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Production Scheduler by PlannerOne© - Manual 2015
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“Production Scheduler” For Microsoft Dynamics NAV
Introduction to the Basics of Production Scheduler
Distributed by: Cost Control Software, Inc. 12409 Old Meridian Street
Carmel, IN 46032
Phone: (317) 846-6025
Production Scheduler by PlannerOne© - Manual 2015
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Table of Contents Application Description ............................................................................... 3
Installation & Setup ....................................................................................... 4
Sequence of Implementation ..................................................................... 5
Workflow ......................................................................................................... 6
Navigate in Production Scheduler ............................................................. 8
New Fields & Views in NAV .......................................................................... 11
NAV Routing for Scheduling ........................................................................ 15
Visualization ................................................................................................... 16
Bi-Directional Integration ............................................................................. 24
Manage Schedule and Exceptions ........................................................... 33
Summary ......................................................................................................... 35
Test Your Knowledge .................................................................................... 36
Bonus Videos by PlannerOne© ................................................................... 37
Student Evaluation ........................................................................................ 38
Course Evaluation ......................................................................................... 39
Support ........................................................................................................... 40
This Training Material is designed for the following individuals:
1-2 trainees per company, that are experienced schedulers
We are not teaching scheduling methodologies
We are working on one company installation.
Trainees will already be trained on setup, workflow and terminology of NAV Manufacturing and will be able to move about Microsoft Dynamics NAV fluidly.
This Basics Training Manual is provided “free of charge” to companies that have purchased PlannerOne through Cost Control Software only. This manual should have come to you directly from Cost Control Software. Any other distribution of this manual is strictly prohibited. Any unreported distribution violation of this material is subject to a training material charge of $1,000. Please report violations of distribution to [email protected].
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Application Description
Objectives of this Class PlannerOne© is a fully integrated and embedded scheduling tool within Microsoft Dynamics NAV Manufacturing. “Basic” training on PlannerOne© will only take one (1) day to setup, and one (1) day for learning how to get started. PlannerOne Production Scheduler is designed to enhance your NAV Manufacturing with Optimized Scheduling; and it is localized to be used with basic NAV Manufacturing or Manufacturing Plus by Cost Control Software.
Key Features
Allows users to easily move orders around with Drag-and-Drop tool feature, and always respects constraints while automatically moving other work out of the way.
Advanced scheduling features like overlap, storage constraints, and custom constraints.
Provides the look-and-feel of Microsoft products for easy usage.
Manages all constraints by taking in to account materials, machines, labor, and tooling.
Infinitely customizes activity labels on our powerful Resource Gantt and Job Gantt.
Shows resource utilization & availability by looking at organized Capacity Plan graph & grid.
Highlights problems, like bottlenecks, in red so you’ll never miss a scheduling conflict again.
Color Coded Operation Stickers
Benefits
Improved customer service level
Increased productivity through optimized capacity and set-up times
Reduced cycle-time and inventory
Improved responsiveness through the tight integration into Microsoft Dynamics NAV 2009 R2 and Microsoft Dynamics NAV 2013
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Installation & Setup Installation & Setup will be completed by Cost Control Software remotely. For the best possible scheduling results and to stay within a reasonable implementation budget we recommend the following:
1. Ensure your SQL Installation meets the Hardware Requirements specified during the sales process.
2. Ensure we are able to work with your IT Staff on a timely basis to expedite the installation.
3. Ensure we have the necessary credentials and instructions to work remotely on your server. (Install and Troubleshoot)
4. After Installation the application will be in the hands of your Production Scheduler. Be sure they have access to your Development Database and your live Production Database.
5. This class is designed for an experienced scheduler. It does not teach concepts of scheduling, it covers how to use Production Scheduler with Dynamics NAV.
6. We also assume the student of this class knows NAV Manufacturing. We have a separate Training DVD on how to use NAV Manufacturing. (Ask about it.)
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Sequence of Implementation Install, Setup, and ensure Production Scheduler is operational
1. Cost Control will create a new “Testing Database” with Production Scheduler installed. This will be done at Cost Control Software. Note: New Dynamics NAV Manufacturing installations will take less time than an existing NAV customer with NAV Manufacturing fully operational.
2. After the “Testing Database” is operational at Cost Control, we will install the “Testing Database” on Client’s Development Database. This Database will now be ready for the learning process to begin.
