Did you know that in SyteLine you can now plan with estimated scrap factor for a specific operation?

We often encounter a question how to calculate in production with estimated shrink factor or defective work in general. Consider this example: Product A is a molded part produced in batches of thousands. Not every part, of course, turns out well, whether because of the quality of the material, tool wear, or it may be damaged during a planned destructive testing. If the customer requires 1,000 pieces and we know that 10% of it will be irreparably lost during production, then it is logical that the system plans an increase in number of produced pieces, capacities and material so that the customer can receive the required quantity.

Solution is to Enter a Yield (Shrink Factor)

In earlier versions of the SyteLine information system, the estimated loss for a product, semi-finished product or a part was cumulatively set in Shrink Factor field on item. That ensured that the system increased a consumption (of material, part or capacities) in the plan in order to produce the required quantity. At the start of the production, however, the following information was missing: that is necessary to initiate production of larger quantity in order to produce the required quantity.

Now it is possible to specify where losses occur, directly in job routings – in operations. As losses may arise in different phases of production, it is possible to enter it at the level of individual operations into the Yield field. Yield is an expected percentage of production of a given operation, and unless specified otherwise, it amounts to 100%. The information system counts the expected (final) quantities, or more precisely final production of the whole batch (job order, planned quantity), across all operations. The cumulative percentage is then automatically updated to the value of Shrink Factor field on Item.

Operation yield and expected quantity from a production batch

 

Benefits

  • When planning a forecast or customer order, APS planning already calculates with higher consumption of material and capacities. In result, the production can’t be suddenly stopped due to a lack of material or parts.
  • The planner doesn’t have to manually manage the increase of a job order, information system will do this for him at the correct amount and on time. On the job order, there is a new field: Expected, which shows expected final quantity of the job if the yields entered in operations are less than 100%.
  • It works through a multi-level BOM: each part, semi-finished product or product may have its own rules for managing scraps.