The DEAR Production Scheduler visualises Production Order information. Production Order information, Sales Orders (containing goods to be produced) and Resource capacity can be viewed in the form of a Gantt chart.
The main goal of the Scheduler is to create a schedule for production, so all finished products are produced on time, providing smooth production without any delays. The second main goal is to provide transparency for the production process so that the user always knows what should be produced and when it should be completed. One of the core abilities of the Scheduler is to reschedule Production Orders, Production Runs and operations.
This tool helps to assess how long the order should take, determine the resources loading, and plan in which sequence the operations should be completed. The Scheduler also enables you to view and manage the dependencies between operations.
- Follow Getting Started with the Production Module
Table of Contents
- Scheduler Basics
- Editing the Scheduler (Rescheduling Orders, Runs and operations)
The Scheduler contains the following views:
- Planning – the Gantt view of Production Orders in planned status.
- Production Orders – the Gantt view of Production Orders in released status.
- Sales Orders – the Gantt view of Sales Orders which finished goods are in production now.
- Resources Gantt – the Gantt view of allocated resources by their Production Orders.
- Resources Table – this optional view can be toggled on and off on the other views to show resource capacity vs. allocation for the selected period.
Only users with the full access permission to the Scheduler will be able to edit the Scheduler to reschedule Production Orders, Production Runs and operations. All settings and views are available to any user with at least read-only access. See Managing Users & Roles and User Permissions Explained for more information.
Configure Scheduler Settings and Filters
Scheduler settings and filters can be configured at the top of the Scheduler screen. Choose whether to view the Planning Gantt, Production Orders Gantt chart, Sales Orders Gantt chart or Resources Gantt chart. Not all filters are available for each view.
Production Orders can be viewed for one Shop Floor location at a time, selected from the drop-down list. Gantt charts can be displayed in hours, days or weeks – each cell can be equal to one hour, one day or one week.
The Resource view toggle makes the Resources table visible/invisible. See Resources Table described below. The Resources table is available for the Planning view, Production Orders view and Resources view.
View (Layout Settings) – this drop-down field allows you to change the layout and visuals of the Scheduler grid. This setting is available for all Scheduler views.
- Horizontal lines – displays horizontal lines for the grid.
- Vertical lines – displays vertical lines for the grid.
- Dependencies – displays the dependencies for the operations.
- Expand all – expands all lines.
- Collapse all – collapses all lines to the top level.
- Show completed – shows completed orders.
- Show weekends – shows weekend days (weekend days are shown in grey).
Dates – this drop-down field allows you to choose the time frame for the Scheduler view (this setting is available for all Scheduler views):
- All dates
- Due today
- This week
- 7 days ahead
- 14 days ahead
- Custom time frame.
Use Scheduler filters to filter which results show in the Scheduler view. Multiple filters can be applied at once.
Buffer % – allows the filtering by the remaining percentage of the Manufacturing Buffer for an order. It is possible to select multiple options. This filter is available for the Production Orders view.
Work Centre – allows the filtering by Work Centres set up for the Production Module. It is possible to check as many checkboxes as needed. By default, the All option is selected. This filter is available for the Production Orders view and Resources view.
Resource – allows the filtering by resources codes which are utilised in the Production Orders, Production Runs and operations. It is possible to check as many checkboxes as needed. By default, the All option is selected. This filter is available for the Production Orders and Resources view.
Manufacturing Buffer is a value set in the Production BOM to protect production order deadlines. The buffer is set to allow enough time to complete the Production Order when something goes wrong. The manufacturing buffer is added to the Release date of the order.
The manufacturing buffer is set in percentage terms to define how much production time is needed as a buffer.
Each delay causes a reduction of the total buffer percentage. There are 3 manufacturing buffer zones:
- Safe zone (66.6+%): There is plenty of time to complete the Production Order.
- Warning zone (33.3-66.6%): There is time to complete the Production Order. Production should not be delayed any further.
- Unsafe zone (0-33.3%): The Production Order can't be delayed anymore and should be processed urgently.
The manufacturing buffer is visible on the Planning view, Production Orders view and Sales Orders view.
Total Manufacturing Buffer is applied to the whole Production Order.
- Example: The Manufacturing buffer for the finished good Chair is set to 40%. A Production Order for 10 chairs takes 40 hours of pure production time. The Manufacturing buffer for the order is 40% x 40 = 16 hours. The total time calculated for the Production Order is therefore 40 (Production time) + 16 (Buffer) = 56 hours.
A Production Order can be made up of multiple Production Runs. The Manufacturing buffer is applied to each Production Run proportionally in the same way as to the whole Production Order.
- Example: We have three Production Runs for the finished good Chair.
- Production Run 1 – 2 chairs
- 8 hours (Production time) + 3.2 (40% x 8) hours (Buffer) = 11.2 hours (total time)
- Production Run 2 – 3 chairs
- 12 hours (Production time) + 4.8 (40% x 12) hours (Buffer) = 16.8 hours (total time)
- Production Run 3 – 5 chairs
- 20 hours (Production time) + 8 (40% x 20) hours (Buffer) = 28 hours (total time)
- Production Run 1 – 2 chairs
NOTE: The manufacturing buffer is not applied to individual production operations.
Production Orders with Planned and Released status will appear in the Planning view of the Scheduler.
Select one or more orders (use Shift + click or Ctrl + click to select multiple orders) in the Planned section and click Release Orders to move them from Planned status to Released. You can also double-click an order to open the release confirmation window.
