Definitions and setups

Manufacturing Process (Template)

Manufacturing Processes are the templates

• they are 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

• may attach to many manufactured items

Process Flexibility

Scaling factor

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

Example

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

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

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

Build Process

When the time comes to build an item - the build process is created

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

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

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

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

Processes steps may revisit workstations

Process steps and their sequence determine the flow through workcenters

Build process steps have a sequence.

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

1. Planning: Stations have hours of work they can complete by date (Rosters)

2. 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

Production Venue

Venues are your manufacturing centers

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

Stock Article Setups

1. Link to the build process

2. with an optional multiplier.

1. Tags - indicate if process steps are included or excluded.

2. Tags are individual letters - can have multiple Tags

Build Planning

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

1. Create build for this item creates the build steps

   1. Copy from the build process and apply multiplier and tags

2. Build steps can be individually modified to improve planning

   1. ie additional time may be required to do different seaming based on design etc.

It is common for

1. An order to have more than one item - it will have one build per item

   1. eg order with 2x 2 seater And 1x 3 seater = 3 builds (one per item being built)

2. Manufacturing of all the items on one order flow through together

Build Planner view

The build planner

1. Creates build steps once materials available and ready to plan

2. Modifies the build steps if required (example modifications to standard design)

3. Manages priority (order ExWarehouse date)

Modifying Build Steps for an individual item

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

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

1. 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)

Example Roster Pattern

Example Roster Pattern filtered for an individual

Preview of example roster pattern

Rosters

Rosters are work shifts

Rosters can be created manually or from a roster pattern

When creating a Roster from a Roster Pattern

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)

Results in

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

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

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

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

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

Driver will update Portal with drops and in situation photos