Capacity Planning - Part 1 - Planner

Capacity Planning - Part 1 - Planner


Capacity Summary

The Capacity Summary screen can be used as an overview of the factory’s current capacity. At first you will see a summary of the entire factory based on the ‘View’ selected. Below that you can see the summary of any ‘Departments’ you have linked to your user. Then below is a closed section where you can see all the other departments in your site.



Under each, you will see the number of ‘Planned’ and ‘Unplanned’ jobs and the TOT (Total Operational Hours) along with a ‘progress bar’ for a visual capacity reference. You can also place your cursor over the sections to see additional details:



You can add departments from the ‘Other’ list to the ‘My’ list by clicking the ‘Assign Department’ icon as below:





















You can change the ‘View’ to show the summary by date or date ranges:



For example, changing from a single day to a week view will change the format of the screen to show each day:



Against the department, click on the ‘bar’ icon to see the capacity against individual machines in that department:



From the machine view you can see the capacity and via a ‘hover over’ you can see the allocated hours v the available hours:



You can then click on the individual day, department, or machine:



And IQ will open the capacity planner to that ‘Day’:



‘Department’:



or ‘Machine’:


Planning a Job

Bulk Schedule Multiple Jobs

You can bulk auto schedule multiple jobs at once.
From the “All Jobs’ board (as displayed here) or the ‘Pre-Production’ board, filter to jobs that require planning. In this example we have the status of ‘Planning Ready’ only selected. From here we can multi select all the jobs and click the option ‘Schedule Jobs’:



A modal will show asking how you would like to schedule. In this example we select to schedule from the ‘Due Date’ back. Once an option is selected, click ‘Schedule’:



IQ will process the jobs and plan into the relevant machines and days required. All the jobs showing in green signal that all operations were successfully planned (if there were and issues they would show in red):



You can click the arrows on the right to see the dates and times each operation was auto scheduled to:



Bulk auto schedule to individual machines

You can select to ‘Auto Schedule’ all unplanned jobs at a machine level by opening each resource and clicking the ‘Auto Schedule’ button against each. This will place all jobs in the list to the next available space that can accommodate the time required for the selected day:



Any job that does not have all the operations scheduled will show a ‘puzzle’ icon that represents that the job is currently only ‘Partially Planned’:



You can click on the job number to open a details screen. Here you can easily see what is planned and what is not by the ‘calendar’ icon next to each planned operation. Place the cursor over the icon to see the date and time the operation is planned:



Schedule at an individual job level

In this example we have a job that is due on 12th. Production wise, the job contains operations for printing, guillotining, drilling and bundling:



Once the job is ready for planning, from within the ‘Job Details’ screen, select ‘Capacity Planning’ from the top dropdown list:



This opens the ‘Capacity Planning’ board with the selected job showing each of the resources that need to be planned.
To start the planning, click on ‘Not Planned’ on the first resource:


Here you will see the operation for that job on the selected machine:



Auto Schedule total job

You can auto schedule all operations at once. This will place all operations in the next available space that can accommodate the time required.
Place the cursor over the ticket to show the ‘three line’ icon. Click on the icon and then from the sub list, select ‘Auto Plan Job’:



This will show a modal with various options on how to schedule the job. You can schedule from:
First Available – Schedules all operations in the first slot available that can accommodate the time required:


Once selected, you can see the details of the date and time each operation has been scheduled to:



Close the modal and the board will update:
See below there is a buffer between each operation. In this example the default setting is 30 minutes. We can set a ‘Buffer in Minutes’ that will be used as a default.


You can also plan from the ‘Print Date’ forward, ‘Due Date’ backward or if used, ‘Expected Date’ backward. In this example we are selecting to auto schedule the job from ‘Due Date’ of the 30th backward:



The operation selectors are broken into two sub fields, ‘Due dates not set’ and ‘Due dates set’. This is so you can see any jobs with no due dates and add them in prior to planning:





Once ‘scheduled’, this will then show you each operation scheduled start date and time:



Close the window and the board will update showing the days and times for each operation:



You can ‘drag and drop’ to refine the boards from here.

