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Defintions
Processes
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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
Suppliers > Special > Manage Supplier WIP >
lists all items that need to be purchased (every line on the order that is externally sourced)
Send purchase orders
Once supplier sends invoice > create in system invoice
Track Deposit Payment made
Track ETA and update when received (removes from this dashboard)
Create build steps when ready to plan production
Production is a process
When ready to start planning production
Suppliers > Special > Manage Supplier WIP > Production Plan
All top level items that are to be manufactured are listed
Confirm the attached drawings are ok to be used
Definitions and setups
Manufacturing Process - the Template of steps
Manufacturing Processes 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
A Manufacturing process
has a number of steps through different Stations
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may attach to many manufactured items
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Example simple manufacturing process
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Example DetailedManufacturing Process
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Process Flexibility
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Manufactured items can have a scaling factor - eg Process “Sofa” may have a multiplier of x1 for a 2 seater, but x2.7 for a 3 seater. In this way a single process definition becomes more flexible in use.
A Process Step may have a TAG and only be included/excluded if the Manufactured item has the same TAG
Process Steps
Processes have a number of steps through different work centres.
Sequence indicates timing and if can be done in parallel
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Stock Article Setups
The manufactured item is linked to a default build process with an optional multiplier.
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Tags can indicate if process steps are included or excluded. Tags are individual letters and can have multiple.
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Builds
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 build for this item creates the build steps required (by reference of the default process for the item)
Build steps can be individually modified to improve planning - ie additional time may be required to do different seaming etc. So individual steps may be modified.
It is common for
An order to have more than one item (eg 2 seater and 3 seater) and hence will have more than one Build (one per item)
Qty of 2 on a line will create two different build jobs
Manufacturing of all the items on one order tend to flow through at the same time
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Stations
Stations have a pile of build steps to complete
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
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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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 manufacturing job
From the Order create the required Jobs.
Production Process Overview
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Scaling factor
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
TAGS
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
Build Process - the actual work for an item
When the time comes to build an item - the build process is created
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
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
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
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
Note : If you want to assume infinite capacity you do not need to use time estimates or rosters. The sequence numbers combined with Order ExWarehouse date will prioritise the work for you.
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Processes steps may revisit workstations
Process steps and their sequence determine the flow through workcenters
Build process steps have a sequence.
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
Planning: Stations have hours of work they can complete by date (Rosters)
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
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Production Venue
Venues are your manufacturing centers
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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Edit > make this my default venue defaults a venue to be opened when the screen is opened |
Stock Article Setups
Link to the build process
with an optional multiplier.
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Tags - indicate if process steps are included or excluded.
Tags are individual letters - can have multiple Tags
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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
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)
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
Rosters can be created manually or from a roster pattern
When creating a Roster from a Roster Pattern
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)
Results in
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View and edit the Roster shifts once created from the venue
From a view of the Roster can:
edit
delete
clear to create new shifts
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Sourcing
Stocked items - Available or Out of Stock
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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Not Stocked Items Purchasing
The WIP dashboard lists all Authorised orders that have outstanding components to order externally
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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
Internal Manufactured items
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.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 lineThe production process linked to the top level item will create Production steps
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
Production Planning
Jobs priority is based on
Fulfilling Customer ETA
Keeping work centres Busy
The production dashboard provides key information for production planning
Customer, Customer ETA, Warehouse required Departure
Externally supplied Components ETA’s
Overall time required
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
Add to a delivery run
View overall delivery plan
Driver will update Portal with drops and in situation photos
Manufacturing setups
Manufacturing Stations
Production work orders pass through manufacturing stations
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Special types can trigger other system processes > like label printing etc
Production rate factors are used if some are faster than others for the same production process
Location is used if raw materials are issued to a job at the start of the job to hold the material in WIP until completion
Manufacturing station Types setup
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Manufacturing Processes - configurable Job
Manufacturing processes involve
Production Centres
Production Steps
Expected times
A Product Category that components may come from
Tag (used to include or exclude based on component choices)
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SKU BOM settings
Manufacturing Flag
When the SKU has manufacturing flag ON the product will default to manufacturing
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Manufacturing Process link
Link to the manufacturing process from the manufacturing tab
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SKU component TAG
The TAG is used to include or exclude manufacturing process steps in a Job
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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
Each order has an exWarehouse Date
All the work in all workstations for an order must be completed by the end of the exWarehouse Date
Hence total time by workstation type to be completed
Capacity ( Rostered shifts )
Roster has person + Station + start / end / breaks
Hence hours by Station Type per day
Required work ( Build Steps )
Hours required by Station Type
Plan shows
On promise date
effort required before that date
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
Question - am I staffed correctly for the orders I need to complete ?
Key questions to answer
What do I have to get done - effort required for my promised order dates
Have I staffed correctly across all workcentres
Do I need to delay some orders (change ex-warehouse date) - or add shifts
Which orders can I bring forward (change ex-warehouse date)
Can I fit more orders in before a date - do I have capacity ?
Framing example - lots of time to get ahead
Could drop 2 shifts here
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Fabric Cutting does not have enough Shifts to keep up
need to add more shifts to meet deadlines
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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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