Resource related time concepts in Produce / Operator

Operation detail view

In Produce / Operator, an operation’s detail view displays the following three time values for each resource used in the operation, in <hh:mm:ss> format:

• Setup time – The time it takes to make the resource operational
• Planned time – The time it takes for the resource to produce the planned quantity of items
• Completed time – The time period while the resource has actually been used so far during the operation.

PDC Step 3 - Resources

In Step 3 of the PDC workflow, Produce / Operator displays three time-related columns for each resource: Expected time, Calculated time and Time. The top of the screen shows the actual Time spent.

Expected time

Expected time is based on the resource setup and the produced quantity of items:

<expected time> = <setup time> + <planned time> = <setup time> + <job time> * (<completed quantity> + <scrap quantity>)

Calculated time

Calculated time is determined by distributing the actual time used (i.e. Time spent) into setup and job time components using the following formula:

<calculated time> = [<longest setup time of all resources> or <time spent>, whichever is shorter] * <setup time>/<longest setup time of all resources> + {<time spent> - [<longest setup time of all resources> or <time spent>, whichever is shorter]} * <job time>/<longest job time of all resources>

The above basically may have two outcomes:

1. In a typical case, the Time spent would be longer than the longest Setup time of the resources. Then the formula would be reduced to:

<calculated time> = <setup time> + {<time spent> - <longest setup time of all resources>} * <job time>/<longest job time of all resources>

This means that we take the Setup time of the resource, and then add a proportional part of its job time to it, based on the time that remains from the total Time spent once even the last resource has become operational.

2. If the operator spends shorter time with the operation than the longest Setup time, then the calculation becomes:

<calculated time> = <time spent> * <setup time>/<longest setup time of all resources>

In this case, there is no time left for the job itself. The whole Time spent has not been enough to make the slowest resource operational. Consequently, we take a proportional part of the total time spent for setting up the resource.

Time

For resources that are managed manually in the ERP system, the last, Time, column in Step 3 of the PDC workflow contains the Calculated time value by default. This value can be overwritten manually by the operator to enter the actual time used by the resource, provided that the operator's Time change allowed setting is set to Yes.

For backflushed resources the Time column shows a lock icon (). No value can be entered manually, since the usage will be issued by the ERP system automatically.

PDC Step 5 - Review

If a resource’s issue method is manual in the ERP system, then in Step 5 of the PDC workflow, we have two time values displayed for the operation as a whole: Resource time, and Expected time.

Resource time

The Resource time for manually issued resources can be edited by operators by clicking Change (), provided that their Time change allowed setting is set to Yes. 

Resource time is calculated as:

<resource time for the operation> = <longest setup time of manually issued resources> + {[<actual time> – <setup time>] of the manually issued resource with the longest job time}

Actual time in the formula above is the value displayed in the Time column in Step 3 of the PDC workflow which, by default, is the Calculated time of the resource, but, as mentioned, may be changed manually.

If all resources are backflushed in the ERP system, then the Resource time box will contain the following text:

Expected time

Expected time is calculated as:

<expected time for the operation> = <longest setup time of manually issued resources> + <longest job time of manually issued resources> * (<completed quantity> + <scrap quantity>)

The formula for Expected time assumes that no resource can start working before even the last one gets operational.