Production sheets

These sheets include details about production processes, the bill of materials, and the routing of production.

Production Definition

Purpose: List all productions involved.

Instructions: Enter the name of all productions you want to use in the model. If you want to use a different name for displays, you can use the Description column.

Production Groups

Purpose: For each production, you can determine which group it belongs to.

Instructions: Assign productions to their respective groups by filling in the Production column with the appropriate group and entering the production that belongs to that group in the SubProduction column. Each subproduction must be in a different row and the Active column must be set to 1.

Bill of Material Groups

Purpose: For each BOM, you can determine which group it belongs to.

Instructions: Assign BOMs to their respective groups by filling in the Bill of Material column with the appropriate group and entering the BOM that belongs to that group in the Sub Bill of Material column. Each subBOM must be in a different row and the Active column must be set to 1.

Production

Purpose: Define production-related data.

Instructions: Enter data specific to production, like: 1. Availability 2. Capacity data 3. Cost data 4. Opening/Closing data 5. Custom Objectives data

If you want to define data on this sheet you have to fill in the Production, Location, Step, and Period columns for each supplier you want to use in the model.

Bill Of Material

Purpose: Define the bill of materials for products.

Instructions: Enter components and quantities required for produce each product.

Production Routing

Purpose: Specify in which production facility the final product is made.

Instructions: Enter data specific to production.

Production Routing Ratio

Purpose: You can set ratio constraints related to production.

Instructions: Fill in the first 8 columns and define the Minimum/Maximum ratio or both. You can read more about ratio constraints in Ratio Constraints.

How the Bill of Material works in SC Navigator?

This page explains how the Bill of Material (BOM) works in SC Navigator. In particular, the capability for modeling is now extended to the full supply chain, including the raw materials and the intermediate products.

The template contains a Bill of Material sheet where you can define the BOM data:

On this sheet you can define how the raw materials are combined into final products. For example, for creating one unit Poly-Crystalline final product the following raw materials are needed:

• 10 unit of Raw Material 1

• 10 unit of Raw Material 2

• 10 unit of Raw Material 3

• 10 unit of Raw Material 4

• 10 unit of Raw Material 5

As shown in this example, you can use different units of measurement for the raw materials and for the final products.

In the Product Created column you can define how many final products can be made from the given amount of raw materials. This can be any positive number.

In the Product Needed column you can define how many raw materials are needed for the given amount of final product. This can be any positive number.

On the Production Routing (Bill of Resource) sheet you can also specify in which production facility the final product is made.

On this sheet you can define the following attributes:

• Consumed Capacity: the amount of capacity consumed in one iteration of the given Bill of Material at the given Production, Location, and Period.

• Minimum Capacity: the minimal amount of capacity that needs to be used for the given Bill of Material at the Production, Location, and Period. This is conditional on the Force Open attribute of the sheet, meaning that if Force Open is not set to one, the model may choose not to use the given Bill of Material at the Production, Location, and Period. In that case, the minimum would not apply. If Force Open is set to one, then the minimum capacity is absolute.

• Maximum Capacity: the maximal amount of capacity that can be used for the given Bill of Material at the Production, Location, and Period.

• BOM Fixed Cost: the cost of the Bill of Material being in use at the Production for the given Period and Location. BOM Fixed Cost is independent of the inbound or outbound volume. BOM Fixed Cost remains the same no matter how much the volume is.

• BOM Variable Cost: the cost of using one iteration of the given Bill of Material at the Production for the given Period and Location.

• Opening Cost

• Closing Cost

• Force Open

• Force Close

• Open as Group

• Initial Status Closed

• Custom costs

Please know that the Minimum Capacity and Maximum Capacity are in terms of capacity consumed and not in terms of products created. (Of course, if Consumed Capacity is 1, these are the same.)

For example, see the image above, where we make 1 unit of Poly-Crystalline from the given amount of raw materials. That process requires 2 units of capacity, and its variable cost is 1. So, if we want to make 10 units of Poly-Crystalline, the consumed capacity will be 20 units, which exactly hits the maximum capacity specified, the variable cost will be 10, and the fixed cost will also be 10.

If one Bill of Material in one location is specified over multiple production facility, SC Navigator can pick among those production facility to get the best solution. This might mean it uses one or it might mean that it uses them all.

In SC Navigator every production facility should have routing, which means that if we define a production facility on the Production page we have to define it on the Production Routing (Bill of Resource) sheet as well for the model to take into account.

In Backwards Compatibility we have to define the production facility on the Production data sheet as well as the Bill of Resource and the Bill of Material sheet. Otherwise, if the production facility availability is 1 on the Production Product sheet and the production facility has no routing, the model will take it into account as a supplier. Or, if the production facility is not available on the Production Product sheet and has no routing, the model will not take it into account.