Schedules Based on Algorithms and Detailed Rate Calculations
EmbTrak has two major production scheduling programs–one for embroidery and one for screen printing. Each program takes into account the same factors that an industrial engineer would use to develop the man-hour rate, run-time, and total time necessary to run an order on a specific machine. EmbTrak is like having a team of onsite industrial engineers to calculate standard times for each and every order.
This approach determines which machines are capable of running each order, selects the best machine for each order, calculates the best sequence of orders on each machine, and establishes a budget run-time and total time for each order. This plan serves as a production list, but it also creates a standard for each order, which becomes the basis for evaluating individual operator performance on each order.
Operators quickly learn that this approach adjusts time standards fairly, based on the factors that actually impact performance, which leads to improved operator morale and performance. And managers learn that they won't be blind-sided by changes in order volume, mix of goods, or decoration characteristics.
Shortcomings of Approaches Used in Other 'Scheduling' Software
Calendaring: With the exception of EmbTrak, every 'scheduling' tool we have seen in the various "decorated products software" designed for the Promotional Products industry simply presents a calendar which the user is asked to place orders upon. The runtime for each order? The person doing the 'scheduling' is asked to enter (that is, guess) the time it will take. The result will be a schedule that dramatically underestimates actual runtime. And if produced in paper form and presented to operators will be useless.
ERP System Schedulers: Many larger Promotional Products companies have purchased major ERP systems, such as Microsoft Dynamics 365 Business Central. This type of system is excellent for inventory, finance, human resources and other general business functions. They may even have ordering systems usable for ordering decorated products. However, because these system are sold to a wide variety of business they often include "scheduling calculators". The will use either the classic Runtime = Setup Time + (Quantity * Time per Piece), or something similar. They may also give the user the option to modify the formula. This approach is appropriate for calculation of simple products, such as stamped metal parts, injection molding, and even very simple processes such as Heat Press or Direct to Garment. It is very inappropriate for embroidery or screen print, and will calculate runtimes off by 20% to 50%. Why? Because there are about 40 factors to consider when scheduling embroidery and about 15 factors for screen printing. It considers none of these. Stitch count, trims, number of heads, doff times, number of thread changes for order, etc.--these factors must be considered.
Standard Units per Hour: Other production scheduling systems use standard units per hour for calculating machine schedules (e.g. “1,200 pieces per hour per machine”). The scheduling program divides the number of units to be produced by standard throughput rates to determine run-time. This is adequate for some discrete manufacturing production situations, but too simplistic to generate accurate embroidery or screen print schedules, much less calculate how long individual embroidery or screen print orders should take.
Rules of Thumb: Ballpark assumptions based on experience and anecdotes may yield an accurate overall schedule as long as the mix of goods and decorations do not vary. But when production circumstances fluctuate–for example, when average stitches per logo drops from 5,000 to 1,000–machine operating efficiencies change and the entire schedule is soon wildly inaccurate. Using the “rule of thumb” approach does nothing to set a realistic rate for an individual order.