Start the Learning Process with our “Warm Up” Self Study Manual. (This book)
3. Client will complete this Manual’s pre-recorded “Warm Up” training on their Testing Database. This class begins on Page 6.
4. Client will attend 1 Web Training Sessions. (~ 2 hrs each). We will want to confirm that the “Warm Up” process is complete. We will be asking the “Scheduler / Student” to demonstrate what they have learned so far.
5. Client may continue to practice with software and develop a list of questions for the trainer.
6. Client will attend a 2nd Web Meeting to get answers to their questions on the basics.
Next is Level 2 training either on premise or via web meetings.
7. Now we start to “Apply” Production Scheduler to your business. With new NAV installations we setup Production Routers to optimize scheduling. With existing NAV installations we analyze your setup and make changes to optimize scheduling. Many use case scenarios are processed so you practice the real day in the life of a scheduler.
Advanced Training Topics (optional)
8. This is optional: Our Trainer travels to the client’s location for a minimum of 3 Days of on-site training and application configuration. This advanced training might also be provided through frequent web coaching sessions. We want to be sure you are properly applying Production Scheduler to solve your scheduling needs.
On-Going support will always be available to you via web meeting and billed as needed.
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Workflow The 3 Key Issues that we think you face every day:
1. Manually Scheduling - Whiteboard, Excel Spreadsheet, Paper - Can’t take account of all the factors
2. How to “Share” the schedule
- Print-outs, Post on Board, and Photo Copies
3. Duplicate Entry - Enter in both Excel and re-enter in NAV?
In conclusion: This is not a productive way to spend your time!
How we address your 3 Key Issues above:
1. Automated Scheduling - Just like MRP makes purchase recommendations, your Scheduling Software
makes recommendations - The Master Scheduler accepts, rejects, or adjusts.
2. Make it Visual with Drag & Drop Adjustments
- See you Schedule Graphically Displayed - Your monitor or “Big Screen” in the Shop
3. Fully Integrated in NAV
- Just Accept the schedule or adjust if needed - Close work period, Move an Operation, Change a Due Date, … - Move the “What if” to “Live” with ‘Publish’
(Publish the “Working Plan” to the “Published Plan”)
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First think in terms of who will use the software: Scheduling Software is for your Scheduler – This will let them “Visualize” the operations in a Graphical Format with Drag & Drop Options.
Benefits of the software:
Embedded in Dynamics NAV Designed to make your Scheduler’s job more efficient (not accountant) A very interactive presentation of the ROUTER’s date data Bonus: Sharing of the schedule - Post on a Big Screen in the Shop
For use with NAV Manufacturing or “Manufacturing Plus” from Cost Control Software
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Navigate in Production Scheduler Topics covered in this section:
Production Scheduler Orientation o NAV Production Orders = PlannerOne Work Orders
o NAV Operations on Routers are scheduled in PlannerOne
(We are not scheduling inventory or BOM)
o Views – Resource Gantt, Work Order Gantt, Load, Resource Sequence
o How to Save a View - ie: Filter for just Work Center 100 Operations
o Ribbons – Upper tabs – Planning, Optimization, Display, Actions, Filter
o Plans – Working Plan, Published Plan
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o Columns
o Indicators & Details KPI, Work Center, Machine Center, Tools, Personnel,
Multiple Types of User Access: o Planning User (probably you) o Collaborative User (Controlled by security) o Viewing User (Controlled by security)
Steps of the Scheduling Process: o New NAV Production Order (SO, MPS, Forecast, Manual) o New Operation Stickers goes to “Production Scheduler” in Stand-By section
(These new operations now need to be scheduled) o Planner runs “Schedule” Action o New Operations (Stickers) move to the Working plan o When satisfied with Working Plan you then “Publish” the plan
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Status initially indicates o Scheduled o Unscheduled (In Stand-by Section)
Subsequent operation statuses indicate o Not Started o In Progress (Indicator Bar) o Closed/completed (No longer shown on Scheduling Board)
Test your knowledge:
