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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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1. External supplied components are identified on the order line and an ETA is required before can create a Build

Creating a build

On the Sales Order > right click on the sofa to create the job

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

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Creating Builds

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from the Production Plan Tab

First confirm you have viewed the drawings are ok to manufacture (audit tracked)

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People do NOT need to be rostered on to take build steps

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Starting - Users select from the top of the waiting list and indicates their station and name

1. They can print detailed instructions, review drawings and update estimated time required

2. Start button moves the status of the build step to in process

Completion - User later selects from the in process list and indicates the actual time and finishes their step

• Common to attach QA photographs as last step

• The next process step for the job is now top of the list for the next station

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Starting and completing Build Steps

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• Completion of the last step completes the build process for that item and progresses the status of the item

• Last item to progress then progresses the order

  • to Awaiting Final Payment if not yet finally paid

Production Process Overview

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Once the product has arrived it can be removed from this dashboard

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• Once each line has a supplier reference and ETA then the Build can be created

Stocked components only need to be purchased in there is not enough Stock on hand and this is indicated if OOS.

Creating Build (one per Sofa Order Line)

Creating builds is best done by reviewing the order for any modifications required to the standard build job.

On the Sales Order > right click on the sofa to create the job

1. Quantity will be the order line

   1. Builds are one per item - so a qty = 2 will create 2 build jobs

2. Build Steps are created

   1. Where a component has a TAG that tag will be respected to add or remove production steps

      1. Example

         1. Production Process step “sew cushion full cover” is only required when feathers are chosen

            1. Feather choice has a tag of “F”

            2. Production step has a tag of “F” and is set to “Include only with TAG”

         2. So a 2 Seater sofa with a feather fill seat will have an additional step of sewing cushion covers

Production Planning

Jobs priority is based on

1. Fulfilling Customer ETA

2. Keeping work centres Busy

The production dashboard provides key information for production planning

1. Customer, Customer ETA, Warehouse required Departure

2. Externally supplied Components ETA’s

3. Overall time required

4. Time by work centre

Work Orders and production

The workorder screen allows a workcenter to start on the production tasks for a job

A list is provided in priority order > select one

• View of overall sofa, related drawings

• Select to start Task/s

• Select to finish Task/s

• Select to indicate materials used

• Select to indicate materials left (eg: Externally purchased Material Qty)

• Upload image (PHOTO step)

Last task (normally QA / Photograph / Wrapping) completed > completes the job

Customer is then asked for final payment before delivery is planned

Delivery Management

Delivery runs are planned for completed items

1. Add to a delivery run

2. View overall delivery plan

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