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George Moroses

Infor LX & BPCS Manufacturing Tip of the Week: Backward Scheduling

Operations are automatically backward scheduled at shop order release time. The backward scheduling algorithm starts with the shop order due date and schedules each operation based upon the standard move and queue times in the routings and the number of days the job is expected to run at standard. The system calculates and stores the operation scheduled start date. The dates may be modified by the shop order maintenance program. The number of days that a job is expected to run an operation is dependent upon the available capacity for that work center and the total hours scheduled for that operation.

The backward scheduling algorithm also considers the shop calendar for weekends, shutdowns, holidays, and partial days.

Backward Scheduling Process

The algorithm starts with the due date of the shop order or planned order. The system makes the following calculations for each operation in the reverse sequence:

  1. The number of move days is subtracted from the due date (or initial date of the previous operation) to get the due date for this operation. The move days are only used on valid shop calendar days.
  2. The system uses the following calculation for the number of clock hours for the operation: Standard run or machine hrs/No. of operators + setup hours
  3. The number of clock hours is spread over the available daily capacity of the work center for those given days. The system uses the following calculation for the daily capacity of the work center: Number of shifts x hours per shift x average efficiency/100
  4. Each day is checked against the shop calendar; the calculation bypasses inactive days or adjusts for any changes in the work center capacity for that day.
  5. Queue time days are subtracted in the same manner as move time days. The resulting date is the operation start date.

The algorithm then goes to the previous operation. When all operations have been included, the resulting date is the scheduled start date of the shop order. Note that MRP uses the item lead time to determine material requirement dates on planned orders.

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George Moroses

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Tips:  LX | BPCS | M3

The challenge in cost accounting is tracking your manufacturing to the levels needed for useful management information. You need feedback for corrective action; but, you need to minimize the cost of collection. Some parts of your operation require specific job-cost tracking while the Just-in-Time areas require

costing in terms of cost per process hour or day. Apply overhead in different ways to different processes and products. Segregate costs into enough detail

to provide management with an accurate picture of the contents of your product. Material, material overhead, labor, fixed overhead, variable overhead, outside processing, outside processing overhead, and so forth all have to be considered.

 

LX meets your cost accounting needs with the following functionality:

â–ª Four sets of costs: actual, standard, frozen standard, and simulated

â–ª Nine user-defined elements per set

â–ª Full and partial cost roll-up and simulation

â–ª Cumulative in-process cost tracking

â–ª Cost summaries by item

â–ª Cost definition tied to work centers or material type

â–ª Process hour costing

For years, repetitive manufacturing industries have been applying many of the principles in Just-in-Time philosophy. They have established balanced production lines that depend on a steady flow of material to each work station. They schedule production in daily or weekly rates rather than in discrete shop order lots. They track finished inventory by work center rather than by job. They typically backflush stock balances (decrement stock balances upon completion of specific manufacturing steps rather than issued at the beginning of each production run).

 

Costing is typically based upon a daily rate or hourly rate rather than being associated with specific shop orders. 

 

Repetitive manufacturers use MRP II software adaptable to their environments

in the following key areas:


â–ª Product definition

â–ª Inventory tracking

â–ª MRP/Master Scheduling

â–ª Shop Floor Control

â–ª Purchasing

â–ª Costing

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Tips: LN | Baan

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