Defintions
Processes
A fabrication process has a number of steps through different Stations
One process may attach to many manufactured items.
Process Flexibility
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
Stock Article Setups
The manufactured item is linked to a default build process with an optional multiplier.
Tags can indicate if process steps are included or excluded. Tags are individual letters and can have multiple.
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
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
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
Manufacturing station types setup
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
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
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.
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
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