Wright Williams & Kelly
Factory Explorer® v2.3
Summary: Factory Explorer® will not calculate correct release and throughput rates for models where multiple sub-transform products are transformed into a single product, and downstream from this product a unit throughput rate is specified. Since it is not clear what the correct release and throughput rates are in this case, the next release of Factory Explorer® will contain a validation routine that generates an error if this situation is detected. To avoid this problem, contact technical support for detailed information on alternative methods of modeling this type of product flow.
Details: When a Factory Explorer® model specifies a throughput rate for an end-product, Factory Explorer® 's capacity analysis engine uses this information to calculate the throughput and release rates for all up-stream products (i.e. products that are transformed or assembled into this end-product). For example, if product A is transformed into product B, and a throughput rate is specified for product B, Factory Explorer® uses this information to calculate the required throughput rate and release rate for product A. The difficulty arises when multiple products are transformed into a single product, and downstream a unit throughput rate is specified. For example, suppose products A1 and A2 are both transformed into product B, and that product B specifies a unit throughput rate. Factory Explorer® knows that either A1 or A2 can be used to produce product B, but it has no a priori way of deciding how to set the throughput rates of A1 and A2. In version 2.3 of Factory Explorer® , this situation is not detected, and the end result is that Factory Explorer® sets the throughput rates of both A1 and A2 to be enough to support the required throughput for B, leading to an overproduction of product B. Since it is generally not possible to know how much of B's throughput the analyst intended to supply with A1 vs A2, the next release of Factory Explorer® will contain a validation routine that generates an error if this situation is detected. Note that it is possible to model the transformation of multiple products into a single product, as long as downstream products do not specify unit throughput rates.
Workaround: If you have multiple products that are transformed into a single product, and you wish to specify a unit throughput rate downstream from this product, please contact technical support for detailed suggestions on alternative modeling techniques.