Configuring Bottleneck Analysis
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Bottleneck analysis is based on production data that is gathered over time. Before bottleneck analysis can be used, all initial administration activities must be completed, and production data added to DPM for some time.
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Bottlenecks are operations that constrain a site’s ability to meet production demand within the planned schedule. The bottleneck analysis functionality in Performance Analysis identifies bottlenecks by determining the bottleneck impact for each work center in a given area, for a given demand window. To understand how bottlenecks are identified, it helps to understand a few terms:
• A demand window is a period of time during which production demand can be scheduled for a site.
• TAKT is the time required to produce a unit of material in order to meet the customer demand for a given time frame. DPM calculates the TAKT for each work center as the total planned production time for the work center divided by the total demand for that work center. If you know a work center’s TAKT for a given demand window, you can use a manually entered TAKT value instead of the value calculated by DPM.
• Deviation from TAKT is the difference between the actual cycle time for a work center (how long it actually takes the work center to produce a unit of material) and the TAKT time for the work center. The greater the deviation from TAKT, the larger the bottleneck impact is for that work center.
• The total demand for a work center is the total production demand for the work center, for a given demand window. When the demand setting for a demand window is Set on Materials, the total demand for a work center is calculated from the demand that is allocated to the work center from individual materials. When the demand setting for a demand window is Set on Work Centers, you must manually enter the total demand for your work centers.
• The bottleneck impact for a work center is calculated for a given demand window as (deviation from TAKT) * (total demand for the work center).
The following table describes the three options for configuring bottleneck analysis for a given demand window. Which option you choose depends on the information that you have. You can choose different configuration options for different demand windows.
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Configuration Option
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Use this option If you know:
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The TAKT for your work centers, but no other demand information.
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The total demand for your work centers.
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The demand information for individual materials.
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Understanding the Demand Setting for a Demand Window
The demand setting for a demand window (Set on Work Centers or Set on Materials) determines where DPM looks for the information it uses when calculating bottleneck impacts.
• When the demand setting is Set on Work Centers, DPM looks only at the TAKT and Total Demand values on the Demand Settings tab for a work center to calculate the work center’s bottleneck impact, and ignores any demand information that is specified on individual materials. This means that you can work on adding demand information to materials, such as building out a demand BOM, while bottleneck impacts are calculated from the work center information.
• When the demand setting is Set on Materials, DPM uses the demand information that is specified on individual materials, on their Demand, Demand BOM, and Demand Allocation tabs, to determine the Total Demand for each work center, then uses the TAKT and Total Demand values to calculate the bottleneck impact for each work center.
You can edit a demand window at any time to switch between the demand setting options for that demand window.
Leveraging Demand Information for New Demand Windows
Regardless of which demand setting option is selected for a demand window, all demand information that is present on a demand window, whether it is specified on materials or on work centers, is copied to a new demand window when the original demand window is duplicated, or when it has an end date that most closely precedes the start date for a new demand window that is being created. This allows you to leverage demand information that you’ve already specified for new demand windows, saving you the time of entering it manually for each demand window.