Manually schedule at an operational level

You can manually ‘drag and drop’ operations individually on each resource:



Initially when you go to the capacity planning screen directly from within the job, the ‘day’ defaults to ‘todays’ day.  As generally the entire job will not be all produces on the one day, you need to navigate the various day throughout the week to manually plan the job.
In this example we can see the job involves multiple operations and the job has a due date of the 12th:



Starting at the last operation of ‘Handwork’, I want to plan from the due date back. The due date is on the 12th. Using the filtering options:



With the date selector, you can view various options such as today, tomorrow, the ability to view multiple days on a specified resource or to select a single custom date:



I select filters and as I do the filters break down further to allow me to show the ‘Handwork’ operation over multiple dates to see where I have space:



Now I can see multiple days planned on the selected resource. I can now decide what day and when I want to plan the operation:



I then drag/drop the operation to the required spot on the resource:



Then it is a matter of working your way back through the operations. As the previous operation is ‘Drill’, I then do the same filtering but against the ‘Drill’. I then drag the drill operation onto the required day and time:



I follow this process until I have planned all the operations:



You can plan one (or more) operations manually and then against a selected operation, select ‘Auto Plan Job’:



This then adds the additional options to bulk plan the remaining operations either backwards or forwards based around the planned selected operation:


IQ will the plan back for the remaining operations:




Department Filters

When viewing the capacity planner via the ‘All Jobs’ option, we have access to ‘Department Filters’.
This is a way of using advanced filtering to help set the production order of planned jobs for the most efficient production order based in the individual machine:



There are two filtering options:
Linked Filters – These ‘link’ the selected filters allowing users to narrow down the selected options:



Individual Filters – This option is more open and will show cards that match any of the selected filters:


Filtering works on both ‘planned’ and unplanned’ cards:



Cards in the unplanned list that match filters reorder to the top and cards that don’t match reorder to the bottom and go grey.
The auto plan button above the unplanned list will only plan jobs that match the filters.

When entering filter mode, all cards will display in white:



As you select filters (multiple filters can be selected in the one field): 



The cards that do not match the filter will grey out:



Selecting multiple filters:



Will further filter down the ‘white’ cards allowing you to view matching cards to then manually move/group together for the most efficient production order of operations within a job:




Additional Options

Moving job tags

When a machine has multiple jobs assigned, you can drag/drop tags in groups by selecting multiple tags.
In this example we want to move the top three jobs below the fourth job:



Click the ‘ctrl’ key on your keyboard. The multi select mode will activate and flag you on screen:



Clicking on the first tag will highlight it in ‘Blue’ and the modal will update showing how many tags are selected:



You can manually click on each tag you wish to select as part of the group:



Or by holding both ‘ctrl’ & ‘shift’ at the same time you can click on the last tag, and this will auto select all tags in-between:



Now you can drag/drop the selected tags to the required gap in the machine or to a different machine. The tags will change to an icon depicting the number of tags selected:



Once moved, the tags will split back out into their new position:



Multi selecting also works in unplanned job tags:




- Pushing the ‘esc’ key at any time will cancel this mode and revert to the original view.
- Clicking a previously selected tag again will un-select it

From the planning board, clicking on the ‘three line’ icon gives you access to the additional options:



Operation Details

Opens the details screen related to the selected operation:



Move to

Lets you change the date the operation is planned or the machine it is allocated to:



You can also ‘Split Operation’ (splits can also be done in a dedicated modal with more options but basic splits can be done from here).
This allows you to break the operation into parts for situations where the process will require more time to produce that you have available in that day. Once split, you can either plan on different days or even split the operation over two different machines:



Here we have a 15000 qty operation. Click the ‘Move’ option:



When using the ‘Move To’ function, if the move will place part of the job outside working hours, a message will show telling the user how many minutes of the job are planned into overtime



You can ‘accept’ the operation running into overtime by clicking ‘Move’ or you can click the ‘Split Operation’ option. This will auto populate the split details to make a split of the operation based on the overtime minutes:



This will make a split that can then be moved to a different day:



To split an operation, you enter the quantity required to be split from the base operation. In this example of 15000 qty, we want a 10000 split and a 5000 split. Enter 5000 into the ‘Split Qty’ field and click ‘Move’:



The original card will adjust size based on the new time and a second card will be generated and added off to the side ready for planning:



Manually moving from one press to another

You can manually override the tag from the quoted ‘press’ to another by dragging and dropping. Here we have a job planned on the 40” KBA:



Dragging this to the 20” KBA will show an option screen asking if you want to ‘Confirm’ using the ‘Modify Duration’ option (where you can manually adjust the time or you can select to ‘Edit Job’ and select a different quoted production path):



If using this option with ‘multi-select’:



The modal will be different, limiting you to the option to ‘Schedule card’ or ‘Skip card’:



Split (Manual)

The dedicated ‘Split’ modal allows advanced splitting op operations:


This modal by default will auto calculate the split quantity, number of splits and time based on your inputs. It was also calculate the ‘last split’ when the numbers do not match the ‘common’ splits:



The operation will then show in its split parts ready to be moved. You can also see the quantities per slit on the tag:



The tags ‘hover’ details will show the time required for each split:



Split (Auto)

Job cards can be set to auto split on planning.

