This section describes procedure for Production management, version 2.1.
Production schedule defines stage performance deadlines, and it is a basis for organizing works in departments. Operational decision-making in the department is delegated to a local dispatcher. The local dispatcher creates a work timetable within planning intervals based on the current production situation.
The local dispatcher has the following responsibilities:
- Control of how stages are supplied with resources.
- Creation of timetable for works to be performed and for work center load.
- Selection of local production batches for processing (route sheet generation).
- Monitoring of production process progress in the department.
- Replanning of a route sheet completion timetable.
- Timely notification of the chief dispatcher about critical variances from the production schedule.
A route sheet is the main management object for the local dispatcher.
Route sheet generation
Generate the Route sheet documents for stages for the selected planning interval (day or week). Initially, one route sheet is generated for each stage.
When generating route sheets, the local dispatcher can specify parameters of their completion:
- Split the generated route sheet in several route sheets by selecting certain production batches.
- Select the operations sheet for completion in the route sheet and refill route sheet components according to it.
- Specify demand for resources manually.
- Specify assignees for work kinds (teams). Teams are generated from individuals.
The specified actions form local standard indicators of stage completion.
After specifying data for route sheets, you can generate a timetable for work centers. You do not have to generate a timetable for all route sheets. The availability of a timetable does not affect the capability of recording stage completion results. You can specify an individual planning model for each department. Available models are described in sections below.
The For completion status selected for a route sheet shows that resource supply procedures and preparatory works have been started. The Active status (only for the DBR/SDBR model) shows that the route sheet is being completed.
Route sheet management for all planning options is based on the declarative principle. After defining a completion procedure for the route sheet and putting it into operation, it is considered to be completed at scheduled time. The local dispatcher records only variances from the timetable. Thus, the data, which you need to specify in the application, is minimized. The local dispatcher is free to choose time of entering data on route sheet completion, but it needs to be done before the next stage is started.
It makes replanning easier. If the route sheet is generated and accepted for completion, its stage is not to be replanned. If the route sheet is generated but not accepted for completion (the For completion status or the following statuses are not selected), replanning is done automatically.
In route sheets, on the Additional information tab, you can see the following information:
- Operations sheet selected for route sheet completion (this attribute is optional).
- The local dispatcher who generated the route sheet.
- Production order within which the stage registered by this route sheet is being completed.
- Manufactured products – result of production process which includes redistribution containing the stage registered for completion by this route sheet.
- BOM for manufactured products which describes production process including redistribution with the stage registered for completion by this route sheet.
- Semi-finished product as a result of redistribution including the stage registered for completion by this route sheet.
- BOM for semi-finished product as a result of redistribution including the stage registered for completion by this route sheet.
Receiving and writing off materials
As overall supply of material resources is fulfilled against production orders, the following happens:
- When passing route sheets for completion, materials are considered to be always received from department inventory.
- Route sheets do not reserve materials in a warehouse.
- Availability of materials is not controlled in a department (and in a warehouse).
In the Manufacturing – Shop management – Dispatching (DBR) workplace, in the column, you can see material shortage in the department for completion of each route sheet. The following supply states are shown:
- Indicator is not displayed – there is enough materials for all route sheets created and passed for completion.
- Yellow icon – there is enough materials for the current route sheet but it might be insufficient for other route sheets.
- Red icon – there is not enough materials for the current route sheet.
If there is a shortage, you can register a reference for material receipt based on a certain route sheet. In the form of the Route sheet document, click Create on the basis – Ship materials from warehouse to open the Adjustment of order for materials for production form. Within this form, you can select further actions to transfer materials from the warehouse to the department.
You can see information on shortage in material supply of route sheets in the Route sheet documents, on the Materials and works tab, in the Balance field. Colors of icons and supply states they indicate are the same as described above.
It is difficult to transfer some materials from a warehouse to production within the existing demand. These are various kinds of sheet, roll-fed, pumped, and other materials. They can be transferred from the warehouse to departments in volumes exceeding the current department demand. Quantity received beyond demand is left in unfinished production and can be used for completion of the following stages to be supplied in the future.
