Capacity Planning based on Production Order
Capacity Planning feature of ERPNext means that companies can effectively trace and plan production activities, tracing how jobs are distributed to various Workstations. The feature optimizes the use of resources by synchronizing the production schedule with workstation capacity, preventing overloads, bottlenecks, or idle time.
Operations:
In order to start utilizing Capacity Planning, users need to establish Operations that reflect the various phases of production, i.e., cutting, welding, painting, etc. Each operation has particular tasks that are to be executed in the manufacturing process. The operations can be defined and assigned to Bills of Materials (BOMs) by going to: Manufacturing > Bill of Materials > Operations Here you can specify the operation name, description, operation time, and so on, which will be mapped to workstations later.
Workstation:
After defining operations, the following step is to create each Workstation in ERPNext. This can be achieved by navigating to: Manufacturing > Bill of Materials > Workstation In the Workstation master, users can set important properties like the operations assigned to the workstation, hourly operating costs, default working hours, holiday lists, and production capacity.
Such precise configuration enables the system to compute job timings, costs accurately, and schedule jobs based on available capacity and operational constraints. These settings make Capacity Planning accurate and according to the actual world capabilities of your production setup.
Bill of Materials (BOM):
In ERPNext, the Bill of Materials (BOM) not only carries a comprehensive list of raw materials to be used in manufacturing a finished item, but also enables you to indicate the operations and workstations through which the raw materials will go.
Every operation may be sequenced and mapped to a designated workstation so that the system can schedule and control production tasks better. The incorporation of routing information in the BOM provides the system with complete visibility into the entire manufacturing process, from raw material usage to the end product, including the time and resources utilized for each process.
Production Order:
As a Production Order is submitted, ERPNext produces Job Cards and Timesheets for operations as laid out in the BOM automatically. These production job cards are employed to schedule and assign production jobs to respective workstations according to capacity and availability.
Planned and actual operation times are both monitored by the system, allowing you to track performance, capture time elapsed, and accurately manage costs. This automation assists in efficient production scheduling and guarantees that every operation is posted to the right workstation.
Question: On Submission of Production Order, we are getting following error message.
On coming across an error while submitting a Production Order, one should first ensure whether Working Hours have been set in the Workstation master. If not, make the update in the working hours under the concerned workstation setup.
ERPNext plans operations (as specified in the BOM) on workstations and believes that every operation starts and ends on the same working day. If the system is not able to schedule an operation into available time in a single day, it invokes a scheduling error. This is most likely to happen when the duration of an operation is longer than available working hours.
Answer:
To correct the problem, make sure the Working Hours are properly configured in all Workstations. If working time is already brought up to date but the mistake is still there, it is probably due to one of the operations taking too long to be done within a single working day.
You then have to split the operation into smaller, discrete tasks so each can be processed within the specified daily working period. By splitting the operation, ERPNext is able to allocate the split operations between the slots available in the workstation schedule and execute them effectively.