Capacity Load Planning

As a production planner
I want to calculate capacity and load per work center for a date range
So that I can see which work centers are overloaded in that period

Setup:

1. On Shop Floor Overview, set Status, From Date and To Date.
2. Choose Update Capacities. On the Shop Floor Tablet role center, choose Update Capacity Load instead.
3. Review Capacity, Allocated capacity and Load Pct. in Capacity Load Lines.

Note: Each calculation replaces your previous lines. Your lines are only visible to you. The on-screen calculation always uses one period from From Date to To Date. If To Date is blank, the period runs from From Date for one Period Length.

As a production planner
I want to know what the capacity figures mean
So that I can trust the numbers when I discuss them with the team

Setup:

1. Capacity is the effective capacity of the work center or machine center in the period, from its calendar.
2. Allocated capacity is the load in the period. For a work center, it is the allocated time of the capacity need on the work center, including operations on its machine centers. For a machine center, it is the needed time of the capacity need on that machine center.
3. Load Pct. is Allocated capacity divided by Capacity, multiplied by 100 and rounded to a whole percentage.

Note: When a work center or machine center has no effective capacity in the period, Load Pct. is shown as -100. Concurrent Capacities and Efficiency are copied from the work center or machine center card for reference.

As a production planner
I want to open the operations that make up a work center's load
So that I can decide which jobs to move

Setup:

1. After Update Capacities, look at Total operations, Operation starts and Operation ends in Capacity Load Lines.
2. Choose a value to open Prod. Order Routing with the matching operations.

Note: Total operations counts operations that overlap the period, Operation starts those that start in it and Operation ends those that end in it, for the selected Status. The counts include operations planned directly on that work center or machine center. Operations on a work center's machine centers are counted on the machine center rows.

As a production planner
I want to leave out work centers below a load threshold
So that I only look at the bottlenecks

Setup:

1. On Capacity Load Setup, set Show Greater Than Qty and Show Greater Than Pct on your line.
2. Choose Update Capacities or Export Capacity Load to Excel.

Note: A row is shown when its load is above Show Greater Than Qty or its load percentage is above Show Greater Than Pct in at least one period. With the default value 0 for both, work centers with no load are hidden. The thresholds apply to both the on-screen calculation and the Excel export.

As a production planner
I want to see machine centers under their work center
So that I can balance load between machines

Setup:

1. On Shop Floor Overview, turn on Show Machine Centers.
2. Optionally enter a Machine Center Filter.
3. Choose Update Capacities.

Note: Machine center rows are added for the machine centers of each work center in the calculation. The machine center load is based on needed time and, in this version, is not limited by the Status, Include Load from Orders or Include Load from Journals settings. Compare machine center rows with each other rather than with the work center row.

As a production planner
I want to choose whether the load comes from production orders, planning worksheets or both
So that I can compare committed load with planned load

Setup:

1. On Shop Floor Overview or Capacity Load Setup, set Include Load from Orders and Include Load from Journals.
2. Choose Update Capacities or Export Capacity Load to Excel.
3. When you export with only journal load selected, you can enter Worksheet Name and Batch Name on the request page to use a single planning worksheet.

Note: At least one of the two must be selected, otherwise the calculation stops with an error. With both selected, load from production orders and planning worksheets is added together.

As a production planner
I want to export the load for several periods to Excel
So that I can share a load plan with colleagues

Setup:

1. On Shop Floor Overview, choose Export Capacity Load to Excel.
2. On the request page, set Start Date, Period Length (for example 1W or 1M) and Number Of Periods (1 to 12).
3. Set Production Order Status Filter, Work Center Filter and Show Machine Centers as needed, and choose OK.

Note: The workbook has one column per period, with the start date of the period in the first header row and the end date in the second. Each work center gets a name row followed by Workload, Capacity and Workload % rows, depending on Show workload, Show capacity and Show workload %. Machine centers are indented one column under their work center. Values you change on the request page are saved to your Capacity Load Setup line.

As a production planner
I want to colour periods by load percentage
So that overloaded periods stand out at a glance

Setup:

1. On Capacity Load Setup or on the Excel request page, set Colour green limit, Colour yellow limit and Colour red limit.
2. Choose Export Capacity Load to Excel.

Note: A period is coloured red when its load percentage is above the red limit, yellow when above the yellow limit, and green when above the green limit. Periods at or below the green limit are not coloured. The colour is applied to all the rows of that work center or machine center for the period. Colours are only used in the Excel export.

As a production administrator
I want to restrict the capacity calculation to the work centers that matter on the shop floor
So that planners are not distracted by other work centers

Setup:

1. On Shop Floor Setup, choose Set Fixed Work Center Filter.
2. Define the filter on work center fields, for example Work Center Group Code, and choose OK.

Note: The fixed work center filter applies to both Update Capacities and Export Capacity Load to Excel for all users, on top of each user's Work Center Filter. It does not filter Operation Lines. Clear all conditions in the dialog to remove it.

As a production planner at a multi-site company
I want to calculate capacity only for work centers at my location
So that the load picture matches my site

Setup:

1. On Capacity Load Setup, set Location Code on your line.
2. Choose Update Capacities or Export Capacity Load to Excel.

Note: Location Code limits the work centers and machine centers included to those with that location code. It also filters Production Order Lines and Operation Lines on Shop Floor Overview.

As a production planner
I want to use a short period on screen and a long horizon in Excel
So that I can steer today's work and plan ahead with the same setup

Setup:

1. On Shop Floor Overview, set From Date and To Date for the on-screen period.
2. On Capacity Load Setup, set Start Date, Period Length and Number of Periods for the Excel export.

Note: From Date and To Date are only used by the on-screen calculation and the order and operation lists. Start Date, Period Length and Number of Periods are only used by the Excel export. Show Capacity, Show Workload and Show Workload Pct affect both, so keep them turned on to see all three values on screen.