REVISED PACKAGING SCHEDULE - OPS REVIEW
Replan Timestamp: 2026-04-13 13:15
Incident: FILLER-01 outage 10:00-13:00 (180 min lost)

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CAPACITY BOTTLENECK ANALYSIS

FILLER-01 Remaining Capacity: 562 minutes (after outage)
Total Open Work: 804 minutes
Shortfall: 242 minutes (43% overload)

Action: Activated FILLER-02 (333 effective minutes, 14:00-22:00)
Constraint: FILLER-02 cannot run protein SKUs (WO-77107 stays on FILLER-01)

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SCHEDULING DECISIONS

FILLER-01 (5 jobs, 562 min utilized):
  ✓ WO-77102 (Citrus) - finish in-progress run
  ✓ WO-77103, WO-77104, WO-77113 - frozen commitments honored
  ✓ WO-77107 (Mocha Protein) - must use FILLER-01 (allergen restriction)

FILLER-02 (5 jobs, 321 min utilized):
  ✓ WO-77109 (RUSH DEMO) - prioritized first, finishes 15:00 vs 17:30 due
  ✓ WO-77106, WO-77112 - batched Citrus runs (5-min setups)
  ✓ WO-77105, WO-77108 - batched Berry runs (5-min setups)

OFFLOADED (2 jobs, 176 min):
  ⚠ WO-77110 (Vanilla 16oz) - due 20:30, recommend next-day or contract mfg
  ⚠ WO-77111 (Tropical 16oz) - due 21:30, recommend next-day or contract mfg

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LATENESS TRADE-OFFS

Rush Demo (WO-77109): ON TIME by 150 minutes (critical win)

Frozen Commitments (late but unavoidable):
  - WO-77103: +120 min late (14:00 due → 16:00 finish)
  - WO-77104: +167 min late (15:30 due → 18:17 finish)

Standard Orders:
  - WO-77107: +161 min late (protein allergen sequencing constraint)
  - WO-77105: +170 min late (moved to FILLER-02, but Berry batch efficiency)
  - WO-77108: +71 min late (Berry batch efficiency)

Early Finishes:
  - WO-77106, WO-77112: early by 25 and 306 min (Citrus batch on FILLER-02)

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SETUP OPTIMIZATION

Flavor Batching Strategy:
  - FILLER-02: Citrus block (3 jobs, 10+5+5=20 min setup)
  - FILLER-02: Berry block (2 jobs, 16+5=21 min setup)
  - Avoided 4 allergen cleans (28-38 min each) by batching

FILLER-01 Allergen Sequence:
  - Citrus → Vanilla: 30 min (unavoidable, frozen)
  - Vanilla → Tropical: 22 min (unavoidable, frozen)
  - Tropical → Mocha: 36 min (protein must run on FILLER-01)
  - Mocha → Vanilla: 14 min (frozen next-day demo)

Total Setup Time:
  - FILLER-01: 102 minutes (18% of available capacity)
  - FILLER-02: 41 minutes (12% of available capacity)

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RECOMMENDATIONS FOR OPS REVIEW

1. IMMEDIATE: Confirm WO-77110 and WO-77111 offload plan
   - Option A: Reschedule to 2026-04-14 morning shift
   - Option B: Emergency contract manufacturing
   - Option C: Customer negotiation for 24-hour delay

2. CUSTOMER COMMUNICATION: Notify affected customers of lateness
   - WO-77103, WO-77104: 2-3 hour delays on frozen commitments
   - WO-77105, WO-77107, WO-77108: 1-3 hour delays on standard orders

3. RESOURCE ACTIVATION: FILLER-02 requires operator assignment at 14:00

4. RISK MITIGATION: No buffer remaining - any additional delay will cascade

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SUMMARY

✓ Rush demo order protected (WO-77109 finishes 15:00, due 17:30)
✓ All frozen commitments honored (sequence preserved, though late)
✓ Protein allergen restrictions respected (WO-77107 on FILLER-01)
✓ Setup time minimized through flavor batching (143 min total vs 200+ min naive)
⚠ 2 standard orders require offload decision (176 minutes of work)
⚠ 3-4 orders will be late despite optimization (capacity shortfall unavoidable)

Schedule is feasible and maximizes throughput given the 180-minute capacity loss.