To ensure that departments are supplied with materials, use predefined scenarios within the Manufacturing – Materials accounting – Receipt and return of materials workplace.
On the Receipt and return of materials tab, you can see the following data which reflects the current state of material resources in unfinished production:
- Remaining quantity in department – remaining quantity of material resources involved in unfinished production in the selected department. The positive value indicates the volume of received but not written-off materials. The negative value means that a material was written-off to releases (specified in the Route sheet documents with the Completed status and in the Write off release costs and Allocation of materials and works to product cost documents), but receipt of required quantity from the warehouse was not registered.
- Ship from warehouse – volume for which the Order for materials for production documents with the To supply status were created.
- Current surplus (shortage) – calculated control value which shows material quantity available for use at the current moment. The positive value (surplus) shows that the department has available resources, which can be used in following production processes. The negative value (shortage) shows the need to receive the material from the warehouse. The parameter value is calculated as a sum of the Remaining quantity in department and Receive from warehouse values minus the route sheet demand.
- Planned to receive – quantity of material previously reserved for production orders.
- Planned surplus (shortage) – calculated control value which shows a forecast of material surplus or shortage in the department based on the current stock balance, demands of production orders not accepted for production yet, and planned activities to receive the material from the warehouse (for example, the Order for materials for production documents in the To supply status).
To manage the current situation, on the Receipt and return of materials tab, click Surplus (shortage) adjustment.
Select one of the following options to adjust material surplus or shortage in the department:
- Create an invoice for negative balance of the department – it is supposed that materials were actually transferred to the department (otherwise, it makes no sense to specify them in release documents, which caused the negative balance), but it was not recorded in the infobase on time. In this case, you need to register the Material transfer in production document in the Shipped status, which will cover the negative balance.
- Create return to the current surplus – creation of the Return from production document to fully or partially return the positive material balance specified in the Remaining quantity in department column from the department to the warehouse.
- Adjust order for materials – adjustment of demand for materials specified previously. Adjustment is made in the Adjust order for materials form in which you can see how many materials and against which production order (production orders are used as references) are to be received from the warehouse. Use the form to manually adjust material receipt from the warehouse.
To plan material receipt from the warehouse to cover the planned shortage, click Reserve. The Adjust order for materials form opens. In this form, select an action to supply materials.
To allow material shipment from the warehouse to cover the current shortage in the department, click Ship from warehouse.
Click Create invoice to generate the Material transfer in production document.
You can register the material transfer against orders used as references for goods shipment from the warehouse or by the actual shipment (based on notes). Register the material transfer on the To register invoices tab.
For each reference, you can see indicators that show discrepancies of the Order-Invoice and Invoice-Note kinds. Click Register by shipment to refill the selected material transfer with shipped quantity. If the order is selected, the material transfer is created for the quantity shipped by the note. If several material transfers are registered against the order and there are discrepancies between the note and the invoice, the Reregister material transfer form opens when filling in data by shipment. Use the form to eliminate the Note-Invoice discrepancies by changing data in created invoices or by creating new invoices.
When creating the Material transfer in production documents, you can select materials from orders/notes. Selection procedure is defined by the Master data and settings – Master data and sections – Warehouse and delivery – Warehouse – Procedure of invoice and goods issue note registration setting. You can switch the mode when selecting and edit the selected quantity manually.
You can create Material transfer in production documents for the total quantity exceeding the demand of the current orders. The volume exceeding the demand is recorded in separate lines. Its availability is specified in the document header.
Document lines with quantity exceeding the demand of the current orders are marked with icon .
Route sheet completion
A clear distinction should be made between volume and results of route sheet completion.
The result being registered has material embodiment – quantity of manufactured products resulting from route sheet completion (it is specified on the Finished products tab).
The volume of route sheet fulfillment reflects the completeness of the set production task. Usually, it does not directly correspond to the result being registered by quantity. Completion volume is a relative value, it is specified in the document header, in the Produced field. For example, volume of the production task by the route sheet is 10 units (the Planned field in the document header). Only 80% of the planned volume was fulfilled. In this case, specify 8 in the Produced field. Later, you will be able to create a new route sheet for the unfulfilled volume.
