DelmiaWorks Finite Scheduling is a superb scheduling module, a great time saver and a company’s ultimate test. Finite Scheduling will work well, actually it will work really well, but only if your ERP building blocks are set correctly.

What are those building blocks? For starters, the following need to be configured and accurate:

• Production Calendar – set to accurately reflect the availability of the different work centers
• Sales Order Entries – parts entered have correct BOM’s at all levels
• BOM – properly notes: Work Center, Cycle Time, Raw Material type, Raw Material  Quantity, Cavitation, Scrap%, and Bucketing
• Inventory Item Record – includes: quantity on hand, Min/Max configurations, E-Kanban, Lead Times for purchased items

A work order that pops up but is ‘not right’ (example: shows 'must start date' from last year) is an indication of bad data that must be corrected. If not corrected, it can cause a buyer to purchase material that is not needed (waste), or make an order late (lose future business with the customer). This is why I recommend using DelmiaWorks Finite Scheduling as a barometer for how well your MRP system is configured and running. Make sure to address the root cause behind work orders that are obviously incorrect.

Addressing Incorrect Work Orders

A constructive way to address incorrect work orders is to correct the root cause leading to the error, rerun Update Schedule and confirm that the problem went away. Common errors that result in incorrect work orders are:

Outdated BOMs – Outdated BOM’s that wrongly call for parts that are not required will result in work orders for those unnecessary parts which will inevitably result in waste of resources. The flip side are outdated BOM’s not calling for parts that are required, hence no work orders will be generated. This error can result in late shipments to customers.

If the Scheduling Module is not creating the correct work order, a manual work order can always be created, yet that is not the recommended course of action as it does not solve the problem. Remember, we want to eliminate the root cause. The preferred method that is in line with GMP and ISO 13485/9001 is to correct the BOM so that it generates only the work orders needed.

Sales Orders that call an incorrect part or part revision – this can result in work orders calling for manufacturing of parts that are not needed and/or result in inaccurate timelines.

Inventory Items that have an incorrect BOM or no default BOM – DelmiaWorks will not create a work order for an inventory item with no default BOM. A check & balance strategy that I recommend is running a query that returns with active WIP and FG SKU’s that do not have an active BOM. Catching incorrect BOM’s is a bit trickier. A good inventory system will assure that any incorrect BOM is identified during production reporting/floor disposition as the extra or missing raw material/WIP is an indication that there is a discrepancy between the BOM and the real world.