Definitions and setups

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Definitions and setups

Manufacturing Process - is the Template

Manufacturing Processes are a template

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

ExampleExamples

1. Manufacturing Process “Sofa” Linked to

   1. 2 Seater - has scaling factor of x1

   2. 3 seater - has a scaling factor of x 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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Modifying Build Steps for an individual item

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

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Creating Builds on the Production Plan Tab

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

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Then create the build

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Capacity Planning

Capacity from Rostered shifts

1. Time in Stations each day

2. Working forward from today

Required work from Build Steps

1. Hours required in Stations

2. Working backwards through build steps from ExWarehouse Date

Due dates for each order

Each order has an exWarehouse Date

Changing the exWarehouse date changes the required work dates for each of the build steps

The Capacity planner has two numbers for each workstation each day

1. The total number of hours of work required to be completed by that day

2. The total number of hours of capacity left after work completed

Workstations taking work

Stations have a pile of build steps to complete

1. Priority of the pile is based on the order ExWarehouse date

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

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

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

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

Starting and completing Build Steps

Selection of a build steps provides a place to print drawings and instructions then indicate are starting / pausing / finishing and update actual times

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Station setup

• Production rate factor can be used to indicate if more or less time than standard required (ie faster machine)

• Overhead rate is used to calculate overhead loading on all tasks and is added to the person at the work centre overhead rate

• The WIP bay is used if materials are issued from stock then fabricated items are returned at the end of the station

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Manufacturing station types setup

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Order Must Be Authorised

1. Deposit Received or not required

External components must be ordered - example material

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

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Trigger to create a Build

Order Must Be Authorised

1. Deposit Received or not required

External components must be ordered - example material

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

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

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Modifying Build Steps for an individual item

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

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Creating Builds on the Production Plan Tab

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

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Then create the build

1. The build once created shows in this dashboard

   1. the time already completed

   2. The qty

   3. The scaling factor

   4. The date production started

   5. if the build is in process

   6. and the Estimated Date of arrival (based on capacity)

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Capacity Planning

Capacity from Rostered shifts

1. Time in Stations each day

2. Working forward from today

Required work from Build Steps

1. Hours required in Stations

2. Working backwards through build steps from ExWarehouse Date

Due dates for each order

Each order has an exWarehouse Date

Changing the exWarehouse date changes the required work dates for each of the build steps

The Capacity planner has two numbers for each workstation each day

1. The total number of hours of work required to be completed by that day

2. The total number of hours of capacity left after work completed

Stations starting and completing build steps

Stations have a pile of build steps to complete

1. Priority of the pile is based on the order ExWarehouse date

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

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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

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

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

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

Starting and completing Build Steps

Selection of a build steps provides a place to print drawings and instructions then indicate are starting / pausing / finishing and update actual times

Production Process Overview

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