Many chemical manufacturing companies struggle with the best way to schedule the variety of products that are going through the production floor. One of the key things that manufacturers have to consider for their production planning is how to minimize the changeover and cleanup between production runs, in order to optimize the use of limited production space and resources.
In a facility that produces paints and pigments, it would be desirable to sequence those paint products from light colors to darker colors. For example, the campaign might start with white, followed by yellow, green, blue, red and last black.
Depending on the importance and costs, it may be logical to run production from light to dark for a particular container type, like quart cans, and then change over and run the color campaign for gallon cans of paint. Or, if the changeover of the container size is not that costly or complex then the sequence might be based on color going from a quart of white, to a gallon of white and then to a quart of yellow, to a gallon of yellow, to a quart for green and so forth.
Dynamics 365 for Finance and Operations at Work
These sequencing options can be modeled in Dynamics 365 by utilizing sequence codes and sequence groups to take planned orders that were generated through Master Planning and propose a new sequence of those orders based on the defined sequencing strategy.
For example, here we have two Sequence Codes called Container Type and Paint Color.
Sequence codes used within a Sequence Group called Container-Color with a ranking value. Using this Sequence Group with the Sequences in this order, the planned production will be sorted first by container type and then by paint color.
With the Sequence Groups and Sequence Codes setup in this way, Container Type will be the first sort to plan orders generated by Master Scheduling. This means that all of the quarts of paint will be sequenced first, followed by gallons of paints. Since the next ranking is Paint Color, the color sequence will run from light colors to darker colors within each container type.
So the overall campaign cycle will sort quart containers, light to dark, followed by gallons, light to dark. At the end of the campaign cycle a single change-over and cleanup would be performed.
When assigning Sequence Codes to Items, the Table-Group-All methodology is used so that the items can be assigned, updated and managed easily by group.
The Sequence group needs to be assigned to the Resource that the planner has identified as the bottleneck or limited capacity resource (in this example, the resource is the PaintMixer1).
In the Master Plan definition, sequencing can be turned on or off by toggling the Sequencing Planned Orders to ‘Yes’. Additionally, the time fence and the campaign bucket needs to be set up to define each campaign cycle. In this example, the Time Fence is 60 days and the Campaign Cycle is setup to cover 30 days. This means that there would be 2 campaign cycles in the planned orders generated by Master Planning.
When the Master Planning is completed, the Sequenced Planned Orders page will show the planner the sequence in which the system sorted the planned orders and, from here, the planner can accept and firm these orders.
Production Sequencing in Dynamics 365 will enable chemical manufacturing companies to leverage scheduling rules and defined sequences to provide suggestions as to the most efficient way to run orders through production to minimize changeovers and maximize the efficiency of the plant.