Production Plans

About Production Plans

Each Production Unit can generate one or more products. For each product that it generates, a production profile will exist to identify information about that product, such as the maximum demonstrated rate of production and the amount of profit one of those products yields.

For each Production Unit, you will have one or more Production Plans in which you can define criteria, as outlined in the following table:


Plan Details	Description	Example
What	The products that you plan to produce. Each plan can include one or more products.	You plan to produce water bottles and labels.
When -or- How Much	When: The time period for which you want to track the production. In this case, you will provide the start and end dates, and the planned product quantity will be determined automatically based upon the production profile. This option is called a time-based plan. -or- How Much: The amount of each product that you plan to produce. In this case, you will provide the start time and the planned product quantity, and the end time will be determined automatically. This option is called a quantity-based plan.	When: You plan to produce bottles and labels from January 1, 2015 through April 30, 2015. -or- How Much: You plan to produce 50,000 bottles and 100,000 labels, starting January 1, 2015.
During Which Hours	The hours each day that you produce the specified products.	You have one shift running 8:00 A.M. to 5:00 P.M. -or- You have two shifts: 8:00 A.M. to 8:00 P.M. 8:00 P.M. to 8:00 A.M.
How Often You Enter Data	The frequency by which you enter production data and production losses. You can choose the Data Entry type to select the frequency by which you enter data.	You enter production data daily. -or- You enter production data once per shift.

Each production plan is represented by a Production Plan record.

About Usage of the Planned Production Values

After you create a Production Plan, the plan will contain a row for each period for which you plan to produce a given product (i.e., an entire day or a specific shift within a day). Each row will contain a planned production value, where the product associated with those values is specified in the column heading. The following image illustrates planned production values for Gasoline.

When you access the Production Data workspace for a production plan, for each product, you will see a similar row for each period in the plan. Each row represents a separate Production Data record. In each row, the value in the Short Range Plan column is a copy of the planned production value.

Note: Via the Production Data workspace, the short range value can be changed manually if needed.

About the Short Range Plan

When you create a Production Profile, you define the amount of product that can be consistently produced by a production unit without having any adverse effects on the piece of equipment or location or the quality of the product. This value is stored in the Maximum Sustained Capacity Rate field in the Production Profile.

When you create a Production Plan, with this value in mind, you can define the amount of product that you plan for that production unit to produce during a given time period. This value might be the same as the Maximum Sustained Capacity (MSC) rate, or it might be different based on your knowledge of planned events within the facility. The Short Range Plan can be edited to account for external and other factors that can impact production rate, such as weather and demand fluctuations. For example, known or anticipated loss of cooling capacity due to high ambient temperatures is a valid reason why MSC values could not be achieved. Additionally, demand for certain products increases or decreases seasonally, which is another valid reason why Short Range Planned values would be altered.

When you access the Production Data section of a Production Plan, for each product listed as an option, a row will be available for each period in the plan. Each row represents a separate set of Production Data. In each row, the value in the Short Range Plan column is a copy of the planned production value.

As you enter production values for a specific day, you can enter an adjusted planned production value based on significant events that occurred that day and could not have been predicted when the plan was created. For example, while a Production Plan might call for 15,610 barrels to be produced on June 1, if a hurricane occurs and the facility is shut down for several weeks for cleaning and repairs, you might want to indicate that the planned production during those days decreased significantly. The adjusted value will be stored in the Short Range Plan field in the Production Data.

Access a Production Plan

Procedure

Access the PLA Overview page.
Select the Production Plans tab.

The Production Plans section appears, displaying a list of Production Plans available in the database.
In the row containing the Production Plan whose details you want to view, in the Plan ID column, select the link to access the details of the Production Plan.
The Plan Details workspace appears, displaying the details of the selected plan.

The Plan Details workspace contains the following items:
- Start Time : The start time of the production plan. This value is read-only.
- End Time: The end time of the production plan. If this is a time-based plan, you specified this value manually in the Production Plan Builder. Alternatively, if this is a quantity-based plan, this value is determined automatically based upon the product quantity and start time that you specified. This value is read-only.
- Plan Basis: The type of plan: Time-based or Quantity-based.
- Production Model: The order in which the products will be produced: Concurrent or Sequential.
- Data Entry Type: How often you plan to enter production data and losses.
- Upper Grid: In the Plan Details workspace, each row in the upper grid represents a separate product that is being produced during the plan. All values in the grid are read-only. The grid contains the following columns:
  - Product Name: The name of the product.
  - Quantity: The amount of product that should be produced during the entire plan. If this is a time-based plan, this value is determined automatically based upon the start and end times that you specified in the Production Plan Builder and the batch production values that you specified in the associated Production Profile. Alternatively, if this is a quantity-based plan, you specified this value manually in the Production Plan Builder.
  - UOM: The unit of measure that is associated with the product.
  - Sequence: The order in which the product will be produced during the Production plan (represented by a number 1 through n).
    
