We have one work center for finish product(PB05 u2013 Filling m/c for 2Litre fresh products ). This is a filling machine and we can Fill two finish products on it one is Fresh Milk and the other is Fresh Laban.
If we use PB05 for filling Milk, we can run this machine for maximum run length of 24 Hrs and if used for filling Laban, the maximum run length is 36Hrs. In both cases, it is mandatory to stop the machine after Maximum run length and do the cleaning of that machine, it is called as CIP- cleaning In Process. And the time of CIP is four hours. We have some issues to map this CIP process in routings.
What we are looking for>> 1) If m/c is used for Laban, it should be stopped for CIP, after every 36Hrs running. 2) If m/c is used for Milk, it should be stopped for CIP after each 24Hrs running. 3) If m/c is used for Milk Filling after Laban, it should be stopped for CIP irrespective of run length of Laban.(product change over). 4) If m/c is used for Laban filling after Milk, it should be stopped for CIP after 30Hrs.
What we have tried and achieved >>
1) Mapping CIP time of 4hrs as a teardown time in routing for both products Laban and Milk and maintaining maximum lot size in respective material master: MRP will generate planned orders in multiple of maximum lot size and teardown time will be considered. But when the planned order will be less than maximum lot size, system will consider teardown time of 4hrs with that. This is not required, as we will receive sales order for next day for same material and we will continue production of same material on same m/c.
2) In continuation to above, we can configure tear down formula in different ways so that, a) it can consider teardown of 4Hrs irrespective of planned order qty. b) we can ignore tear down time if the planned order quantity is less than base qty(max lot size). C) teardown time can be considered in proportion of planned order qty. With all these options, it will not meet the CIP requirement if the planned order is for less than max lot size and followed by a next planned order with max lot size where in we need CIP in between of next order.
3) Also Cleaning In Process u2013 CIP requires a cleaning machine. And this machine should be available at the time of CIP. If not available we should be able to postpone the CIP time
We are using repetitive manufacturing Production Planning set up.
Please suggest the way to configure this and please get back to me if you need further details.
Thanks
Suresh