If the Completed status is selected, the Produced field in the document header and the Fact field in the tabular section on the Finished products tab are filled in.
To change the value in the Produced field, click (Change). All data on changing route sheet completion volume is registered in the Route sheet completion result form.
In the Route sheet completion result form, specify the actual volume of stage fulfillment by this route sheet and the volume of detected defective goods. If a variance from the planned volume remains after you enter this data, the link will be available in the header of the Route sheet document to create a separate route sheet for the remaining quantity.
In the form, you can also select an adjustment option for consumed resources. According to the specified rule, the values in the Fact fields on the Materials and works and Labor costs tabs of the route sheet will be automatically refilled.
Labor costs and materials consumed when completing the route sheet can be written off in the Active and Completed statuses.
Selection of the Completed status for route sheets is a reason to write off resources in unfinished production that were planned for use but not written-off yet.
Register labor costs of particular assignees using the Employee output documents.
Register product release using the Product release and work performance documents.
Using the Drum-Buffer-Rope model
To organize work of the local dispatcher by the Drum-Buffer-Rope model (DBR)—management by key work centers—set up the following:
- For the department, in the Route sheet management method parameter, select the DBR/SDBR value.
- Select the Use work center kinds check box for stages of the used bills of resources.
- Specify loaded work center kinds for stages of the used bills of resources. It is recommended that you specify one work center kind which is considered to be a bottleneck. If you need to estimate availability of press and stamp at the same time, specify two work center kinds. If the technological chain includes several candidates for causing production capacity limitation, you can specify two or three work center kinds. Increase in the number of work center kinds makes it difficult to find a planning interval to place the stage when creating the schedule (within the interval, all loaded work center kinds should be available at the same time).
The general procedure of working with route sheets using the DBR model is displayed in the diagram:
When using the DBR model, it is supposed that there is a key work center kind for the planning interval.
However, in practice, it is sometimes difficult to specify a constant key work center kind (bottleneck) considering variable and different in content load.
The application can automatically define a key work center kind among all loaded work center kinds specified for stages. That way you can consider the unique set of production tasks for each planning interval and optimize production processes locally within intervals.
Key work center kinds are selected automatically by the highest relative load. It is a ratio of occupancy time to availability time of loaded work center kinds in the planning interval. After key work center kinds are selected in the planning interval, adding of other stages to the interval does not lead to automatic reassignment of the key work center kind even if the initially used ratio of relative load of work center kinds is changed.
Selection of a key work center kind can lead to the situation when work center for which the timetable is to be generated will be missing in some route sheets. Completion of such route sheets does not require a special control. The local dispatcher processes them on a regular basis because all stages in the interval are equal regarding the need for completion.
In the departments using the DBR/SDBR method (management by key work centers), the local dispatcher can use the Manufacturing – Shop management – Dispatching (DBR) workplace. Within this workplace, the local dispatcher can do the following:
- Generate route sheets (click Generate route sheets) – route sheets are created for stages planned for completion in the selected planning intervals.
- Generate work center timetable for route sheets of the selected planning interval (click Generate timetable).
- Dispatch route sheets on the Route sheet dispatching tab.
- Manage work center timetable on the Work center dispatching tab.
To specify completion parameters for generated route sheets before creating the timetable, click (Edit). That way you can select or replace an operations sheet, make manual adjustments to required resource standards, etc.
One route sheet is generated automatically for one stage. Click (Split route sheet) to split it in several route sheets by selecting separate production batches for completion by different assignees and by different parameters. Several route sheets for completion of one stage can be also generated automatically depending on the settings specified in the stage.
To transfer route sheets to the shop, print them (click Route sheet). The print form can be easily customized according to your needs.
It is not required to generate a timetable for key work center kinds. In this case, route sheets will be managed manually. Timetable generation allows you to define operation performance procedure for a certain equipment unit of the key work center kind. You can optimize the performance procedure for the generated timetable by various criteria (for example, minimize equipment changeover).
Generate the timetable in the Create work center timetable window. Its cross-functional flowchart is displayed below:
Click Select a period and a work center kind to open the full list of planning intervals and work center kinds by which you need to generate the timetable.