You will be able to change the Release date when Releasing an Order; however, orders in this view cannot be dragged and dropped to reschedule.
Production Orders in the Releasing section of this view will be shown according to their Production Runs. Releasing a Production Order from the Planning view will automatically create one Production Run for the entire quantity of the order. You can click through to the order itself from the list on the right to divide the order into more Production Runs if required.
Production Orders Gantt
Production Orders Gantt visualises scheduling information for Production Orders, Production Runs and production operations. Orders are visible in the Scheduler once they have been released. Orders are prioritised in order of release date.
To the left of the screen, the Production Order number is listed with the finished good SKU and the progress percentage of the order. Click the Production Order name to be taken to that Production task. To the right is the Gantt chart display. Hovering over any Production Order line will show a pop-up window displaying extra information for that order including problems such as lack of resource capacity.
The Scheduler lists the orders to be performed or resources on the vertical axis, and time intervals on the horizontal axis. The vertical axis rows are expandable:
- Level 1 – Production Order # – lists the number of the released Production Order.
- Level 2 – Production Run # – lists all Production Runs that are within this Production Order.
- Level 3 – Operations – lists the operations in their sequence for the Production Run. Light-shaded areas of the bar indicate non-working hours.
- Level 2 – Production Run # – lists all Production Runs that are within this Production Order.
Click the arrow to the left of the Production Order number or Production Run to expand or collapse any line of the Scheduler.
The Production Orders view allows the user to reschedule production tasks from the Edit Mode. See Rescheduling Production Orders, Production Runs and operations below for more information.
Resources Gantt displays scheduling information for each of your Resources. Resources Gantt can be displayed in hours, days or weeks – each cell can be equal to one hour, one day or one week. The rows of the vertical axis are expandable:
- Level 1 – Resource – lists all resources set up in Production Settings. Dark-shaded sections indicate the resource being used, light-shaded sections indicate a resource not being used.
- Level 2 – Operations – lists the operations where the resource is utilised. The Production Order # of the operation and its cycle time are listed to the left. Dark-shaded sections indicate working hours, light-shaded sections indicate non-working hours.
Example: As you can see from expanding the Resources view for LAB-001, dark-shaded sections of the red bar indicate the resource being used, and light-shaded sections indicate a resource not being used. Light-shaded sections of the red bars indicate an under-utilised resource.
Example: LAB-002 is fully shaded in darker red, indicating the resource is being used to capacity. Light sections of the purple operation bars correspond to a midday break and the non-working hours of the night and weekends.
Sales Orders View
Sales Orders Gantt visualises scheduling information for Sales Orders that include finished goods. Sales Orders Gantt can be displayed in hours, days or weeks – each cell can be equal to one hour, one day or one week.
The rows of the vertical axis are expandable for Sales Orders:
- Level 1 – Sales Order # – lists the Sales Orders that contain one or more finished goods.
- Level 2 – Production Orders # – lists all Production Orders that are created to address the Sales Order demand.
Hovering over any line will show a pop-up window displaying extra information for that order, such as the Required by Date and the expected date and time of completion for the order.
The Resource view toggle (Resources Table toggle) makes the Resources table visible/invisible. The Resources table displays the amount of allocated capacity in the vertical axis. The Resources table is displayed showing resource capacity compared with resource allocation per day. The Resource view toggle can be toggled on/off in the Planning view, Production Orders view and Resources view.
- Resources in green are within capacity.
- Resources in yellow are allocated at capacity.
- Resources in red are overallocated for that day.
Auto-Planning and Auto-Releasing Production Orders
Planning or Releasing of a Production Order can be automated in order to save time on planning similar orders. Production Orders created by sales can be set to be created with Draft, Planned or Released status. Auto-planning an order will automatically add it to the Planning view of the Scheduler. Auto-releasing a Production Order will automatically add it to the Planning and Production Orders views of the Scheduler.
This setting can be configured from Settings > General Settings > Production Process Customisation. Set Create Production Order to When Sales Order is authorised and Create Production Order status to Planned or Released.
When an order is released, it is automatically placed in the Scheduler with one Production Run for the whole order. The Planned date and Release date will be calculated automatically using the From Required by Date backward method.
Rescheduling Production Orders, Production Runs and Operations
The editing mode is opened by clicking Edit Mode in the top right of the Scheduler screen. It is not possible to edit the Scheduler if it is being edited by another user. The Edit mode is only available for the Production Orders view of the Scheduler.
The orders displayed on the Scheduler can be rescheduled by dragging and dropping Production Orders, Production Runs, and operations. Any movement of a scheduled object causes changes throughout the Production Module. You can also click Reschedule next to a Production Order line to automatically reschedule orders according to available capacity.
The rules for drag-and-drop for the orders/runs/operations are:
- An object can't be dragged into the past, i.e. it is impossible to schedule any object to the date later than the current date.
- It is impossible to drag one object above the other. The objects can't overlap each other.
- Dependencies for the objects are not interrupted and connect the objects anywhere where they are moved.
- Dragging and dropping an object means rescheduling and re-planning of components and resource capacity.
When an object is dropped, the following processes take place:
- The initial release date marker is not moved for the Production Order to show the initial release date.
- The resource capacity is re-planned for this Production Order – reversed allocation of the resource capacity (see Capacity Planner).
- The spare capacity is re-allocated to the other Production Orders where it is needed.
- Allocated components are not changed for this Production Order.