run plan generator - trenton metro area localtrentonmetroarealocal.com/runplangenerator.pdf · run...
TRANSCRIPT
RUN PLANGENERATOR
Run Plan Generator - Why have a run plan?
∎ Move away from reactive visual management ofmail volumes to proactive planned management .
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Use historical data to predict upcoming mail volumes .
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Have a plan in place to allow MDOs and supervisors tomake decisions on how to best utilize their people andequipment.
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Improve staffing decisions.
Slide - 2
Run Plan Generator - Managing vs Planning?
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A run plan is meant to complement, notreplace, management of the workfloor .
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Conditions may require varying from the plan .•
Volumes can differ from projections .
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Outside influences can affect the processing of themail (e.g., wet mail affecting thruputs) .
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Unscheduled maintenance .
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Personnel management issues .
Slide - 3
Run Plan Generator - Managing v Planning .
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The run plan can be used to gauge progressthrough the day .
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Other tools give information to compare actualprocessing to the plan .
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MPEwatch .
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Floor Inventories .
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Managers can use the information to decide todeviate from the plan .
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Even when deviating the plan can be useful inshowing where capacity is available .
Slide - 4
Run Plan Generator - Daily Analysis
∎ At the end of the day, compare how the runplan matched up to actual processing .
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A good plan should generate operating windowsthat are similar to actual processing windows .
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A plan may need adjusting to better approximatereal conditions.
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Mail arrival profile, estimated volumes .
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Actual processing may not have attainedproductivity numbers assumed in the plan .
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Thruput goals, equipment downtime .
Slide - 5
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Run Plan Generator - Improvement Cycle
4) Change run plan model tomore accurately describe
processing in the facility and tostrive towards production goals .
1) Create a daily runplan for processing
the mail .
3) Compare whatactually occurred tothe plan. Analyzediscrepancies.
2) Plan is used duringprocessing as a template
for the day .
Slide - 6
Run Plan Generator - Run plans are not static
∎ There will be various reasons for havingthe run plan go through iterations .
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End of day analysis may show that the planneeds to be adjusted to more accurately modelmail processing .
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A satisfactory plan can be adjusted in order tolead the facility towards production goals .
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Separate plans can be created to handle certainextreme conditions (e .g., Christmas, fall mailingseason) .
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Variations of the run plan can be used tosimulate different scenarios .
Slide - 7
Run Plan Generator - You want to change what?rosni saevi
∎ The goal of the PPC Run Plan Generator (RPG)is to minimize the amount of work needed toproduce plans on a daily basis .
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The most useful run plan will be one based on volumeestimates specific to the day being planned .
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The RPG is designed so that almost all of theparameters are set up in advance .
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Most operational variations are contained within aweekly cycle (as opposed to volume variations) .
Slide - 8
Run Plan Generator - Run plan parameters
∎ Mail processing can be modeled if certainparameters can be determined .
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Expected volume .
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Mail arrival profile .
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Operating window .
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Production Units (Machines) .
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Productivity (Thruputs) .
Slide - 9
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Run Plan Generator - Run plan output
∎ With acceptable parameters the RPG can beexpected to give :
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The number of machines that will be needed to processthe mail volume .
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The timeframe each machine will run each sort planduring . These timeframes will be set up to process allvolume while avoiding two circumstances .
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Running equipment outside of desired operationalwindows.
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Running out of mail before the total daily volume has beenprocessed .
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Run plan output is set up to resemble WebEOR autocharts.
Slide - 10
Run Plan Generator - How the RPG works
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The hierarchy numbers for the sort plans areused to created a queue that determines theorder they will be processed in .
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It will attempt to schedule all the volumeestimated for a sort plan before moving on tothe next one in the queue.
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It will notify you if your operating parameterswere too tight to allow for all of that day'sestimated volume .
Slide - 11
Run Plan Generator - The method, illustrated
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Run Plan Generator - Output magnified
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Slide - 1 4
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Run Plan Generator - Facility information
∎ Facility information includes the followingitems .
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Identifying information .
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Site name, zip code, FOR ID number .
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Machine information .
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Types and numbers (names) .
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Sort plan information .
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Operation number and machine loadable name .
Slide - 1 5
Run Plan Generator - Operating Parameters
∎ Any sort plan for which you wish to include inthe run plan needs the following .
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The order in which the plan falls in the hierarchy .
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Machines on which to run the plan .
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Thruputs .
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Time information; earliest start time, clearance time,time needed for both prep and clean up, tour.
∎ Additionally, the following information may beneeded .
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Volume/Mail arrival profile; Lunch and Break ratio .
Slide - 1 6
Run Plan Generator - Volume information
∎ Volumes need to be estimated at the sort planlevel in order to produce a run plan .
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Need volumes for NV42203 or 271 FUMIX, not just foroperations 918 or 271 .
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So far this has been the item that has been theleast readily available for a plant .
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If you have been manually producing run plansyou may already have this information .
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The RPG looks for this information in a simpletable format.
