Example

A sofa has been sold with a choice of fill, legs, material and other items - and now needs to be manufactured

The sofa is a top level order line (eg 3 seater sofa XYZ)

• Choices made are each sub order lines (eg lines for: material, legs, seat fill, back fill, etc)

Source all components required

Sourcing of any non stocked items (or stocked items that are out of stock) is the first step

1. Suppliers > Special > Manage Supplier WIP >

   1. lists all items that need to be purchased (every line on the order that is externally sourced)

      1. Send purchase orders

      2. Once supplier sends invoice > create in system invoice

      3. Track Deposit Payment made

      4. Track ETA and update when received (removes from this dashboard)

Create build steps when ready to plan production

Production is a process

2. When ready to start planning production

   1. Suppliers > Special > Manage Supplier WIP > Production Plan

      1. All top level items that are to be manufactured are listed

   2. Confirm the attached drawings are ok to be used

Definitions and setups

Manufacturing Process -

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the Template of steps

Manufacturing Processes are a template

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Template is copied to create a Build Process once an order item is ready to build

• a build process may then be modified to suit the unique item

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• has a number of steps through different Stations

• may attach to many manufactured items

Example simple manufacturing process

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Example DetailedManufacturing Process

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Process Flexibility

Scaling factor

When linked to individual SKU’s the Manufacturing Process Template can be scaled up or down from standard times.

Examples

1. Manufacturing Process “Sofa” Linked to

   1. 2 Seater - has scaling factor of x1

   2. 3 seater - has a scaling factor of x 1.75

2. Manufacturing Process “Cushion”

   1. 30x30 factor = 1

   2. 90x90 factor = 1.75

The result is less process are required to be defined

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Tags on a Manufacturing Step are Matched with TAGS on a SKU to modify the Build Process Created

Example

1. Manufacturing Process Step Mode (include) with a TAG (A)

   1. SKUS with a TAG of (A) will include this step when the build is created

2. Manufacturing Process Step Mode (exclude) with a TAG (B)

   1. SKUS with a TAG of (B) will exclude this step when the build is created

SKUS with a TAG of (AB) will include the TAG (a) step AND exclude the TAG (B ) Step when a build is created

The result is that less processes are required to be defined

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1. a copy of the Manufacturing Process is made for each item to be built

   1. Example order 2x 2 seater will result in 2 build processes (one each)

2. Build Processes are attached to the ordered item

3. Build Processes can be modified as required for each items unique design requirements

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1. Where the sequence is the same - steps may happen in parallel

2. Where the sequence number is greater - the step must wait for previous sequences to be completed

Example - multiple steps (Seq 2) may commence after the first step complete AND Uphosltery and Fabric cutting are revisited

1. Build Process: Seq - (Station): Step

   1. Seq 1 - (Woodwork) Make Frame

   2. Seq 2 - (Woodwork) Fit legs

   3. Seq 2 - (Fabric Cutting and sewing) Make slip cover

   4. Seq 3 - (Upholstery) Cover frame with foam

   5. Seq 4 - (Fabric Cutting and Sewing) cut Fitted fabric

   6. Seq 5 - (Upholstery) Fit Fitted Fabric

Manufacturing Stations

Stations are where people work and complete build steps

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1. Each center has multiple Areas

2. Each Area may have multiple workstations

Example:

1. Manufacturing Venue may is at Street Address XYZ

   1. This is used on supplier purchase orders to indicate delivery address

2. This venue has the following Areas

   1. Woodwork

   2. Material Cutting

   3. Upholstery

   4. Fit Finish and QA

3. Stations are within areas

   1. Example - the Woodwork Area may have 3 stations

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Example Roster Pattern

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Example Roster Pattern filtered for an individual

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Preview of example roster pattern

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Roster Shifts

Rosters are work shifts

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1. Will skip existing shifts

   1. Example

      1. roster pattern has nobody on Monday - but a person is now hired for Monday > so the roster pattern is adjusted

      2. Rosters were already created some time ago

      3. Using the roster pattern to create rosters will only add the Monday shift (it skips where the shift already exists

2. Can skip weeks

   1. Example

      1. every second week we work the weekend

      2. create a roster pattern for the weekend work only

      3. then when creating the roster by enter the # weeks to skip (every 1 week)

Example using a roster pattern to create 4 weeks of work (skipping 1 week between weeks)

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