Auto Plan
When using to job based auto schedule from the boards, the ‘Allow Split’ modal will show. If any part of the job has a operation that cannot fit into a single days work space, it will auto split out over multiple days:



On successful scheduling, you will see the days the operation is split over. In this example the 06pp Roll Fold is scheduled to start on Saturday and completed on the Monday:



This can also be seen when viewing the job on the capacity planner board:



The auto split will also activate when manually planning cards. When dragging an unplanned card into a space that is smaller than the planned time:



A modal will show asking how you want to proceed. You can select to ‘Schedule & Continue’ (this will plan the excess into overtime for that day) or ‘Split to following working day’ (where the card will plan the remaining onto the following day):



Merge

Any split can be combined back into the original card only if not timing has been done against either card. Select the ‘Merge’ option:



The card will join back to one:



Modify Duration

Lets you quickly edit the duration that was quoted against the job:



Unplan Job

Lets you quickly unplan the total job and start again:



Search Job

Lets you quickly filter the board to show you all the machines and days operations for that job are scheduled for:



Lock

Let’s you lock the operation in position. The operation will show a lock icon once this is applied:



Unplan

Unplans only the selected operation:



At a machine level, you can filter as well: 



Filter to Machine

You can select to show that machine only for a week:



This option will add any machine to the view that is configured as a ‘Related Machine’ (in that it will display other machines that can do the same function as the quoted machine). This allows you quick access to see what other machine the job can be planned on in the situation that the quoted machine is at capacity for that day:



Also Include

This option opens the date selector, allowing you to select an additional ‘day’ to the screen. This is useful when the current day is at capacity, and you want to find another day that has capacity to plan the operation on:


Close Gaps

Lets you close the gaps between planned operations based on the buffer setting selected:



Unplan all

Unplan All operations on that machine in one go for example if it breaks down:



Under each machine, you can also see the planned capacity percentage currently planned against it:



Block Time

You can ‘block out’ time to reserve space by placing the cursor over a blank space on the machine and ‘double-clicking’. This will open the ‘Lock Time Block’ option where you can set the time and add a note:



Zoom

From the main filter section at the top of the screen you can select the zoom options:



Progress Bar

When a user is logged onto an operation, it will show in orange with a progress bar that moves across the tag vertically. Completed operations will show in green and not started will show in white:



Planning Conflict/Issues

If there are any planning conflicts or issues, IQ will alert you via a ‘warning bell’ on the top right of your board:



Clicking on the bell will show you a list of the issues with a description:



Clicking on the job number will search filter the board down to that job. The operation mentioned in the error will show on the screen with a warning bell against it:



Place your cursor over the icon to see the issue message. In this case IQ is telling us that the preceding operation for ‘Gloss Laminate’ has not been scheduled yet:



Clicking on the warning bell will open the details summary. Here we can see that the ‘LAM Gloss’ has been outsourced (this is represented by the blue outsource icon) so the error can be ignored:



For Partially Planned jobs an orange jigsaw icon  appears to the right of the planned operations to indicate that not all operations for that job have been planned.
In some cases, you may have planned the job out of the standard order for a reason. In this case you can ‘ignore’ the warning by licking the ‘x’ next to the warning message:



While job is still in production, any ignored warnings will show in a list at the top:



You can ‘restore’ a warning if required. Click the job number to view the job on the board:



Against the relevant card, choose the ‘Restore Exceptions’ option:



You can also choose to ignore the warnings at a ‘job card’ level by selecting ‘Ignore Exceptions’ on the job tag:



Past Due

Capacity Planner does not allow you to plan jobs in the past. However, at times operations that have not been started end up in the past on the board.
There is a filter on the Production Board which lists all jobs with an un-started operation in the past.


























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