    Note: The Sequence column is displayed only for the Sequential Production Model.
  - Start Time: The time at which that product will start being produced. If multiple products are being produced, the start time for each product is determined based upon your production model selection in the Production Plan Builder. For example, if multiple products are being produced sequentially, for each product after the first one, production will start after production ends for the previous product.
  - End Time: The time at which that product will stop being produced.
- Lower Grid: In the Plan Details workspace, each row in the lower grid represents a separate period in the plan (e.g., a separate day or a separate shift within the same day). The grid contains the following columns:
  - Start Time: The start time of the period.
  - End Time: The end time of the period.
  - <Product Name (<UOM>)>: The planned production amount for that period. You can modify the value as long as it does not exceed the maximum demonstrated capacity that is defined in the associated Production Profile.
  You can modify values in the Plan Details section by selecting the value that you want to modify. Doing so will update the value in the Quantity column in the Products section and the plan start and end time above the Products section.

Access the Production Summary

Procedure

Access the PLA Overview page.
Select the Production Plans tab.

The Production Plans section appears, displaying a list of Production Plans available in the database.
Select the row containing the Production Plan whose summary you want to view.
Select View Summary.
The page for the selected plan appears, displaying summary information for the Production Plan in the Production Summary workspace.
The Production Summaryworkspace contains the following items:
- Total Production: The sum of all values in the Actual column on the corresponding Production Data workspace, appended with the value in the Product UOM field in the Production Profile that is associated with this Production Data. If the Production Plan includes more than one product, however, the total production value is appended with Units.
- Total Losses: The sum of all values in the Losses column on the corresponding Production Data workspace, appended with the value in the Product UOM field in the Production Profile that is linked to the Production Plan that you selected when you accessed the Production Data workspace (e.g., Barrels). If the Production Plan includes more than one product with different units of measure, however, the total losses value is appended with Units.
- Cost of Losses: The cost of all losses across all products that are included in the plan, where the value is calculated using the following equation:
  Cost of Losses = Σ Losses x Margin
  Note: The currency symbol that appears in the Production Summary workspace and the number of decimal places that appear in the Cost of Losses value are defined via the Production Loss Analysis Application Settings.
- Product: The name of the product and its associated unit of measure.
- MSC: The value in the Maximum Sustained Capacity Rate field in the Production Profile that is associated with this Production Plan.
- Planned: The sum of all values in the Short Range Plan column in the corresponding Production Data workspace.
- Actual: The sum of all values in the Actual column in the corresponding Production Data workspace.
- Loss: The sum of all values in the Losses column in the corresponding Production Data workspace.
- Cost: The sum of cost of all losses for all days in the plan, where the value is calculated using the following equation:
  Cost of Losses = Σ Losses x Margin
- Production Data Summary Plots: Displays a graphical representation of the data that exists in the Production Data workspace.
- OEE: The OEE percentage for the products that are selected in the production grid. OEE is calculated using the following equation:
  OEE = (Availability x Performance x Quality) x 100
- Performance: The performance percentage for the products that are selected in the production grid. Performance is calculated using the following equation:
  Performance = [(Good Production + Quality Loss) / (Good Production + Performance Loss + Quality Loss)] x 100
- Availability: The availability percentage for the products that are selected in the production grid. Availability is calculated using the following equation:
  Availability = [(Good Production + Performance Loss + Quality Loss) / (Good Production + Availability Loss + Performance Loss + Quality Loss)] x 100
- Quality: The quality percentage for the products that are selected in the production grid. Quality is calculated using the following equation:
  Quality = [Good Production / (Good Production + Quality Loss)] x 100

Create a Production Plan via the Production Plan Builder

About this task

This topic describes how to create a Production Plan via the Production Plan Builder. Alternatively, you can:

Create a manual Production Plan.
Copy a Production Plan to create a new plan.
Create a Production Plan from a Plan Template

Procedure

Access the PLA Overview page.
On the upper-right corner of the page, select New Plan, and then select Build a Plan.

The Production Plan Builder window appears, displaying the Select Production Unit screen.
In the Select Unit box, select the Production Unit for which you want to create a new Production Plan.

The list of available products appears.

Note: The Production Plan will be created in the time zone of the Production Unit.
Next to each product that you want to add, select the check box.

Note: If you want to create a sequential plan, you must select at least two products.

Tip: If the list of products that you can add is long and you are having trouble finding the product that you want to add, you can search for a specific product by entering a value in the search box.
Select Next.

The Select Plan Basis screen appears. You can use this screen to determine whether the plan will be time-based (i.e., you will define the time period for which you want to track production), or quantity-based (i.e., you will define the amount of each product that you plan to produce).
If you want to generate a time-based plan, accept the default selection.