Slide - 1 7
Run Plan Generator Operating Window
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Each sort program has a defined operatingwindow
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An operating window is also defined by themachines that can run a sort program
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Rank sort programs and machines in the orderthey will be scheduled
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Five different methods for scheduling : adefault and 4 alternatives
Slide - 1 8
Run Plan Generator Operating Window
Default method : start at clearance time andwork backward to the startup time .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
Machine1
Slide - 1 9
Run Plan Generator Operating Window
Alternate method : begin processing at startuptime, such as for Standard mail .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
MachineI
Slide - 20
Run Plan Generator Operating Window
Alternate method: overlap operating windowsby using the same startup and clearance times .The figure below shows two non-overlappedwindows.
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
MachineI
Machine2
Machine3
Slide - 21
Run Plan Generator Operating Windowvu,TID SaTISIOSU L stw~ri
By giving both sort programs the same startupand clearance times, the gap is eliminated . Inthis example, the green sort program is rankedbefore the black one .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
Slide - 22
Run Plan Generator Operating Window
When the priority is reversed to black overgreen, the following schedule is generated .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
MachineI
Machine2
Machine3
Slide - 23
Run Plan Generator - Operating Window
Alternate method : partially overlappingwindows can also provide better packing .Below, the green sort program has precedenceover the black one .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
MachineI
Machine2
Machine3
Slide - 24
Run Plan Generator Operating Window
If the black sort program has precedence overthe green, the following, less-efficient scheduleis generated .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
Slide - 25
Run Plan Generator Operating Window
Alternate method : wholly overlapping operatingwindows can also provide better scheduling .Below, the green operating window is whollycontained within the black operating window .
Time
12 13 14 15 16 17 18 19 . 20 21 22 23 00 01 02 03 04 05 06 07
Slide - 26
Run Plan Generator Operating Window
However, this changes considerably if the blacksort program takes precedence over the green .Note the gap .
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
T
MachineI
Machine2
Machine3
Slide - 27
Run Plan Generator Operating WindowUNITIDsnrnIosi*& snrin
The concept can be extended to as many sortprograms as necessary. Below are threeoverlapping windows on a single machine .
Time 12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
Slide - 28
Run Plan Generator - Volume Arrival Profile
The percentage of a run's volume available at agiven time can be specified to avoid runningdry.
Time
12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07
20% 35%
65% 80% 100%
Slide - 29
Run Plan Generator Lunches and Breaks
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Not explicitly scheduled, but RPG will expandthe processing period to cover them .
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Default factor is 0 which allows for onehour of lunches and breaks over 8 .5 '%ours
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The factor can be adjusted using t'following formula :
Lunch and break factor = I -Time setTotal
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Run Plans
Main Menu
Current Run Plan
Create an Auto~ interface
Create an Excel Based Run Plan
Start Date
Enter a Date(mNVOYyyy)
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Welcome to Eastern AreaPPC Run Plan Generator
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Slide - 31
Run Plan Generator Using RPG
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An RPG Help Desk is available Mondaythrough Friday from 8 am to 7 pm Eastern time
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Telephone number is 703-891-2684
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Email address is rpghelp@nortelgov .com,
Slide - 32
Run Plan Generator Master Machine List
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Machines are grouped by user-definedcategories, such as Automation or Flats
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Machine types and numbers must match FOR
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Manual operations can also be scheduled bysetting up a machine type called "Cases"
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For each machine category, enter the numberof people needed to staff the machine
Slide - 33
Run Plan Generator Master Sort Program List
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Enter by operation number
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Can use nonstandard sort program names to :
1) add a maintenance window
2) roll up sort programs that process the sametype of mail (draw from the same volumeestimate), but differ by machine type, numberof bins, or other factors .
Slide - 34
Run Plan Generator Creating a Run Plan Model
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Use selected machines and sort programs frommaster lists
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Create different models by machine category,time period, etc .
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Can add or delete machines and sort programswithout affecting master lists
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Assign specific machines to a sort program
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Set machine startup order by day of week,groups of days, or for all days
Slide - 35
Run Plan Generator Creating a Run Plan Model
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Rank sort programs by day of week, groups ofdays, or for all days
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Modify sort program operating parameters,including throughput, expected startup time,setup time, sweep time, lunches and breaks,VAP, and scheduling method
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Enter machine-specific operating parametersthat adjust sort program parameters
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Assign sort plan aliases (optional) to groupmachines on the master sort program list
Slide - 36
Run Plan Generator Projecting Volume
Volume forecasting involves the following steps :
1 . Grouping similar sort programs
2 . Establishing a weekly base volume
s. Adjusting the base volume for recent changes
4 . Spreading the volume over days of week
5. Modifying forecast volumes as necessary
6. Entering volumes on Excel spreadsheet
Note: The Eastern Area model does not includeholiday weeks
Slide - 37
Run Plan Generator - Creating Run Plan Reports
There are two types of run plans :
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Excel-based run charts
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Run plans and Plan vs . Actual reports based onan RPG-generated AutoPlan Interface (AI) fileimported into an Access database
Slide - 38