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When linked to individual SKU’s the Manufacturing Process Template can be scaled up or down from standard times.
Examples
Manufacturing Process “Sofa” Linked to
2 Seater - has scaling factor of x1
3 seater - has a scaling factor of x 1.75
Manufacturing Process “Cushion”
30x30 factor = 1
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
Manufacturing Process Step Mode (include) with a TAG (A)
SKUS with a TAG of (A) will include this step when the build is created
Manufacturing Process Step Mode (exclude) with a TAG (B)
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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a copy of the Manufacturing Process is made for each item to be built
Example order 2x 2 seater will result in 2 build processes (one each)
Build Processes are attached to the ordered item
Build Processes can be modified as required for each items unique design requirements
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Where the sequence is the same - steps may happen in parallel
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
Build Process: Seq - (Station): Step
Seq 1 - (Woodwork) Make Frame
Seq 2 - (Woodwork) Fit legs
Seq 2 - (Fabric Cutting and sewing) Make slip cover
Seq 3 - (Upholstery) Cover frame with foam
Seq 4 - (Fabric Cutting and Sewing) cut Fitted fabric
Seq 5 - (Upholstery) Fit Fitted Fabric
Manufacturing Stations
Stations are where people work and complete build steps
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Each center has multiple Areas
Each Area may have multiple workstations
Example:
Manufacturing Venue may is at Street Address XYZ
This is used on supplier purchase orders to indicate delivery address
This venue has the following Areas
Woodwork
Material Cutting
Upholstery
Fit Finish and QA
Stations are within areas
Example - the Woodwork Area may have 3 stations
Rosters are linked to venues and the created roster shifts are visible and can be modified from here
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Stations are mandatory for Production Rosters
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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Will skip existing shifts
Example
roster pattern has nobody on Monday - but a person is now hired for Monday > so the roster pattern is adjusted
Rosters were already created some time ago
Using the roster pattern to create rosters will only add the Monday shift (it skips where the shift already exists
Can skip weeks
Example
every second week we work the weekend
create a roster pattern for the weekend work only
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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edit
delete
clear to create new shifts
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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
Create build for this item creates the build steps
Copy from the build process and apply multiplier and tags
Build steps can be individually modified to improve planning
ie additional time may be required to do different seaming based on design etc.
It is common for
An order to have more than one item - it will have one build per item
eg order with 2x 2 seater And 1x 3 seater = 3 builds (one per item being built)
Manufacturing of all the items on one order flow through together
Creating and managing Builds
The build planner
Creates build steps once materials available and ready to plan
Modifies the build steps if required (example modifications to standard design)
Manages priority (order ExWarehouse date)
Build steps have expected time in a station.
Trigger to create a Build
Order Must Be Authorised
Deposit Received or not required
External components must be ordered - example material
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
Quantity will be the order line
Builds are one per item - so a qty = 2 will create 2 build jobs
Build Steps are created
Where a component has a TAG that tag will be respected to add or remove production steps
Example
Production Process step “sew cushion full cover” is only required when feathers are chosen
Feather choice has a tag of “F”
Production step has a tag of “F” and is set to “Include only with TAG”
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 from 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
The build once created shows in this dashboard
the time already completed
The qty
The scaling factor
The date production started
if the build is in process
and the Estimated Date of arrival (based on capacity)
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Capacity Planning
Capacity from Rostered shifts
Time in Stations each day
Working forward from today
Required work from Build Steps
Hours required in Stations
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
The total number of hours of work required to be completed by that day
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
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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Starting - Users select from the top of the waiting list and indicates their station and name
They can print detailed instructions, review drawings and update estimated time required
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
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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Available or OOS of stocked items
Items indicated as stocked will show OOS if not sufficient for this order after previous orders
Stocked items are purchased to stock normally and not to order (although they can be purchased for an order if required)
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Purchasing Not Stocked Items
The WIP dashboard lists all Authorised orders that have outstanding components to order externally
Components for Fabrications to be done in house (supplier to send to your fabrication centre)
Components for Fabrications that are to be done by others (supplier to send to your external fabricator)
Fabrications that are to be done by others
Note that external fabricators can use the supplier portal to view and accept all work as it comes in
Right click to send orders to suppliers.
Last email referencing the order to the supplier date is indicated and correspondence is attached to the order.
Each customer order will be ordered separately - including all items required from that supplier.
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Can update across any order the ETA of all items for that order
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Once the supplier has accepted and sent the deposit invoice - right click to create the deposit invoice
Once the product has arrived it can be removed from this dashboard
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Sourcing
Available or OOS of stocked items
Items indicated as stocked will show OOS if not sufficient for this order after previous orders
Stocked items are purchased to stock normally and not to order (although they can be purchased for an order if required)
...
Purchasing Not Stocked Items
The WIP dashboard lists all Authorised orders that have outstanding components to order externally
Components for Fabrications to be done in house (supplier to send to your fabrication centre)
Components for Fabrications that are to be done by others (supplier to send to your external fabricator)
Fabrications that are to be done by others
Note that external fabricators can use the supplier portal to view and accept all work as it comes in
Right click to send orders to suppliers.
Last email referencing the order to the supplier date is indicated and correspondence is attached to the order.
Each customer order will be ordered separately - including all items required from that supplier.
...
Can update across any order the ETA of all items for that order
...
Once the supplier has accepted and sent the deposit invoice - right click to create the deposit invoice
Once the product has arrived it can be removed from this dashboard
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Build Planner
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
Create build for this item creates the build steps
Copy from the build process and apply multiplier and tags
Build steps can be individually modified to improve planning
ie additional time may be required to do different seaming based on design etc.
It is common for
An order to have more than one item - it will have one build per item
eg order with 2x 2 seater And 1x 3 seater = 3 builds (one per item being built)
Manufacturing of all the items on one order flow through together
Creating and managing Builds
The build planner
Creates build steps once materials available and ready to plan
Modifies the build steps if required (example modifications to standard design)
Manages priority (order ExWarehouse date)
Build steps have expected time in a station.
Trigger to create a Build
Order Must Be Authorised
Deposit Received or not required
External components must be ordered - example material
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
Quantity will be the order line
Builds are one per item - so a qty = 2 will create 2 build jobs
Build Steps are created
Where a component has a TAG that tag will be respected to add or remove production steps
Example
Production Process step “sew cushion full cover” is only required when feathers are chosen
Feather choice has a tag of “F”
Production step has a tag of “F” and is set to “Include only with TAG”
So a 2 Seater sofa with a feather fill seat will have an additional step of sewing cushion covers
...
Modifying Build Steps for an individual item
Can modify all details name, sequence, station, materials and estimated time for individual build steps
...
Creating Builds from the Production Plan Tab
First confirm you have viewed the drawings are ok to manufacture (audit tracked)
...
Then create the build
The build once created shows in this dashboard
the time already completed
The qty
The scaling factor
The date production started
if the build is in process
and the Estimated Date of arrival (based on capacity)
...
Capacity Planning
Capacity from Rostered shifts
Time in Stations each day
Working forward from today
Required work from Build Steps
Hours required in Stations
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
The total number of hours of work required to be completed by that day
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
Priority of the pile is based on the order ExWarehouse date
People do NOT need to be rostered on to take build steps
...
Starting - Users select from the top of the waiting list and indicates their station and name
They can print detailed instructions, review drawings and update estimated time required
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
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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