Manufacturing Module

Manufacturing is making products from components - either in house or getting external companies to do the work.  See the flow in Working in Manufacturing for an overview.

Manufacturing has a number of concepts

• Manufacturing Locations
  
  • A machine or work area that needs to be scheduled through Manufacturing Orders and Cleans
  • Has a normal start and end time to simplify manufacturing dashboard
  • Has default Employees who normally work in this location.
  • Has an overhead recovery rate - used for journal creation based on time in the room.
  • Used for internal and external (supplier) manufacturing locations
  • Locations have types that are used to allow alternative places for Manufacturing Orders to be produced (for example if you have multiple labelling machines)
    • Types have speed relationships - so a faster room will take less time for the same Manufacturing Order
• Cleans
  
  • Each location has multiple cleans depending on the sequence of products.  
    • For example Grey to White might require a full clean, but white to grey might require only a minor clean
• QA Tests
  
  • Questions that are answered before, during or after Manufacturing Orders to track QA test results
  • Questions that are answered as part of Cleans
• QA Test Groups
  
  • QA Tests are grouped into test groups to make it easier to add them to locations or Articles
    
    • Multiple QA Test Groups can be linked to each clean definition
    • Multiple QA Test Groups can be linked to an Article to be used by a Manufacturing Order
• Employees 
  • Employees can be enabled for Manufacturing Orders and QA Tests and use their initials to sign test results, raw material and finished goods checks.
• Manufactured Articles
  
  • Have a BOM of ingredients required
  • Links to the type of Manufacturing Location required
  • Links to the production QA Test Groups for production
  • Links to the supplier if externally manufactured
  • Can be purchased instead of being manufactured
• Manufacturing Order
  
  • An Manufacturing Order is the document that tracks production from plan to completed, has visibility to the journals produced, the QA tests and results and the audit trail.
  • Different views are available at the different stages (Proposed, Plan, Picking, Packing (If external), shipped (if external), Starting, producing, completing, receiving (if external), stocking, closed).  See Plan/Review Order and 
  • Different capabilities at different stages.
    • Scale the qty to be produced based on raw ingredients (to use full bags instead of partial bags for example)
    • Find alternative ingredients if some ingredients are low and alternatives exist.
  • Manufactured product cost is based on Raw Materials, quantity completed, returns, waste and time in the room and journals linked to the Manufacturing Order
• Linked Manufacturing Batches
  
  • Used to autocreate and syncronise linked manufacturing orders for JIT items that may be made in different Manufacturing Locations
    • For example to Produce Labels where the information for the labels are actually in the main Manufacturing Order and scaling the main Manufacturing Order during planning requires scaling the quantity of labels to be produced.
• Forecasting uses the normal forecasting process that understands manufactured items
  • Recommends Manufacturing Orders for manufactured items
    • Has visibility to purchase orders for manufactured items that can also be purchased as an alternative to production.
  • Recommends purchases for manufactured items and raw materials to n levels
  • Has visibility to raw materials in stock or still expected via purchase orders, and existing Manufacturing Orders
• /wiki/spaces/SI/pages/33054928
  
  • A review of manufactured stock based on expiry date and sell rate to recommend production orders as a simpler process to Forecasting.
• Manufacturing Dashboard
  
  • Viewed by Manufacturing Location to plan Journal Batches and Cleans sequence
  • Used by the planner to change sequences, choose Cleans required, review proposed orders, then set to plan once ready for production
  • Provides a view of history and direct access to Manufacturing Order information.
  • Manufacturing Orders float start time as the day proceeds and using the expected durations (note normal start/end times can be over-ridden)
• Production jobs are Picked for Manufacturing using a separate dashboard and process to reduce errors
• Where used Report
  • provides recall information including batches, sales orders, purchase orders and complete list of customers affected by a recall or other problem.
• Simple Manufacturing allows the system to auto-pick from stock at the start of the batch and auto-put-away to stock at the end of the batch (into default locations). A user can over-ride and adjust the values if required.