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Scheduling with Synchronized Start of Successor Operations
PLUSPLANNIG · Advanced Planning and Scheduling
Have you ever considered that when a batch production order is opened, successor operations sit idle until the first piece arrives? This is where the quietest loss in production scheduling occurs: the machines appear to be running, but the line is actually waiting in queue. Successor Operation Synchronization (SOS) is the scheduling capability of PLUSPLANNIG designed specifically to eliminate this very loss.
What is the Feature?
Successor Operation Synchronization (SOS) is a scheduling behavior that allows the consecutive operations within a work order to start at the same time. In classical sequential logic, operation B waits for operation A to finish the entire batch. When SOS is active, however, the moment A starts, operations B, C and the following ones also engage on their own machines; from the moment the first piece begins to flow down the line, all machines run simultaneously.
APS offers this feature to the user as a scheduling rule that can be enabled with a single parameter: you do not need to redefine the route, split the work order, or pass special instructions to the operator. The scheduler aligns the start times of operations simultaneously; the finish times are released according to the actual speed of each machine.
Benefits of the Feature
Simultaneous Start
Successor operations that would normally have to wait for one another to finish are started on different machines at the same hour and minute. The production flow stops being a chain and begins to behave like an orchestra.
Zero Waiting Time
The moment the first pieces begin to be processed, the subsequent machines also engage. Queues and waiting times between operations are eliminated; work-in-process accumulation along the line is minimized.
Parallel Line Flow
The production line operates as a single block. The total throughput time (lead time) is noticeably shortened; the planner can quote realistic due dates without having to add a safety buffer.
Higher Machine Utilization
Successor machines are no longer machines waiting their turn. Far more work orders flow through within the same shift; machine utilization rates naturally rise.
Due-Date Reliability
As lead time shortens, the deviation between planned and actual delivery dates decreases. Sales and planning become able to honour the promise given to the customer without adding a buffer.
Example Scenario
Let us consider a group of successor operations that need to be processed simultaneously on different machines. In the APS Jobs List screen below, two separate job groups are visible: the first is Job 1.1 – Job 1.5 (five successor operations sharing the same delivery date), and the second is Job 2.1 – Job 2.5. For all operations in both groups, the “Force Successor Operations (Jobs) to Start at the Same Time” column has been set to 1. This single cell is enough for APS: upon seeing this value, the scheduler no longer treats the related jobs as successor operations waiting for one another to finish, but rather as a group that must start synchronously.
The trigger is that simple. The user does not need to design an additional route, split the batch, or perform any manual intervention. The moment 1 is entered in the column, PLUSPLANNIG automatically rebuilds the schedule and ties these jobs to the same time anchor.
Once scheduling is complete, the result becomes instantly visible on the Gantt screen. In the Gantt output below, each job is listed on its own machine (P1001, P1002, P1003, P1004, P1005). Notice that the blocks for Job 1.1, Job 1.2, Job 1.3, Job 1.4 and Job 1.5 are all on the same vertical line, meaning they begin at the same hour. The same holds for the second group: Job 2.1 – Job 2.5 likewise start synchronously among themselves.
This view is the characteristic signature of SOS. The length of each block is different — because each machine has its own speed, capacity and workload — but their start points are aligned to a single point. The scheduler establishes this alignment automatically, taking into account machine availability, shift boundaries and possible conflicts with other work orders; all the user needs to do is enter the value “1” in the relevant column.
As a result, the time lost in inter-operation queues under sequential logic shortens horizontally on the Gantt; machine utilization percentages rise and total delivery time drops.
Conclusion
Successor Operation Synchronization (SOS) is the most direct way to shorten lead time without buying faster machines, opening new shifts or hiring additional operators. It does not add capacity to the production line — it makes the capacity that is already there visible.
If you have routes with successor operations and you are under due-date pressure, SOS is not a feature for you; it is a loss-prevention tool. With APS you can activate this tool by entering a value in a single cell, and bring the hidden capacity of your production to light today.
Birleşik Yazılım · PLUSPLANNIG | Smart Production Scheduling Solutions