1. What is a Work Order in NAV?
2. What does it mean when you run the Schedule function in PlannerOne?
3. Can you save filtered views of the Resource Sequence List?
4. Provide a real situation where filtered views of the Resource Sequence List would be used?
5. What can a Collaborative User do in PlannerOne?
6. When does Planner One get information from NAV?
7. When does NAV get information from PlannerOne?
8. How do you know when an operation is started in PlannerOne?
Student Name: (required for evaluation)
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New Field & Views in NAV Topics covered in this section:
PlannerOne Additions to NAV On Item Card
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Work Center Card
Machine Center Card
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Routing Lines
Production Order Lines
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Production Order Routing Page
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NAV Routing for Scheduling
Communication between Microsoft Dynamics NAV and PlannerOne Database
See what you know:
1. TRUE or FALSE – All Machine Centers are linked to All Work Centers?
2. TRUE or FALSE – Machine Centers within the same Work Center should be interchangeable?
3. For Scheduling – When do you attach a Machine Center to a Routing Operation?
4. TRUE or FALSE – PlannerOne uses the Production Order Bill of Materials to schedule?
Student Name: (required for evaluation)
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Visualization Topics covered in this section:
1. How to access the “Planner One Desktop” from your Role Center.
2. The “Display Tab” (at the top) and how to move around.
3. The “Resource Gantt Chart” view is described - NAV Data displayed in left column - Timeline on top - Gantt Chart Body with Production Order Operations (Stickers)
4. Data available for display per Sticker/Operation - If you have 100 Production Orders with 5 operations each = 500 Operations/Stickers - Hover to see the Operation ScreenTips and how to define the tool tips.
5. Time scale Control - Adjust to your typical time frame.
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6. Operation Bar Content - You control this content, but don’t overload it.
7. Customization – Row height
8. “Setup Time” Indicator
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9. Double Click an operation to get more information:
10. From the operation ID, you can “Drill Down” to the NAV details. ESC will exit back to Production Scheduler.
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11. Operation Colors
We recommend you normally use the “Advance/Delay” view to spot late operations. However, you might want to set to Work Order/Production Order so all operation on the same production order are in the same color.
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12. Filters, Highlight WO
Shows all the operations within a Production Order
13. Add a new View. Work Order Gantt
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14. Posting Time to an operation of a Production Order
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Test your learning – Try doing all of the following and record answers:
1. What functional area of NAV does the schedule use for the Gantt charts?
2. Access the scheduler from all 5 places. Did you have any trouble finding them?
3. In the Resource Gantt chart, what is the NAV term for the Group Code column?
4. On the Resource Gantt chart, what is the NAV term for the Resource Code column?
5. How do you adjust the time scale?
6. What is a Sticker?
7. What does a black and yellow striped indicator bar on a sticker mean?
8. If the sticker contains: 1011004|10000|20 What is 1011004?
What is 10000? What is 20?
9. How do you change the content of a Sticker’s Help Tip?
10. What indicates a closed period? (Like a weekend or Down Machine)
11. What indicates the duration of an operation?
12. Draw how setup time is displayed on the Gantt Chart?
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13. What happens if I double click a sticker?
14. How do I go from a Gantt Chart View into Dynamics NAV?
15. How do you change the colors of the operations?
16. What is the purpose of the Advance/Delay Colors?
17. What happens when I switch from the Advance/Delay Color mode to the Workorder color mode while on the Resource Gantt Chart?
18. Name two other Color modes?
19. Describe why you would use the Filter Tab?
20. Name all 4 of the Views available in Production Scheduler? (1) (2)
(3) (4)
21. What does the + sign next to the view tabs do?
22. How do you adjust the row height?
23. What does the mean on the Gantt Chart?
Student Name: (required for evaluation)
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Bi-Directional Integration
1. Get Data (Real Time)(Stand-By Machine) 2. Schedule 3. Publish to NAV
1. New Production Orders immediately go into “Stand-By” for Scheduling Process.
(Sources of Prod Orders)
Notice the “Frozen Period” above. (Typically 2 or 3 Days) New Prod Orders are optimized outside of the Frozen Period.
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2. Manually enter two (2) new Production Order and Refresh in Dynamics NAV.
Exercise: Try this process in your Testing Database. Create 2 Production Orders and confirm that they show up in the “Stand-By” section of the Resource Gantt Chart. Do NOT Schedule yet.
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3. Now run the “Schedule from” to move STAND-BY Prod Orders to the Schedule:
Try this process in your Testing Database.
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2.5 Either Accept the Schedule as presented, or MOVE the Operations as needed.