You can put unplanned route sheets from previous intervals in the timetable for future planning intervals. The local dispatcher is authorized to specify the start date and end date (the fields on the Route tab) of route sheet completion beyond the planning interval in which the stage was included when generating the production schedule.
In the Create work center timetable workplace, in the list of route sheets for which it is required to create a timetable, in the End according to schedule field, specify the completion date by schedule. If the set completion time is expired and the route sheet was not included in expected planning interval, the date will be highlighted in red. You can include all available route sheets not included in timetables of previous planning intervals in the timetable for the current interval without limitations (records of route sheets not included in a timetable are kept in accumulative way).
When creating a route sheet completion timetable, specify availability of key work centers for a particular stage. When you do this, consider the work center schedule.
The local dispatcher can select a key work center kind manually (click More actions – Manage key work center kinds). Such assignment has the highest priority and does not change when you start the calculation again. Use this option reasonably and carefully to prevent the situation when stages planned for the interval are unfulfillable.
When creating a timetable, you can group route sheets:
- By released product.
- By setup options of key work center kinds. A setup option is specified for a loaded work center kind in the stage of the bill of resources.
- Using external data processors by various optimization algorithms specific for a particular production.
You can make manual adjustments:
- To the sequence and volume of jobs assigned to work centers.
- Exceed the allowable availability of some work center with capability to automatically and proportionally decrease route sheet processing time in accordance with available working hours of a work center.
It allows the local dispatcher to cope with shortcomings of the adopted technological standards and manage one-time overtime.
You can change the timetable:
- In the tabular section, on the Schedule tab.
- Interactively in the work center load schedule on the Availability schedule tab.
Specify a time axis format of the availability schedule to display the timetable. Load for different equipment setup options is highlighted in different colors. With route sheets, you can do the following:
- Move to another completion time.
- Specify completion period.
- Remove from the timetable.
You can arrange route sheets using arrows and sort them by products.
To display route sheets in the Production dispatching (DBR) workplace, you can use a flexible filtering system including two condition groups that reflect different management approaches:
- Filters by task statuses – this group includes all possible actions with route sheets.
- Filters by completion state – allow you to estimate if route sheets can be completed on time:
- There are overdue tasks
- Buffer exceeding 33 %
- Buffer exceeding 66 %
- There is a timetable delay.
Within both filter groups, you can combine imposed conditions arbitrarily.
Click (Select all) to automatically set all filters. As a result, all route sheets for which any actions are required will be displayed in the workplace. If you need to display the list of all relevant route sheets regardless of actions required for them, clear all check boxes.
You can control statuses of route sheet tasks using the following indicators:
- – the work center timetable for route sheet completion is available (generation of the work center timetable is not required).
- – shows that there are uncompleted previous stages. For route sheets, it shows that there are unregistered stages immediately preceding the route sheet completion. In the Route sheet document, click Adjacent stages to open the Execution of adjacent stages of route sheet list. In the list, you can see all nearby stages (previous and following) for the current stage. The information can be useful to understand the work of adjacent stages. It allows you to see the direction of stage result transfer if the results were not embodied in product items.
- – route completion. Specify route milestones to be marked as follows:
- – pass the route sheet for completion.
- – mark route sheet completion as started.
- – mark the key work center as ready for operation.
- – mark key work center operation as completed.
- – mark the route sheet as completed.
- – material receipt control. The icon shown in the line with the route sheet indicates the need to receive materials. Click the icon to create the Material transfer in production document.
- – output registration for employees who completed the route sheet. The icon shown in the line with the route sheet indicates the need to register employee output. Click the icon to select a team of assignees and create the Employee output document.
- – registration of product release or work fulfillment. The icon shown in the line with the route sheet indicates the need to register product release. Click the icon to create the Product release and work performance document.
In the tabular section of the workplace, you can see three parameter groups for each route sheet:
- Route sheet
- Key work center
- Order (production order)
To open the log of previously completed route sheets (the Route sheet documents with the Completed status), click Route sheet archive.
In the Production dispatching (DBR) workplace, you can set up arbitrary filters and sorting.
