Capacity Planning Data Requirements

Capacity planning requires a number of tables to operate properly. Though these are covered in the DemandCaster Data Tables article, they are also provided here for convenience.

Shop Orders (shoporders.txt)

The shop order table may be called different names including work orders, production orders, or jobs. This is applicable to companies that produce, assemble, or kit finished goods.

Each upload deletes the prior shop orders and replaces with new data. Users may choose to only delete and replace a limited time frame i.e. last 3 to 6 months in order to minimize the amount of data being updated. We recommend 6 months of history to be uploaded.

The table columns are as follows - all data comes from ERP:

  1. Shop Order Number and Line (max 20 chars): Order number is typically from the shop order header table and the line is from the shop order detail table. It is preferred that a dash be added between the order and line but it is not required. Required field.
  2. Status (1 char for Open, Closed, Planned): Characters are O = open, C = closed, or P = planned. If a line has been cancelled, please use the status C but leave the completion quantity and date blank. Planned means the order has not been released to production thus no inventory has been issued against the shop order. A planned status (P) order will always explode to the components regardless if back-flushing is off ("No") or on ("Yes"). Required field.
  3. Order Date (date): The date the order was created. This is typically pulled from the shop order header and is a required field. For a shop order with multiple lines if the release to production date is available, please provide this date in place of the order date. Required field.
  4. Item/Product Code (max 40 chars): This is the item that was ordered. This is typically pulled from the shop order detail table. Required field.
  5. Order Quantity (float): This is the original quantity ordered. This is typically pulled from the shop order detail table. Required field.
  6. Scheduled Completion Date (date): This is the date the order was/is scheduled to be completed. If this date is not maintained we will used the actual completion date as a default completion date for the item for a previously shipped item. If appropriate, the completion date may be generically applied using the item lead time. This is typically pulled from the order detail table. Required field.
  7. Actual Completed Quantity (float): This is the actual completion quantity. Leave blank if not completed. If partially completed, include the quantity of the completion but leave the order line status as O for open. If partially completed and the order line has been closed enter the completion quantity and change the status to C for closed. This is typically pulled from the shop order detail table. Required field.
  8. Actual Completion Date (date): This is the actual completion date if the item was completed. Leave blank if not completed. If partially completed, include the date of the completion but leave the order line status as O for open. If partially completed and the order line has been closed change the status to C for closed. This is typically pulled from the shop order detail table. Required field.
  9. Location Code (max 20 chars): This is the location where the order was produced.

Note: If a work order (job / shop order) is created in your system but inventory has not been issued to the order, apply the "P" status to the work order. This will allow DemandCaster to allocate inventory against the job if back-flushing is not the inventory management approach applied to the item.

Work Center (workcenter.txt)

This is the list of work centers used in the routing and capacity planning. Each upload updates the data with a time stamp. This allows user to update the table with only changes with each subsequent upload. If the work center number no longer exists in the upload, the work center remains in DemandCaster with the previously uploaded time stamp.

To identify old work centers or view, maintain, or create new work centers, go to the "Data Maintenance" page under the "Capacity" menu group. Select "Work Center" from drop down. This page support multi-edits but any changes made here will be overwritten by subsequent uploads.

The table columns are as follows - all data comes from ERP or can be manually uploaded if the data does not exist in the ERP.

  1. Work Center Number: Required field 
  2. Work Center Name: Required field 
  3. Location Code (max 20 chars): Ties the work center to a specific location

Routing (routing.txt)

Required for manufacturing companies if capacity planning and scheduling module is enabled. This is the items standard / primary routing. Each upload deletes the prior routing and replaces with new data so any user defined changes will not be retained.

The table columns are as follows - all data comes from ERP or can be manually uploaded:

  • Item/Product Code (max 40 chars): This is the item that is produced. Required field. 
  • Operation Number (max 10 char): This is the operation number of the routing. Typically a sequential number sorted in increasing order. The smallest operation number is typically the first operation. Required field.
  • Work Center Number: Work center that the operation is assigned to. Required field. 
  • Operation Description: Description of the operation. This is not a required field. 
  • Setup Time (minutes or hours): The number of hours (decimal) or minutes required to set up the specific operation. Default to 0 if not available or if quantity based capacity planning is being used. The basis is setup in company setup at the time of creating the DemandCaster instance. If you require this value to change, please contact support.
  • Run Time (minutes or hours): The number of hours (decimal) or minutes to run one part. Take the longest of the labor or machine time.  Default to 0 if not available or if quantity based capacity planning is being used. The basis is setup in company setup at the time of creating the DemandCaster instance. If you require this value to change, please contact support.
  • Lead Time: This is the number of days required to process an outside operation. Not required. Default to 0 if not used. 
  • Location Code (max 20 chars): If the routing is tied to specific location otherwise leave blank.

To view, create new, or maintain existing routing, go to the "Data Maintenance" page under the "Capacity" menu group. Select "Routing" from drop down. This page support multi-edits to allow changes to any of the settings.

Shop Order Progress (shoporderprogress.txt)

The routing applied against an open job in production. This may differ from the standard routing. Each upload deletes the prior routing and replaces with new data. This is used to properly calculated the number of operations or quantity remaining on any open jobs in production.

The table columns are as follows - all data comes from ERP or manually uploaded.

  1. Shop Order Number and Line (max 20 chars): Required field. 
  2. Operation Number (max 10 char): Required field. 
  3. Work Center Number: Required field. 
  4. Completed Quantity (float): 0 if none completed. Required field. 
  5. Completed Date (date): The date the routing operation was completed. Required field. 
  6. Status (1 char): Y = In Process, N = Not Started, C = Completed. Required field. 
  7. Item/Product Code (max 40 chars): Item being produced. Required field. 
  8. Setup Time (minutes or hours): The number of hours (decimal) or minutes required to set up the specific operation. Not a required field. Leave blank if value defaults to routing value.
  9. Run Time (minutes or hours): The number of hours (decimal) or minutes to run one part. Take the longest of the labor or machine time. Not a required field. Leave blank if value defaults to routing value.
  10. Lead Time: This is the number of days required to process an outside operation. Not a required field. Leave blank if value defaults to routing value.

If you are uploading only open orders, you will still need to upload two blank columns for the actual delivery date and quantity. A quick solution is to add one closed order line in the file with actual delivery date and quantity. That will automatically add the columns for the rows that have a blank ship date and quantity.

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