-or-

If you want to generate a quantity-based plan, select Plan is quantity-based.
In the Production Model list, select the option that describes how the unit produces the products that you selected on the Select Products screen. You can select either of the following options:
- Concurrent : The unit produces the products at the same time.
- Sequential : The unit produces the first product first, and then begins producing the second product after production of the first product is complete.
Select Next.

Depending on your selection, the Time-based Plan screen or Quantity-based Plan screen appears.
If you are creating a time-based plan, on the Time-based Plan screen:
1. In the Plan Start Time box, enter or select the date on which the plan begins.
2. In the Plan End Time box, enter or select the date on which the plan ends.
-or-

If you are creating a quantity-based plan, on the Quantity-based Plan screen:
1. In the Plan Start Time box, enter or select the date on which the plan begins.
2. In the Quantity column, in each row, enter the amount of product that you plan to produce.
  Tip: If the unit produces multiple products, you can also sort them using the Product column to change the order in which each product will be produced.
Select Next.

The Useful Production Time screen appears.

You can use this screen to define the hours each day that you produce the specified products. By default, the builder assumes that, Monday through Friday, your production hours are the same (9:00:00 A.M. to 5:00:00 P.M.). It also assumes that you do not produce anything on Saturdays or Sundays.
To refine the hours each day that you produce the specified products, by selecting the appropriate tabs, define your shifts as necessary.
- If your shifts are the same Monday through Friday, you can leave the default I have the same useful production time from Monday through Friday check box selected, and then define the shift only for Monday. It will then be copied to Tuesday through Friday automatically.
- If your shifts are the same every day of the week (including weekends), you can select the I have the same useful production time for the whole week check box. You can then define the shift only for Monday, and it will be copied to Tuesday through Sunday automatically.
- If your shifts are on specific days, clear the I have the same useful production time from Monday through Friday and I have the same useful production time for the whole week check boxes, and then manually define the shifts for each day.
When defining shifts:
- If you run only one shift all day (24 hours a day), make the start time and end time the same, as shown in the following image:
- If you run multiple shifts per day, back to back, match the start time of the second shift to the end time of the previous shift, as shown in the following image:
In the Data Entry Frequency box, select the frequency with which you enter Production Data and Loss information.

Note: If you want to enter Production Data only once over the course of the entire plan period, select Campaign.
Select Finish.

The Production Plan is created and appears in the Plan Details workspace.

Create a Production Plan from a Plan Template

Procedure

Access the PLA Overview page.
On the upper-right corner of the PLA Overview page, select New Plan, and then select Use Plan Template.

The Use Plan Template window appears.
Select the Unit that contains the Plan Template that you want to use.

A list of Plan Templates for the selected Unit appears.
Select a Plan Template.

Note: These steps assume that you want to review or modify the plan details prior to generating the plan. If this is not the case, clear the Review Plan Before Creating check box and proceed to Step 9.
Select Finish.

The Review Plan window appears, displaying the Production Period section.
For a concurrent plan, select the Plan Start Time and Plan End Time, and, in the grid, select the check boxes for any products that you want to include in your plan.

-or-

For a sequential plan, select the Plan Start Time. The Plan End Time is set automatically to one year after the Plan Start Time. In the grid, select the check boxes for any products that you want to include in your plan.
Select Next.

The Useful Production Time section appears.
Specify the days and times when useful production will occur. To do so:
1. Select the appropriate check box to indicate whether the production occurs during the whole week or only Monday through Friday.
2. Use the schedule controls to enter the shift times for each day that production occurs.
3. In the Data Entry Frequency box, select how often data is entered into GE Digital APM.
Select Finish.

The plan is generated and appears in the Plan Details workspace.

Create a Manual Production Plan

About this task

After creating a manual Production Plan, you can add products to the plan, as well as modify the start and end time, via the Plan Details section.

Note: You cannot copy or regenerate a manual Production Plan.

Procedure

Access the PLA Overview page.
Select New Plan, and then select Manual Plan.

The Create Plan by Manual Entry window appears, displaying the Select Production Unit screen.
In the Select Unit list, select the Production Unit for which you want to create a new Production Plan.

The list of available products appears.

Note: The Production Plan will be created in the timezone of the Production Unit.
Next to each product that you want to add, select the check box.

Tip: If the list of products is long and you are having trouble finding the product that you want to add, then you can search for a specific product by entering a value in the search box.
Select Finish.

The plan is generated and appears in the Plan Details workspace.

Tip: The start time is automatically generated as the date the plan is created, and the end time is exactly 24 hours later. The start time and end time can be modified by selecting the field and entering new values.

Note: The initial quantity shown in the Plan Details section is based on the duration of the plan multiplied by the MSCR of the selected product, which can be modified along with the start time and end time.

Modify a Manual Production Plan

About this task

Manual Production Plans can be modified in the Plan Details section.