You can manage the work center timetable (data on the Work center dispatching tab) after creating the timetable for key work center. The timetable can be displayed as a tabular fulfillment list or as a Gantt chart of work center load. To display data in the workplace, use the arbitrary filter by combination of parameters:
- There is timetable delay.
- Some work centers run ahead of the timetable.
- Timetable is not created.
You can adjust the timetable in the Create work center timetable window. To open it, click Generate timetable. Click (work center schedules) to go to the Availability of work centers workplace and specify the equipment work schedule if required.
Using the Simplified Drum-Buffer-Rope model
In the Simplified Drum-Buffer-Rope model (SDBR), it is supposed that a consumer is a limitation and production capacities exceed consumer demand. In this case, the main production cycle depends on planned operations of transferring manufactured products to a consumer. When dispatching, management by indicators showing attention zones is available, but in absence of the drum. The buffer takes the whole production cycle. The application allows you to view production capacities locally for each department. It is controlled by zones how a batch (order) is passing through the whole production cycle.
To be able to use the SDBR model, set up the following:
- For the department, in the Route sheet management method parameter, select the DBR/SDBR value.
- Clear the Use work center kinds check box in stages of used bills of resources.
- Set the Stage duration parameter in stages of used bills of resources.
In the SDBR model, the total time of stage fulfillment in the department is estimated and the work center timetable is not generated.
You can specify duration of SDBR stages (stages with estimated total fulfillment duration) with an accuracy of minutes or hours.
If stage duration is specified in days, use the contractor department calendar to define workdays when planning works. If stage duration is specified in minutes or hours, use the precise department work schedule when planning works (the work schedule is specified in production department parameters by days within the selected planning interval) and specify particular time to place the stage in the production schedule.
That way you can optimally plan short stages (with duration less than one day) included in multi-stage production processes which are to be supplied with materials on pegging basis, dispatched, and documented. You can place multiple stages of this kind within a calendar day:
You can specify zero duration for SDBR stages. When calculating the production schedule, such stage is pinned to the previous or the following stage (depending on the planning direction). If this is a single stage in the bill of resources, it is pinned either to the production start date or to the demand date.
Specify zero duration for stages whose duration is negligible and which are to be fulfilled on the same day as the adjacent stage. If a stage with zero duration relates to semi-finished products produced within the process, their release will be planned for the same day as for manufactured products which include them.
You can use stages with zero duration to add an additional control point in production process in order to supply production with materials, exercise selective control, take samples for intermediate quality control, etc.
When you place SDBR stages in a production schedule, make sure that following stages with resource limitations are fulfillable. When calculating a production schedule, an SDBR stage (stage with estimated total fulfillment duration) standing first in the stage sequence of one redistribution will be placed as close to a DBR stage (stage with set availability of work center kinds) as possible (pinned on the left):
That way you can decrease unfinished production volume and plan stages by the time their results are required for further production.
Use SDBR stages for preparatory activities without production resource limitations. For example, kitting of parts for the following stage.
In the Route sheet document, on the Route tab, the following information is recorded:
- Start of route sheet completion.
- End of route sheet completion.
Production dispatching in the SDBR model is similar to the DBR model. The only difference is that indicators reflect the whole stage fulfillment progress.
Simple operation management
Management by operations is available without creating a full work center timetable. This scenario is provided by the Operation registration (without planning) route sheet management method. Usage of this method is configured in department settings:
- Routes are described by operations.
- The timetable of operation performance in work centers is not created.
- Operations are performed on a queue basis.
- Actual operation performance is registered. The mode by variances is not available.
If the Operation registration (without planning) route sheet management option is selected in settings of at least one department, the Manufacturing – Shop management – Dispatching (operation registration) workplace is available. This workplace is an adapted form of the Manufacturing – Shop management – Dispatching (MES) workplace. Within the specified workplace, you can select key work centers when creating route sheets. Operations being performed before key work centers are assigned the highest priority. Thus, the production process will reach operations being performed on the high-load equipment as soon as possible, and such equipment will be maximally loaded.
