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Simultaneous product manufacturing - Planning, Production and Costing

  • 12 October 2022
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pjcribeiro
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We are a manufacturing company that produces plastic pieces from injection machines. The same mold can produce several pieces simultaneously in the same injection cycle. We are searching for a best practice solution to help us planning, producing and costing each piece. The different shop orders will share the same work enter and the same mold version and be produced simultaneously. 

Any advice on where to start and develop a best practice solution inside IFS?

 

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Best answer by Björn Hultgren 13 October 2022, 08:10

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Paulo Ribeiro

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Saman K
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Hi

I would like to suggest certain functional alternatives that you can think of.  Of course these alternatives can be evaluated to use in your requirement. One is resource share. The other is operation block functionality. Resource share basically support running different product in a same machine simultaneously while operation blocks helping, planners to group operation together in to a execution block where the block can be planned to execute in parallel or sequential manner.  I also would like to hear from someone who is already using these functionalities or has used some other alternative.

Thanks

Saman

Saman K
pjcribeiro
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Hi Saman.

Thanks for the quick feedback.

We will take a look at what you are suggesting, namely the resource sharing.

We already explored block operations. It may solve the plan and production stage but on the cost level there might be some challenges.

Paulo Ribeiro
Björn Hultgren
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@pjcribeiro As already proposed by Saman, defining a Resource Share less than 1 (100%) for the operation would indicate it would not use the full capacity from the machine during its execution. This will lower the cost and load. 

Operation blocks can be used to plan the operations that can be executed by the machine at the same time.

Attaching two slides that describes two scenarios where resource share can be used slightly differently:

 

 

pjcribeiro
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Hi Björn.

Thanks for the feedback.

From a planning and production point of view and even shop order cost it seems to be a solution.

We need to check if from the inventory part standard costing perspective we can also use this approach. 

Paulo Ribeiro
Björn Hultgren
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@pjcribeiro If you define the resource share on the routing it will be considered also in the part cost calculation to set the standard cost.

pjcribeiro
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Thanks Björn.

We will try these clues into our IFS data and if it works we will comeback with the conclusions.

 

Paulo Ribeiro
pjcribeiro
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We have been testing the solution.

If for the costs of the work center, the resource share solves the problem and allows to divide the work center costs in various simultaneous products, for the labour costs the behaviour is different. These costs are not divided accordindgly.

Any suggestions?

Paulo Ribeiro

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