Splitting Manufacturing Orders and Operations

Key Concepts

Manufacturing Orders and Operations occasionally need to be split into multiple Manufacturing Orders or Operations with smaller quantities. For example, manufacturing orders may need to be split when a partial shipment is to be made to a customer when there isn't enough capacity to finish the full order in time. In addition, operations may need to be split among multiple eligible resources so that the order is completed in one shift or one day. Splits can also be useful when there are different production resources that are used to produce parts of the full order. Operations are often split to complete them faster as split activities can be scheduled in parallel, in sequence, on the same resource, or on multiple resources, resulting in a shorter lead-time for the operation. 

Splitting can be done from the Gantt by right-clicking an activity block, selecting "Splitting, and then selecting which level of the operation should be split.

Splitting a Manufacturing Order

When "Manufacturing Order" is selected from the Splitting menu, the following dialog will appear:

                                 

This dialog displays the Manufacturing Order's current number of cycles scheduled to be completed. The "Split Cycles" text box allows users to input the amount for the first split. The remaining cycles will be calculated. Splitting a Manufacturing Order has the following outcomes:

  1. A new manufacturing order is created within the same job with a name automatically generated from the original manufacturing order's name.
  2. The operations are copied into the new manufacturing order with updated quantities based on the quantity specified in the "Split Cycles" text box.
  3. If an operation in the original manufacturing order is finished, then the corresponding operation in the new manufacturing order will also be finished. 
  4. In the Jobs dialog, the manufacturing order will have two rows to indicate that it was split. Each will have an updated required quantity. In addition, the original manufacturing order will have two new fields: 
    1. Split Count: indicates the number of manufacturing orders split from the manufacturing order.
    2. Deep Split Count: indicates the number of manufacturing orders from the manufacturing order or its splits. 
  5. Manufacturing orders that are generated by splitting have their "Split" field set to true in the job dialog to indicate that they are splits.

Note: During imports, if a manufacturing order has already been split but the split MO's are not included in the import, they are still preserved to protect the changes made internally in PlanetTogether without requiring the split MO's to be imported. If the quantity or routing of the imported manufacturing order is different from the original,  the manufacturing order will be updated to the new quantity and routing and any unfinished MO's will be removed. 

Splitting an Operation

To split an operation among multiple resources, right-click on an activity block on the Gantt, select "Splitting", and then select "Operation". This will open the "Operation Splitting" dialog:

This dialog is used to split an operation into multiple activities or to un-split an operation, consolidating split activities into one. When an operation is split, the Remaining Finish Quantity are divided among the activities that make up the split operation. The way these quantities are divided is determined by the options selected in the operation splitting dialog.

  • Split off a % of the remaining finish qty: The specified percentage of the remaining quantity of all activities of the operation is split off to create a total of 2 activities: one with the specified percentage and the other with the remainder. 1 to 99% of the operation can be split off. 
  • Split into this number of activities: The operation is split into the specified total number of activities, each receiving an equal portion of the required quantity. Specifying the number of "1" will un-split the activity. The maximum number of splits is 500 to prevent accidentally large numbers from disrupting the schedule. Note: if the option "Split into whole number quantities" is checked, then the maximum split count is limited to the current required quantity of the operation.
  • Split so that all activities are less than: The operation is split using the maximum duration to determine how many activities to split across. The maximum number of cycles that can be performed within the specified duration is calculated. Note: the resulting activities may be longer than the specified maximum duration when considering the setup and post-processing time, as only the standard run span will be less than the duration specified. In addition, resources may have values set for the cycle efficiency multipliers, which increase the standard run span so that the scheduled run span would exceed the maximum duration specified.
  • Split among the eligible resources: The operation is split into the specified total number of eligible resources, with each activity receiving an even portion of the required quantity. The number of activities is limited by the number of eligible resources that can perform the operation.
  • Split into whole number quantities: If checked, quantities that are split off to create new activities are always integer (non-decimal) values. For example, if the remaining quantity was 10.5 and you wanted to split the operation into 2 activities, this would result in the split-off activity having a required finish quantity of 5 while the original activity would have a remaining quantity of 5.5. If this option was unchecked, then the same split would result in both activities having quantities of 25.25. 
  • Buttons
    • Split: Performs the split as specified by the current dialog settings. Note: If an operation is already split, it will be un-split first and then split again.
    • Un-Split: Deletes all but the original activity, moving all required finish quantities and reported values to the remaining activity.