The Plan is the scheduler’s “Working Plan” until he/she Publishes. NAV will not know of any changes until he/she Publishes. Your “viewers” will also not know of any changes until he/she Publishes. “Viewers” only see the “Published Plan”.
Let’s see this in the live software.
Try this process in your Testing Database.
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Machine Center – Task List/Sequence per Machine
Or from PlannerOne Desktop
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You can “Revert” (Un-do) any changes you have made during the day. You can not “un-do” your last change, only revert to the start of the last Published Plan.
You can also Swith to the current published plan, and back to the Working Plan. (This acts as a toggle)
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3. Once you are satisfied with the schedule, it is time to “Publish” the plan back to Dynamics NAV
and to your “Viewers”.
Question: How frequently should you “Publish”? Answer: As often as you want to - Typically 1 to 10 X per day. Hence you are Re-scheduling and Adjusting as needed.
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It’s time to see what you learned.
1. Where is the Stand-By area in PlannerOne?
2. What data is in the Stand-By area?
3. How does data get into the Stand-By area?
4. Name three(3) ways that data moves out of the Stand-By area?
(a)
(b) (c)
5. What is meant by a Frozen Period? Would you use a Frozen Period in your Business? If so, what would that period length be?
6. Name two(2) new things you see on the Prod. Order Card that are there now that
PlannerOne has been integrated into NAV? (a) (b)
7. What Choices are found on the Upper Optimization Tab?
8. What Choices are found on the Upper Actions Tab?
9. How do I do a Resource Re-sequencing in NAV?
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10. What happens when you “Publish” a schedule? How frequently do you think you will “Publish” a schedule in your business? And Why?
11. What does the following symbol mean?
12. Describe how to set the above symbol on a sticker?
13. Why would you use the above feature in PlannerOne?
14. What does the following mean?
15. How do you get that line to appear?
16. What effect will this line have on the schedule?
Student Name: (required for evaluation)
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Manage Schedule and Exceptions What happens during a typical Day:
- Customer changes a Ship Date
PlannerOne Adjusts the Schedule
- Customer chages a Quantity
PlannerOne Adjusts the Schedule
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- Machine Breaks Down - “Close” the Period
- Resource (Employee) does not show up for work (Sick/Vacation)
- New Order is received, run “Schedule from” Make the Change in NAV; Planner one will adjust
Make the Change in PlannerOne (ie Machine Breakdown),
Publish will push to NAV (What if)
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Summary Real Time
Uses web services
Interacts with NAV functionalities, enabling real-time communications. Ease of Use
Quick and Easy
It’s more about “Re-Scheduling” than Scheduling
Make the schedule to accommodate ‘real life’
Graphical planning is easy to understand. Fully Integrated
Works right out of the box
Simple integration and no data replication
Developed using the latest Microsoft technology (Visual Studio 2010, .Net4)
Fully integrated into Microsoft Dynamics NAV Key Functionality
Visualization for Scheduler and Viewers
Bi-Directional Integration
Manage Schedule & Exceptions.
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Test Your Knowledge: 1. Change the shipment date on a released production order. Go to PlannerOne to see the
changes. Do you have PlannerOne set to Auto or Manual Refresh?
2. Change the quantity being made on a production order in NAV. Go to PlannerOne to see the changes and note here:
3. Try “Closing” the Period on a Machine Center in Planner One. Describe how you did it?
4. Why would you “Close” the Period on a Machine Center?
5. How would you make the same change in NAV?
6. The reference to a Resource in PlannerOne is equivalent to what term in NAV?
7. How are Employees setup in NAV to indicate their usage on a Production Order?
8. If an Employee calls in sick, what two choices do you have to adjust the schedule? Try them in
the live software and then record what you did and where, and record the results below. (a) Action taken: Results on the Gantt Chart: (b) Action taken: Results on the Gantt Chart:
9. Where do you find “Add Calendar Exceptions”?
Student Name: (required for evaluation)
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Videos from PlannerOne©
Videos of Production Scheduler are provided by the PlannerOne Development Staff: These videos were produced by PlannerOne. They go very fast. We recommend you use the pause button and try some of the things they show on your Development Database.
