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Edgewater Fullscope Blog

A real-world look at digital transformation.

From Chaos to Order: How Chemical Companies Can Use Dynamics 365 to Sequence Orders

By Linda Hope | May 7, 2018

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.

Simple Sequencing_Paint Illustation

 

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 Illustration 1          Sequence illustration 2

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.

Sequence illustration 3

Containter Type_PaintColor Illustration

 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.

Sequence illustration 4

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).

D365 F&O Resource Image

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.

Master Plans Screenshot

 Master Plans Screenshot 2

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.

The Result

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.

 

About Linda Hope

Linda Hope is an Edgewater Fullscope solution consultant. Linda began her career in the software industry in 1995 with the ERP products Baan and Axapta (Microsoft Dynamics AX). She started working at Fullscope in 2005 and moved into the solution consultant role in 2008. Linda was the Fullscope product manager for the Dynamics AX TQM product that was sold to Microsoft and she was contracted by Microsoft to train worldwide partners in Process Manufacturing. Prior her software industry employment, Linda worked in process and discrete manufacturing companies selecting and implementing ERP solutions.

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