In figure, you can see operations preceding the Drilling operation, which is performed on the Drilling machine key work center. These operations have the higher priority (High) than others, and it allows the Drilling operation to start as quickly as possible.
The general procedure of production stage fulfillment is displayed in the diagram:
The appearance of the Operation performance workplace is set up automatically depending on settings of the department selected to record operations.
Operations can have the following states:
- Wait for previous ones – performance of the previous route operation has not been started.
- Previous ones are started – performance of the previous route operation has been started.
- Can be completed – all previous route operations have been completed.
- Active – the operation has been started.
- Completed – the operation has been completed.
To perform actions with operations, use the following buttons:
- Assign operation to the work center – assign a work center to operations selected in the tabular section. Before assignment, you can filter operations by a work center kind (filter in the workplace header) or directly by work center. There are various dispatcher action scenarios: Assign operations to work centers when they are ready for completion (readiness is defined by the operation performance state), or for each work center, generate the operation pool for completion in advance for shift, day, etc.
- Cancel operation assignment – cancel performance of the selected operation (operations) on the previously selected work center. Later assign this operation for completion to another work center.
The functionality is available only for Production management, version 2.2 (Master data and settings – Master data and sections – Manufacturing – Production management, version 2.2 is selected).
Use the functionality of production process fulfillment control in a shop to dispatch technological operations manually. With this functionality, you can do the following:
- Generate the list of operations required to fulfill a stage using operations sheet data.
- Allocate operations to work centers.
- Assign an assignee and accept operation for completion.
- Register operation completion with specification of consumed materials and labor costs.
Operation dispatching is configured individually for each department. To configure it, open the production department profile from the Enterprise structure list and on the Production by orders tab, select the Use operation management for production stages check box.
By particular attributes in department settings, you can configure usage of operations to collect actual data on production stage fulfillment:
- Select the Materials in operations check box to register material use by operations.
- Select the Finished products in operations check box to record release in relation to operations.
The new document kind is added for production stage fulfillment management. This is the Production operation document. It does not generate records in accounting, it is only a source of actual data for the stage. As usual, all records are created by the production stage, regardless of whether operations are used for more detailed stage completion control or not.
By default, operations for completion within the stage are defined by the selected operations sheet – the Operations sheet field. To specify the operations sheet at the production stage level, select it from the Manufacturing – Master data – Operations sheets list.
Operation fulfillment volume is specified in time and quantity. For example, the operation of solution preparation is normalized at the rate of 50 kg (performance volume in quantity) per hour (performance volume in time).
Use the following procedure for the Production operation documents:
Employees of the operation and dispatch department, who use the application as chief dispatchers, pass stages for completion. Stages appear in the Manufacturing – Shop management – Stage execution workplace.
A dispatcher in the shop (a user with the rights of local dispatcher) accepts the stage for completion by assigning the Started status to it.
Based on the selected operations sheet, the list of the Production operation documents to be fulfilled is created for the stage.
Operations appear in the Manufacturing – Shop management – Operation performance workplace. In the Operation performance workplace, in the tabular section of the Operation performance tab, relevant operations with different completion statuses are shown.
If you filter operations in the Operation performance workplace by a work center, you will see all operations planned for completion on this work center. You will also see operations for which the work center kind including the work center specified in the filter is selected but a specific work center is not specified yet. It allows you to control the whole volume of operations to be dispatched by a certain equipment kind.
You can create the Production operation documents only based on operations specified in operations sheets. You cannot adjust operations being performed.
Define an assignee for operations and pass them for completion – the Put an operation into work form. A specific employee (the Individuals list) or a team (the Teams list) can be assigned as an assignee.
The operation can be performed by several assignees. For each of them, a separate document for accepting the operation into work is created. For each assignee of the operation accepted into work, a setup time is provided.
If required, in the Production operation documents, assignees fill in data on materials consumed while performing the operation (the Materials and works tab) and on labor costs (the Labor costs tab).
Assignees mark operations as completed. Actual data from the Production operation documents are transferred to the Production stage documents.
After stage operations are completed, the shop dispatcher marks production stage as completed. When completing the stage, fulfillment of all operations is checked.