Beas usage of the resource allocation field in capacity planning (APS)

How to use the resource allocation field on a routing position and read the capacity planning calculation results in beas.

Beas supports 2 different calculation methods

• Detailed planning (THIS IS ONLY AVAILABLE WHEN FORWARD SCHEDULING IS USED WITH APS))
• Exploit the full capacity

1.1.1. Detailed planning

Beas applies this method only if the following conditions are met:

• Forward scheduling is used in APS
• Both the APS Calculation method and the work order priority are set to 100%
• In the routing of a work order THE OPERATION IS SET as Simple utilization / or Percentage = 100%
• THE resource linked to each of the routing positions of the Work order IS SET TO HAVE the master data field Number of machines/Pers = 1 as per example below:

If only one of these points does not apply, Beas automatically switches to "Exploit the full capacity" for the current routing position

How is Detailed planning working:

The detailed planning checks to the minute when a resource is available and whether the work sequence can be completed in the available time windows.

Assumptions: our resource is the same on all routing position on the below reported examples and has a total capacity of 12 hours per day.

Example 1:

Work order nr 1 and Work order nr 2 start at 6 am on the same date/time. Both work orders only have one routing position and each position has an entire duration of  6 hrs

The result of an APS forward scheduling will be::
Work order 1 starts at 6 am
Work order 2 starts at 12 pm because between 6 am and 12 pm the resource is not available and is occupied by work order nr 1.

Example 2:
Work order nr 1: one routing position with a duration of 6 hours, Work order nr 2: one routing position with a duration of 3 hours and work order nr 3, one routing position with a duration of 6 hours.

The result of an APS forward scheduling will be:

Work order nr 1 will start on day 1 at 6 am

Work order nr 2 will start on day 1 at 12 pm

Work order 3, even if you have set the same start date/time for the APS forward calculation, will be moved forward to start on day 1 at 3 pm but will finish on day 2 at 09 am.

Example 3

Work order nr 1: one routing position with a duration of 6 hours, Work order nr 2: one routing position with a duration of 3 hours and work order nr 3, one routing position with a duration of 6 hours.

ATTENTION: THE FOLLOWING EXAMPLE ASSUMES THAT YOU ARE WORKINIG ON THE APS GANTT AND YOU HAVE SET WORK ORDER NR 2 MANUALLY (BY DRAGGIN IT ON THE GANTT CHART) TO START AT A SPECIFIC TIME (AND THE OPERATION IS ALSO THEN AS FIXED BY APS).

In this example, Workorder 3 can start only start on the second day, because between Work order 1 and Work order 2 the free time is not enough.

If you have more than one Resource and you need detail planning, you must define a resource group and link all resources to the resource group. Then you can plan with the resource group and beas will do the APS scheduling with capacity allocation  at single resource level belonging to the group.

1.1.2. Exploit the full capacity

This method checks the total available capacity on a day for a resource. IT WILL NOT CHECK WHEN the capacity is available.

Example 1:

2 work orders, one routing position per work order, each routing psition with a total duration of  6 hours. Both work orders are planned in APS with forward scheduling and with the same  start date/time

The result of an APS forward scheduling will be:

Both work orders will have the same start date and time  because Work order 1 needs 6 hours and 6 additional hours are available for Work order 2. The start / end time of each work order is not checked by beas.

Example 2:

2 work orders , one routing position per work order, each routing position take 8 hours. We have a total duration of 16 hours for both work orders with a total available capacity of 12 hours on the machines.

The result of an APS forward scheduling will be:

Here again both work orders start at same time
But the TIME SPAN BY WHICH BEAS ASSIGNS THE second work order is longer. The routing operation of the second work order will still be 8 hours (as well as the capacity occupied on the resource), but can take only 4 hours from Day 1 and will have to take  4 hours from the second day. That’s why you will have representation in the APS GANTT, for the second work order, that is longer than the first one.If you check the  resource – Dispatches – Detail (by accessing the resource master data) , you will see the calculated time zones for the second work order:
Day 1: 6 am – 10 am ( 4 hours, as the remainder of the capacity has been taken by work order 1)
Day 2: 6 am – 10 am (the remaining 4 hours of work order 2)

Example 3:

Work order 1 and 2 have been set to start on the same Day by APS with forward scheduling. Each of the work orders has one routing position and each of them lasts for 6 hours. You have assigned a resource allocation of 50% for each of the routing positions

In this situation, the Detail planning will not be used. 

The result of an APS forward scheduling will be:

The system will plan the complete day, but on both work orders I will have same start date / time and they will be in parallel
Because of the 50% setting at routing postion resource allocation, the system will represent BOTH WORK ORDERS WITH A LONGER TIME SPAN (12 hours each) BUT EACH OF THEM WILL STILL OCCUPY ONLY 6 hours of capacity of the resource.