Formulas and Effects

PACS uses formulas to calculate the duration of each order operation. All formulas are plant and machine specific and plants can include or exclude formulas for each machine as desired.

Customer service assigns a required dock time when entering an order. Using a configurable formula, PACS automatically calculates the time required for each order operation. Based on these calculated times, PACS works its way back from the required dock time to determine the start and end time for each operation. This information is fed back to a regular or electronic order entry system to aid in booking new orders.

Point System

PACS sorts and assigns a sequence number for orders behind each machine center on a point, cost and time basis. The point system uses an anchor order as the basis to start sort optimization.

Using a configurable sort algorithm for each machine center, PACS continuously sorts all orders and identifies which orders need to be corrugated.

Time Frames

PACS uses two machine specific time frame configurations:

• 1. The Machine Workload Distribution time frame controls workload balance for machine centers.
• 2. The Machine Workload Optimization time frame controls workflow sequencing through each work center.

Machine Balancing

Machine balancing is accomplished by using alternate machine information for each operation sent down from the corporate order system through an order interface. Alternate machines can be determined by the collection of historical run information.

Throughput Improvement

Throughput improvement is achieved and demonstrated with the workload optimization of PACS Point System algorithm. Order Operations are moved to a compatible machine center if an improvement to runtime can be achieved. If the system receives notification of a downtime insertion or a workload imbalance due to a machine stoppage, PACS Planning and Converting Scheduling (PACS) automatically re-distributes and reoptimizes order operations over all machine centers.

Order Operations - Sort & Balance

Late order operations are identified by PACS. Using the Point System, PACS will distribute late order operations to a compatible machine if the move will improve the orders actual end time. As a result of a change to an orders required end time, PACS will redistribute and balance all the machine centers affected.

Full Backward Scheduling

Corrugator Sort

To aid in maintaining a workload and an on-time balance, PACS optimizes the corrugator queue using a Corrugator Sort algorithm specifically configured for that individual corrugator. Plant’s can set a fixed sort point from where PACS will maintain control. Using a configurable plant specified sorting method, PACS will maintain the setup queue and update the ATS Setup Manager accordingly.

SOLUTIONS UP/DOWNLOAD INTO PLANNING BOARD

Using the Planning Board, workload limits can be configured to specify the desired amount of hours of work in process and schedule orders for each individual machine. PACS identifies any “not scheduled” orders required for trimming and updates the list to the Solutions Scheduling Engine. When the Solutions Schedule is complete, PACS will automatically load the orders into Planning Board.

Capacity Charts

Capacity Charts provide graphic and numeric real-time information of the Plant’s backlog state. Information detailing hours booked, crewed, down, available for booking and more can be displayed. The Capacity Chart also provides a function for Sales to obtain order delivery dates.

Multiplant Scheduling

Planning Board will display multiple plant views from any plant on the corporate WAN in real-time. PACS balances the workload of “not scheduled” orders between plants for orders having alternate plant routing ID’s. Only orders having compatible machines at the alternate Plant will be moved. Once orders are transferred, PACS distributes and sequences the workload among the machine centers at each plant. PACS will only transfer orders that have a required datetime greater than a pre-set required datetime. (ie. move and balance orders 3 days out and greater).

Converting Management Solutions