Dynamically Switching SKUs in Racks Based on Product Type Batches

[berkayguz]

Hi everyone,

I’m working on a sequential assembly process for my final year project and I could really use your help. I am still trying to learn the tool and your help would greatly contribute to that goal! I’ve attached my model file to this post. Here's my setup:

• I have a ProductContent table that defines which SKUs are required for each ProductType.

• The SKUList table shows the rack location (Address) of each SKU and the decision point (DP) that handles it.

• The OrderTable specifies how many units of each ProductType need to be produced.

• Two operators pick SKUs into boxes based on the ProductType of the box they receive.

• The SKUs are placed into racks from where operators pick them.

Now, here’s what I’m trying to achieve:

1. ProductType production is sequential: For example, we first produce all units of ProductType 1, then ProductType 2, and finally ProductType 3.

2. Only relevant SKUs should be in racks: While producing a specific ProductType, only the SKUs required by that ProductType should be present in the racks.

3. Changeover logic between ProductTypes:

   • After finishing one ProductType, a third operator should:

     • Remove the SKUs from the previous ProductType from the rack.

     • Place the SKUs required for the next ProductType into their designated rack addresses (as listed in SKUList).

Example:

• Start with ProductType 1 (20 units). Only SKUs 1–4 should be in the racks.

• After completing 20 boxes, a third operator removes SKUs 1–4 and places SKUs 5–8 (needed for ProductType 2) into the racks according to the addresses from SKUList.

• Then the system starts producing 15 units of ProductType 2, and so on.

I don't know if modeling this logic is possible and I’m unsure where to start with implementing this logic. Could you please help me on modeling this logic? 

Thanks in advance for your help!