martes, 17 de junio de 2014

Apparel & Footwear for SAP Business One

How many days do I need to make 5000 Polo Shirts?
Garment manufacturing is a complex task. Capacity and material requirements can be addressed in many ways. Today we will focus on using Standard Allowance Minutes. SAM value of a garment is defined as how much time it would take to complete a garment in sewing. This is also known as garment work content and standard minutes. For those who are seeking the right answer take a look at our new post.

First let’s review some of the basic concepts:

SAM: Standard Allowance Minute. Time required to manufacture a garment. This time could be segmented by operations (cutting, sewing, packing, QA, etc). In our example the SAM will be for an entire send out process.
Resources: machines / employees (internal or external) performing manufacturing operations. We will setup these resources as finite capacity sewing lines.

The example

1.                  SAM of the Polo Shirt (i.e. 16 minutes)
2.                  How many machines will be used to make the order (i.e. 20 machines)
3.                  Daily working hours (i.e. 8 hours)
4.                  Line efficiency (i.e. 100%)

To make 5000 polo shirts-
Capacity required = 5000 X 16 minutes = 80,000 minutes = 1333 Hours
Available Capacity/Day = 20 X 8 hours = 160 Hours
Assumes that line works at 100% efficiency.

So, the days required (theoretical) to produce 5000 polo shirts = 1333 / 160 = 8.3 days ( usually up to 9 days)

Total Min
Total hrs

If factory run at 50% efficiency then = 9 X100%/50% = 18 days

For planning add one more day as in practical, one day will be lost for loading and line setting.
If you production is calculated at 50% efficiency then you need 19 days to complete the above order.

The process
This is how we can implement this in AFS for SAP Business one.

Resource MasterAdd the sewing line. In our example the line or cell is composed by 20 employees working 8 hrs.

Manufacturing Operation (send out)Create a manufacturing routing linked to the style with just one operation called send out. SAM is set to 16 minutes.

Style Master
Add the style with the required data. The process will create bill of materials (BOMS) based on the costing sheet selected.

Customer Order
The planning is based on a Make To Order process (MTO). Usually the planning is based on delivery date and customer priority. This information is set during order entry and validated by the manufacturing department.

Cut TicketThe order information is then transferred to a cutting ticket.

Based on SAM and manufacturing capacity in the sewing line, the resources are allocated accordingly to the planning board. Users can allocate to a different resource (resource leveling) based on the capacity of the sewing line.

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