Procedure

Access a manual Production Plan.

The Plan Details workspace for the selected manual Production Plan appears.
As needed, modify the following details:
- If you want to modify the Start Time and End Time, then complete the following steps:
  1. Select the row of data for which you want to modify the Start Time or End Time.
  2. In the Start Time cell, enter the new start time.
  3. In the End Time cell, enter the new end time.
    
    The values are saved automatically when you select outside the cell.
- If you want to add a row at the bottom of the grid, then complete the following steps:
  1. In the upper-left corner of the grid, select , and then select Add Row.
    
    A new row is added to the bottom of the grid. The start time, end time, and planned production value for the new row will be determined automatically. An equivalent row is added in Production Data section if the start time for the new row is before the current start time.
  2. As needed, modify the values in the cells in the following columns:
    1. Start Time : Enter the start time.
    2. End Time : Enter the end time.
    3. <Product (UOM)>: Enter the quantity of the product based on the Unit of Measure (UOM).
      
      The values are saved automatically when you select outside the cell.
    Note: If an overlap exists in the plan, then a warning message appears.
- If you want to insert a row before or after a row, then complete the following steps:
  1. Select the row above or below which you want to insert a row.
  2. In the upper-right corner of the grid, select , and then select Insert Row Above or Insert Row Below.
    
    A new row appears in the grid based on your selection.
  3. As needed, modify the values in the cells in the following columns:
    1. Start Time : Enter the start time.
    2. End Time : Enter the end time.
    3. <Product (UOM)>: Enter the quantity in the column labeled with the selected UOM for the plan.
      
      The values are saved automatically when you select outside the row.
    Note: If an overlap exists in the plan, then a warning message appears.
- If you want to add a product, then complete the following steps:
  1. In the upper-left corner of the grid, select , and then select Add Product.
    
    The Product List window appears.
  2. Select a product from the list, and then select OK.
    
    The product appears in the grid in the upper section.

Add a Row in a Production Plan

Procedure

Access the Production Plan to which you want to add a row of data.
In the Plan Details workspace, select , and then select Add Row.

A new row of data is added to the second table. The values in the Start Time and End Time columns and the planned production value for the new row are determined automatically.

The values in the Quantity and End Time columns in the first table and the Plan ID are updated.

Copy a Production Plan

About this task

When you copy a Production Plan, a new Production Plan is created. You can copy a Production Plan to create a Production Plan for the same Production Unit for which the source plan was created. The copied Production Plan will be created in the time zone of the Production Unit.

Tip: You can create a new Production Plan without copying an existing plan.

Procedure

Access the Production Plan that you want to copy.
In the upper-right corner of the workspace, select , and then select Copy Plan.

The Production Plan is copied and the list of Production Plans is updated. The copied Production Plan has the same name as the Production Plan from which it was copied.

Remove the Last Row in a Production Plan

Procedure

Access the Production Plan from which you want to remove the last row of data.
In the Plan Details workspace, select Remove Last Row.

The Confirm Remove window appears, indicating that this action will also delete the corresponding row of data in the Production Data workspace.
Select Yes.

The last row of data in the Plan Details workspace and the corresponding row of data in the Production Data workspace are deleted.

The values in the Quantity and End Time columns in the first table and the Plan ID are updated.

Regenerate a Production Plan

About this task

After you create a Production Plan (unless you created a manual Production Plan), you can change only the planned Production Values. You cannot change Production Plan details such as start time, end time, and products. Instead, if you want to modify the details of a Production Plan, you will need to regenerate the Production Plan. Doing so will delete the current Production Plan and create a new one.

When you regenerate a Production Plan, you do not have to enter all details. The details of the previous plan will be retained in the builder. You can keep the details that you want and modify the details that are no longer valid.

You can regenerate a production plan on the PLA Overview page.

Important: Regenerating a Production Plan will delete all the records associated with that Production Plan, including the actual production data and losses.

Procedure

Access the Production Plan that you want to regenerate, and then, in the upper-right corner of the workspace, select , and then select Regenerate Plan.

The Regenerate Plan dialog box appears, asking you to confirm that you want to regenerate the selected Production Plan.
Select Yes.

The Production Plan Builder window appears.
Proceed through the Production Plan Builder to define the details of the Production Plan.

The previous Production Plan is deleted, the new Production Plan is created, and the details are displayed on the PLA Overview page.

Delete a Production Plan

Procedure

Access the PLA Overview page.
Select the Production Plans tab.

The Production Plans section appears, displaying a list of Production Plans available in the database.
Select the row containing the Production Plan whose summary you want to delete.
In the upper-right corner of the workspace, select .

The Delete Plan dialog box appears, asking if you really want to delete the selected Production Plan.
Select Yes.

The selected Production Plan is deleted. The list of Production Plans is updated.