Ctrl + Click PlannerOne Video, Part #1 (4:20 min) Review of the Visualization of PlannerOne
Ctrl + Click PlannerOne Video, Part #2 (4:30 min) Indicators & Details Windows (statistics of overall schedule) What if Machine Breakdown (Adjust Resource Calendar, Operations using this Resource are Postponed, Move Operations, and Suggest Schedule). What if Component Stock Out (View Gantt Chart in Item Color Mode, Fix start date of operation needing the component, subsequent operations postponed, Re-Schedule).
Ctrl + Click PlannerOne Video, Part #3 (4:06 min) Real time Dynamic Integration of PlannerOne with NAV What if Quantity of a scheduled Production Order changes (Make changes in NAV, see changes on schedule, Adding a new Production Order in NAV, Real time scheduling, assign color for new order, See immediately in the Stand-By area in PlannerOne, Schedule, Using the Advance/Delay Color mode, check the new production order’s effect on the schedule, if good, confirm orders due date).
Ctrl + Click PlannerOne Video, Part #4 (2:53 min) Looking at other views in PlannerOne Work order Gantt Chart (one order per line, see markers like green triangle for Start date, and red triangle for due date, Waiting time displayed, Highlight a Work order, show network chaining, and fix date). Load Chart Resource Sequence
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Student Evaluation Congratulations. You have completed the first step toward learning about Production Scheduler
by PlannerOne, a great new scheduling tool for your business.
Step 1 is the Self Study program providing basic knowledge on PlannerOne Production Scheduler
and getting you prepared for the Level 2 training where you will discuss how you will use
PlannerOne with a PlannerOne instructor.
As a prerequisite to beginning Level 2 training we need you to send us pages 10, 15, 22, 23, 31, 32
and 36 with your responses. Shortly after receiving the “Test your knowledge” pages we will
setup a 2-hour web meeting to review the self study topics and your responses, to make sure you
have a firm grasp of PlannerOne basics.
Please sign and return the Question &
Responses pages to:
FAX - (317) 846-6025 or
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Course Evaluation
It is very important to us to know what you thought about the self-study program. We feel that
there is a certain amount of basic training that individuals can gather on their own time and pace
as well as saving the implementation budget for more in depth application topics for instructor
lead training. But, we really need to hear from you. Please, take the time to fill out this short
questionnaire and fax or email it back to us.
Sincerely,
Julia Baxter, CEO
Cost Control Software, Inc.
1. Approximately how much time did it take to go through the program? ________________
2. Did you learn something? YES or NO
3. Was it worth your time? YES or NO
4. Did you like this form of training? YES or NO
Please explain: _____________________________________________________________
5. Would you recommend this form of training to others? YES or NO
6. How can we improve on this training?
Student Name __________________________________________ Date________________
Please return evaluation to:
FAX – (317) 846-6025 or [email protected]
m
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Support Congratulations on your purchase of PlannerOne! We couldn’t be more thrilled for you. Soon, you
will be on your way to enjoying and utilizing the features and functionality of this product.
This training manual is just the beginning. After completing this self study program you should
feel like you can move around in PlannerOne Production Scheduler, understand basic terminology,
the integration with NAV, changing visualization modes and actually doing some simple
scheduling.
Your next step will to work with a PlannerOne special trainer to discuss how you will use this
product in your business. Contact us to schedule the next step, Level 2 training.
On behalf of NAV Software, NAV Solution Centers and NAV Service Providers, we thank you for
your business. Most importantly, Cost Control Software sincerely appreciates your trust in our
products.
Should you have any questions or comments regarding our product, we encourage you to contact
your local NAV Solution Center (NSC). Please also contact your NSC if you are considering
modifications or seeking new software functionality.
Cost Control Software provides many add-on products that may be just the solution you were
looking for. Your NSC can provide you with our complete list of add-ons. You may also check out
our website to see available add-on products as well.
Visit: www.costcontrolsoftware.com for more information.
Distributed by:
Cost Control Software, Inc.
12409 Old Meridian Street
Carmel, IN 46032
Phone: (317) 846-6025
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Addendum
Here are some bonus tips and Ideas to help you along the way.
Some tips to analyze a Work Order Delay:
1. Check the WO Network. See if the Start Date is constrained by a previous WO.
2. Check the Earliest Start Date (Router Line, P1 Field)
- Check the Planner One Setup for Earliest Work Date.
- See Below
The above setting will fix the start date in the “Stand By” Area to exactly 4 weeks before the end
of the requested Ship Date (Due Date).
