Re: Setting up long leadtime operations in OW Mfg and Product Costing systems


Well Known Member
Re: Setting up long leadtime operations in OW Mfg and Product Costing systems

Hello T.G.,
I thought I have the pretty similar case with you but
up to now, I do not see any problems critical.
Could you further explain what you mean multiple WOs
can not reside in the same work center at same time ?
<> ªº¶l¥ó¤º®e: > Dear colleagues,
> I am currently working for a OneWorld client in the
> refractories industry
> and regarding the
> implementation of manufacturing systems for the
> client I have some
> questions that somebody
> on this list might shed insights.
> The client is implementing all the three major
> systems of Financials,
> Distributions, and Manufacturing
> of J.D. Edwards OneWorld.
> The issue that I want to have input from you is
> related to the setup of
> manufacturing leadtimes for some of
> the operations in the manufacture of refractories.
> The typical refractories manufacturing process
> involves use of kilns
> (tunnel kilns and/or shuttle kilns) for
> the burning or drying of the refractories after
> shaping of the refractories
> on press machines.
> The problem is, the burning or drying operation in
> the kilns usually takes
> more than 24 hours and the
> work orders that are operated in the kiln are always
> more than 10.
> This means that you can not set up the real duration
> time of the burning or
> drying operations for the
> refractories in the OneWorld manufacturing system.
> If you setup the
> operation time of the kiln as it
> takes in the real world, you can not have a
> realistic schedules for the
> operations in the kiln because,
> although multiple WOs can be at the kiln work center
> at the same time, you
> can not assume multile
> WOs residing in the same work center at the same
> time in OneWorld
> Manufacturing system.
> I tried one turnaround for the setup of the
> leadtimes for burining
> operation using a surrogate operation time
> short enough and waiting time long enough to cover
> the real operation time
> by adding up the two leadtime
> factors. This made the results of scheduling look
> more realistic but this
> turnaround also had the problem
> of making the operation time of the kiln look
> unrealistic. This turnaround
> leaves the problem of
> unrealistic product costing system setup and
> resultant disability of
> reporting the real operation times for
> the kiln work centers.
> If anybody on this list has an idea to shed on this
> issue, it would be
> heartily appreciated.
> Any idea that can solve the issues regarding the
> Manufacturing system setup
> and Product Costing
> system setup for this case is welcome. If you have
> any experiences
> implementing OneWorld Manufacturing
> system for refractories industry or similar
> industries, please help me.
> T.G. Yoon / Application Consultant, CPIM
> Doosan Corp.
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Legendary Poster
Re: Setting up long leadtime operations in OW Mfg and Product Costing systems

If I understand T.G. correctly he is stating that the amount of time required to burn/dry in the kiln varies depending on how many other refractories are in the kiln and that this number includes refractories from more than one work order.

This is a classic problem for MRP and Operations Scheduling where a work center / resource can simultaneously service multiple W.O.'s but only by reducing its capacity (by taking longer to bake, in effect capacity has been reduced).

Are these the same items sharing the kilns? I suspect they are not the same but if they are, there are several approaches you may take to resolving this issue.

If they are the same item you can instruct MRP to combine multiple demands into a single W.O., or your planners can manually achieve this.

If these are not the same items you may use the capacity approach to control scheduling of the operations IF your planners have enough lead time to play with capacity scheduling. By adjusting the resource units of the kiln Workcenters you can cause the system to stretch out the time an operation would spend in one of those W/Cs. The negative here is that doing so automatically produces a difference between the initial Work Order Start Date and the First Operation's Start Date. You will see the first operation for a WO being scheduled before the W.O. start date (and MRP schedules components and raw material to arrive according to the W.O. Start Date).

I suspect that the above are only partial answers (if that) to your problem T.G. OneWorld is pretty basic MRP and doesn't have many bells and whistles. Some sort of customized solution may be required, but let's hear what other, wiser heads have to say :)


Larry Jones
OneWorld B733.1, SP 11.3
HPUX 11, Oracle SE 8.1.6