraint. Lean Roadmap uses the same number of family
units forecasted to plan capacity and to plan kanban levels.
For non-repetitive items, Lean Roadmap first verifies any available
finished goods inventory. If none exists then the end-to-end
lead-time for the product from MRPII is used to schedule the
cell, consume the capacity, and promise the order. |
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Copyright@2006, All Rights Reserved
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05.05.06
