Wright Williams & Kelly

Factory Explorer® v2.4
Technical Alert #19

Capacity Analysis for Adjustable
Transform & Assembly Percentages


Summary: When performing capacity analysis for products with adjustable transform/assembly percentages, if the original model specifies a transform or assembly percentage of zero, the capacity analysis engine will be unable to properly adjust the percentages to meet end-product demand. To avoid this problem, specify non-zero transform and assembly percentages for products that have adjustable transform/assembly percentages (these percentages will be recalculated anyway by the capacity analysis in order to meet demand). Also, specifying a throughput rate of zero for an end-product downstream from a product with adjustable transform/assembly percentages can cause the capacity analysis engine to halt with an internal error. To avoid this problem, specify small but non-zero throughput rates for end-products downstream from products with adjustable transform/assembly percentages. These problems are fixed in Factory Explorer® v2.5 beta 2.

Details: When performing capacity analysis for models with adjustable transform/assembly percentages, Factory Explorer® first does a regular capacity analysis on the model. It then back-calculates based on demand (required throughput rates) to calculate the appropriate transform/assembly percentages necessary to match demand. Then it repeats the capacity analysis calculations with the adjusted transform/assembly percentages. There were two problems in these process. First, if the original model specified a transform or assembly percentage of zero, the back-calculation would be unable to correctly calculate the proper transform/assembly percentage necessary to match demand, since there would be no flow at all down that particular product path in the initial capacity calculations. Second, if an end-product downstream from a product with adjustable transform/assembly percentages specified a demand of zero, a similar problem would occur, because this zero demand would back-propagate to the point where the adjustable percentages occurred, at which time a zero over zero term entered the calculation, causing the capacity analysis to halt with an internal error.

Workaround: To avoid the first problem, specify non-zero transform and assembly percentages for products that have adjustable transform/assembly percentages (these percentages will be recalculated anyway by the capacity analysis in order to meet demand). To avoid the second, specify small but non-zero throughput rates for end-products downstream from products with adjustable transform/assembly percentages.

Techalert tafx19-9808


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