DPM Administration > Configuring Bottleneck Analysis > Configuring Bottleneck Analysis with Material Demand
Configuring Bottleneck Analysis with Material Demand
When the demand for a demand window is Set on Materials, the total demand for a work center is calculated as the sum of all of the material demand that is allocated to the work center from all materials that are produced by the work center. The high-level flow for calculating the total demand for a work center from material demand is as follows:
1. Specifying material demand
Each material can have demand coming from two places: the independent demand for the material and the BOM demand for the material. A given material can have only independent demand, only BOM demand, or both. The total demand for the material is the sum of its independent demand and any BOM demand.
Independent demand—The number of units of the material that are required as a standalone material, not resulting from its inclusion in a demand BOM. Independent demand is specified on the Demand tab for a material.
BOM demand—The number of units of the material that are required because it is included in a demand BOM for another material. The immediate children of a material in the BOM are specified on the Demand BOM tab for a material.
For example, the Bicycle material has a demand BOM which includes 1 Frame material and 2 Wide Wheel materials as children. This means that for every 1 Bicycle unit that is produced, 2 Wide Wheel units are required. If there is independent demand for 300 Bicycle units, the resulting BOM demand for Wide Wheel units is 600. If there is also an independent demand for 200 Wide Wheel units, then the total demand for Wide Wheel units is 800.
2. Allocating demand to work centers
The total demand for the material is then allocated by percentage to the work centers which can produce the material. The demand allocation is specified on the Demand Allocation tab for a material.
For example, if there are four work centers which can produce the Wide Wheel material, the material demand can be allocated to each work center, either evenly distributed or with different percentages for individual work centers, for example: 10% to Work Center 1 (40 units), 40% to Work Center 2 (160 units), 30% to Work Center 3 (120 units), and 20% to Work Center 4 (80 units).
3. Calculating the total demand for each work center
If a work center produces a single material, then the total demand for that work center is the demand for that material which is allocated to the work center. For example, if Work Center 2 produces the Wide Wheel material, the total material demand for Wide Wheel is 800 units, and 40% of the demand for the Wide Wheel of material is allocated to Work Center 2, then the total demand for Work Center 2 is 320 units.
If a work center produces more than one material, then the total demand for the work center is the sum of the demand allocated from each material to that work center. For example, Work Center 1 can produce the Wide Wheel material, the Narrow Wheel material, and the Training Wheel material. The material demand for each material is allocated to Work Center 1 is as follows:
Wide Wheel—Total demand is 800 units, with 20% allocated to Work Center 1 (160 units).
Narrow Wheel—Total demand is 400 units, with 50% allocated to Work Center 1 (200 units).
Training Wheel—Total demand is 200 units, with 100% allocated to Work Center 1 (200 units).
This means that the total demand for Work Center 1 is 560 units.
The total demand for each work center is found in the Total Demand column on the Demand Settings tab for the work center, in the Equipment List.
Configuring a Demand Window with Demand Set on Materials
To configure a demand window where the demand information that is used to calculate the bottleneck impact is specified on materials, complete the following steps:
1. In Site Demand, select a site and create a demand window. For the Demand Setting, select Set on Materials.
2. In Materials, view a material which has demand during this demand window.
3. On the details page for the material, view the Demand tab.
4. Under Demand Window, click Select and select the demand window. This demand window selection is retained as you move between the tabs.
5. On the Demand tab, specify the independent demand for this material, for the demand window. Independent demand is demand for the material that is separate from any BOM demand.
7. On the Demand Allocation tab, set the target allocation for each work center. This is the percentage of the total demand for the material that each work center is expected to produce.
8. Repeat steps 2 through 8 for each material with demand during this demand window.
9. Optionally, in Equipment List, navigate to a work center in the same site for which the demand window was created and on the Demand Settings tab, edit the TAKT value for the demand window on the work center.
10. Repeat step 9 on each work center with demand for this demand window.