Exception: The Item Card has a longer period. (Usually set based on the typical build time of the
item with consideration to other work in the shop).
Exception #2: TODAY. A production order can’t start earlier than today!
Note: You may get an indicator line to the left showing the calculated Earliest Start, but it just
can’t start before TODAY.
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Some tips to analyze a Work Order Delay:
This field on the Item Card will Trump the Global Setting in the setup area.
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Also here is a screen shot that shows how “Earliest Start Date” is used:
So, this was the best tip to understand or trouble shoot delays:
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Final Results or Optimization/Schedule:
The “Earliest Start Date” held true and all work got scheduled after that based on
availability in the other Machine Centers.
Tip: Before you run the Schedule, Set color to WO. Then it is easier to follow your
production order.
Tip: When you run “Schedule” from the Production Order Card, the results are
easier to follow too. (see above)
Dynamics NAV schedules from the Due Date – backwards based on the duration of each
operation. It is “Infinite” capacity, hence no consideration to other production orders.
Production Scheduler – Users Forward Scheduling Logic and Finite Capacity
If there is another operation on the scheduling board, it moves the new operation forward on the
time line.
Suggestion: Learn by scheduling just One Production Order to begin with.
Draw on paper a 30 Day time line.
Plot: Due Date, NAV End Date, NAV Start Date – Look at the NAV Dates and plot them.
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Now View the PlannerOne Stand-By from the Production Order Card!
Production Scheduler in Stand-by puts the start of the Prod Order on “Earliest Start Date”.
When you select “Schedule” Production Scheduler places the 1st Operation as close to the Earliest
Start Date as possible. The remaining tasks fall in line when a W/C or M/C is available. This means
you will get a more realistic calculation of WO completion Date. (Promise Delivery Date)
Optimization Tip:
If you want to always ship early, set your Earliest Start Date Calc to -6W.
If you want to ship JIT, set your Earliest Start Date on the Item Card to aprox duration to make that
items when there are other jobs on the shop floor. (-12D if it normally takes 10 Days to make)
Publish Tip:
On PlannerOne Setup set the Overwrite option to NO! (No change to NAV Prod Header Dates)
When you publish, only the Router Start and End Dates are updated with more accurate values.
(You might want to create a Scheduling Report based on these published Dates)
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Next Operation Link Type Field
Next Operation Links are constraints that can be added to the Routing steps in a
Production Order. They can either be added to the Master Router for an item or
even added on the fly when editing a Production Order’s Router.
SS for Start-Start Synchronization Links – Both operations start together (example: 20:SS)
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ES for End-Start Synchronization Links – next operation starts as soon as the previous one
finishes (example: 20:ES)
EE for End-End Synchronization Links – Both operations end together (example: 20:EE)
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FU for Full Synchronization Links – Both Operations start and end together (example
20:FU)
NP for Non-Parallel Links – A nonparallel link between two operations means these
operations must not overlap. Yet, they have no precedence constraint with one another; any
of them can be performed first.
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RR for Resource Reservation Links – A planning constraint between two operations. Both
operations must be assigned the same resource, and no other operation can be planned
between them on that resource.
SR for Same Resource Links - A planning constraint between two operations.
Both operations must be assigned the same resource. Still, other operations
can be planned between them on that resource.
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Linking 2 Production Orders that Produce the Same Item to Run Together
In this demonstration we will be linking 2 Production Orders together that
produce the same item to run as a “batch”. Their operations need to be linked so
that they run back to back for both Production Orders.
In this example I created 2 Production Orders for Item DOOR100 – Steel Door &
Frame, one for a Qty. of 35 and the other for 50.
The Routing for this item has 2 operations, so we would like to link them so that
the operations for the two Production Orders run together as a batch since they
are for the same item.
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Go to Links between Production Orders to set up the Links and click New.
Next you will need to set up the Links. We need to Link both OP #10’s together as
well as both OP #20’s. We also need to the 2nd Op #10 to the 1st OP #20 so that
they run in order.
We will use the same Link Code for all 3 links, which is the ES (End-Start) Link code.
This means when one operation ends, the next linked one starts right after.
Example:
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After you have created these links, open Production Scheduler to view the linked
Production Orders along with their Linked Operations.
Video - Linking Production Orders & Operations using Links to Production Orders