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

1. Create build for this item creates the build steps required (by reference of the default process for the item)

2. 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

1. 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)

2. Qty of 2 on a line will create two different build jobs

3. 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

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

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

Purchasing all required Components

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.

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

Manufacturing setups

Manufacturing Stations

Production work orders pass through manufacturing stations

• 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

Manufacturing Processes - configurable Job

Manufacturing processes involve

1. Production Centres

2. Production Steps

3. Expected times

4. A Product Category that components may come from

5. Tag (used to include or exclude based on component choices)

SKU BOM settings

Manufacturing Flag

When the SKU has manufacturing flag ON the product will default to manufacturing

Manufacturing Process link

Link to the manufacturing process from the manufacturing tab

SKU component TAG

The TAG is used to include or exclude manufacturing process steps in a Job