Definitions and setups

Manufacturing Process (Template)

Manufacturing Processes are the templates

• they are 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

A Manufacturing process

• has a number of steps through different Stations

• may attach to many manufactured items

Process Flexibility

Scaling factor

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

Example

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

The result is less process are required to be defined

TAGS

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

Build Process

When the time comes to build an item - the build process is created

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

The build process is used to plan and capture actuals by ordered item

Manufacturing Process (Template) Steps

Processes Steps link to Stations

One step is done by one station

Process Steps have a materials category

Making it easier to find and consume materials from the warehouse

Process steps have a sequence

Used to manage the overall process flow

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

Process Steps have a time estimate

Used for capacity planning - more than one person can work at a station on any date increasing the capacity of that station

...

Processes steps may revisit workstations

Process steps and their sequence determine the flow through workcenters

Build process steps have a sequence.

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

Stations

Stations are where people work and complete build steps

1. Planning: Stations have hours of work they can complete by date (Rosters)

2. Multiple persons may have hours in the same station and same date increasing the capacity of that station

Build steps are linked to the station type they require

Production Venue

Venues are your manufacturing centers

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

Stock Article Setups

1. Link to the build process

2. with an optional multiplier.

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1. Tags - indicate if process steps are included or excluded.

2. Tags are individual letters - can have multiple Tags

...

Build Planning

A build is the process steps for an individual ordered item

Builds are created manually once the sourcing planner is confident the materials are or will be available in time

Create from the Sales Order

1. Create build for this item creates the build steps

   1. Copy from the build process and apply multiplier and tags

2. Build steps can be individually modified to improve planning

   1. ie additional time may be required to do different seaming based on design etc.

It is common for

1. An order to have more than one item - it will have one build per item

   1. eg order with 2x 2 seater And 1x 3 seater = 3 builds (one per item being built)

2. Manufacturing of all the items on one order flow through together

Build Planner view

The build planner

1. Creates build steps once materials available

2. Modifies the build steps if required (example modifications to standard design)

3. Manages priority (order ExWarehouse date)

...

Modifying Build Steps for an individual item

Can modify all details name, sequence, station, materials and estimated time for individual build steps

...

Staff Rosters

Capacity across workcenters requires rosters

...

Definitions and setups

Manufacturing Process (Template)

Manufacturing Processes are the templates

• they are 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

A Manufacturing process

• has a number of steps through different Stations

• may attach to many manufactured items

Process Flexibility

Scaling factor

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

Example

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

The result is less process are required to be defined

TAGS

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

Build Process

When the time comes to build an item - the build process is created

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

The build process is used to plan and capture actuals by ordered item

Manufacturing Process (Template) Steps

Processes Steps link to Stations

One step is done by one station

Process Steps have a materials category

Making it easier to find and consume materials from the warehouse

Process steps have a sequence

Used to manage the overall process flow

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

Process Steps have a time estimate

Used for capacity planning - more than one person can work at a station on any date increasing the capacity of that station

...

Processes steps may revisit workstations

Process steps and their sequence determine the flow through workcenters

Build process steps have a sequence.

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

1. Planning: Stations have hours of work they can complete by date (Rosters)

2. Multiple persons may have hours in the same station and same date increasing the capacity of that station

Build steps are linked to the station type they require

Production rate factors allow for high performant machines vs low performant machines.

Overhead rate is used to estimate production costs based on time in the workcentre

...

Production Venue

Venues are your manufacturing centers

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

...

Stock Article Setups

1. Link to the build process

2. with an optional multiplier.

...

1. Tags - indicate if process steps are included or excluded.

2. Tags are individual letters - can have multiple Tags

...

Build Planning

A build is the process steps for an individual ordered item

Builds are created manually once the sourcing planner is confident the materials are or will be available in time

Create from the Sales Order

1. Create build for this item creates the build steps

   1. Copy from the build process and apply multiplier and tags

2. Build steps can be individually modified to improve planning

   1. ie additional time may be required to do different seaming based on design etc.

It is common for

1. An order to have more than one item - it will have one build per item

   1. eg order with 2x 2 seater And 1x 3 seater = 3 builds (one per item being built)

2. Manufacturing of all the items on one order flow through together

Build Planner view

The build planner

1. Creates build steps once materials available and ready to plan

2. Modifies the build steps if required (example modifications to standard design)

3. Manages priority (order ExWarehouse date)

...

Modifying Build Steps for an individual item

Can modify all details name, sequence, station, materials and estimated time for individual build steps

...

Staff Rosters

Capacity across workcenters requires rosters

Rosters are easily created from a pattern for n weeks in advance - and can be adjusted anytime (shifts added / people changed)

Roster Patterns

Roster patterns are used to create shifts (and hence capacity) - think of them as a template

1. They have links to Rooms, Persons and Stations and hours and breaks

Small manufacturing centres may have a single roster patter for the week

Larger organisations may have patterns for each area (eg paint booth) or skill (eg Electrician)

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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Rosters

Rosters are work shifts

Rosters can be created manually or from a roster pattern

When creating a Roster from a Roster Pattern

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)

Results in

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Workstations taking work

Stations have a pile of build steps to complete

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