Shop Floor control

Shop Floor Control Management in eresource (SFC)

An essential and concise guide to understanding and implementing eresource

Release 2.8

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Copyright
Copyright 2011 ERESOURCE. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of eresource Infotech P. Ltd. The information contained herein may be changed without prior notice. Microsoft, WINDOWS, NT, EXCEL, Word, PowerPoint and SQL Server are registered trademarks of Microsoft Corporation. HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C, World Wide Web Consortium, eresource, eresource Logo. Eresourceerp.com are trademarks or registered trademarks of eresource Infotech in India and several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.

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Table of Contents
Shop Floor Control (SFC) ............................................................................................................................... 5 Shop Floor Control (SFC) in eresource: ......................................................................................................... 5 Concept of Shop Floor Control: .................................................................................................................... 5 Daily Route Availability (Grant Chart): .......................................................................................................... 7 Priority Sequencing Rules: ............................................................................................................................ 8 Production Configuration and Process ......................................................................................................... 9 Planning .................................................................................................................................................... 9 Product Process relation ......................................................................................................................... 10 Add ...................................................................................................................................................... 10 Search/Edit of PPR .............................................................................................................................. 12 Machine Process Relation ....................................................................................................................... 13 Add ...................................................................................................................................................... 13 Search/Edit of MPR ............................................................................................................................. 15 Master Product Planning ........................................................................................................................ 16 Add ...................................................................................................................................................... 16 MPS based MRP (MRP II) ........................................................................................................................ 19 Shift Master............................................................................................................................................. 21 Daily Production Yield ............................................................................................................................. 22 Production............................................................................................................................................... 24 Daily Production Record ..................................................................................................................... 24 Production WIP ....................................................................................................................................... 25 Job Work: .................................................................................................................................................... 28 Job Work Issue/ Receive: ........................................................................................................................ 28 Job Work Follow up for Job work Issued/Received: ............................................................................... 29 Batch Plan: .............................................................................................................................................. 30 Benefits of Shop Floor Control : .................................................................................................................. 31

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Shop Floor Control (SFC)

The Shop Floor Control (SFC) is the detailed management of activities and the flow of materials inside the plant - including the workers, materials, machines and time utilized in production. With increasing emphasis placed upon reducing manufacturing time in support of the need to reduce product time to market, manufacturers have turned greater attention to evaluating their shop floor activities.

Shop Floor Control (SFC) in eresource:

Shop Floor Control in eresource ERP provides all functions required to manage and control the manufacturing floor, including on-line routing maintenance, labour reporting, and scheduling. The shop floor module maintains the data needed to optimize on time completions, evaluate plant workload, and determine capacity needs. Relevant Shop Floor Control is integrated with other modules to maintain current work order information at all times. Management needs timely, accurate information and the ability to manage the shop floor by exception. Cost information must be flexible as well. As factories are realigned to reduce material travel time through a facility, this realignment places an added burden upon the supporting systems. Eresource ERP's Shop floor control system is flexible and adapt to changing needs.

Concept of Shop Floor Control:

Eresource ERP provides full function shop order maintenance capability, allowing the user to evaluate and adjust operation steps and components. Orders can be re-scheduled either backwards or forward. The below figure an example product structure for end item A, which demonstrates basic concepts underlying Shop Floor Control techniques. In eresource ERP one essential input to the Shop Floor Control system is the routing and lead time data for each product item.

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End Item A Lead time = 1

Part B Lead time = 3

Part C Lead time = 2

Part D Lead time = 2

Part E Lead time = 1

The below figure presents this parts D and E of the example given above. The routing specifies each operation to be performed to make the part and which work center will perform the operation. Operation Work Center Run time Setup time 0.4 0.5 0.1 Move time 0.3 0.3 0.2 Queue time 2.0 2.5 0.5 Total time 4.1 4.8 0.9 Rounded time 4.0 5.0 1.0

Part D routing 1 101 2 109 3 103 Total lead time = 10 days Part E routing 1 2 3 4 101 107 103 109

1.4 1.5 0.1

0.3 0.2 0.3 0.1

0.1 0.1 0.2 0.1

0.2 0.3 0.1 0.1

0.5 0.5 1.5 0.5

1.1 1.1 2.1 0.5

1.0 1.0 2.0 1.0

Total lead time = 5 days As per above the figure Production Part D requires three operations of 4,5, and 1 days respectively 10 days. Part E requires four operation of 1, 1, 2, and 1 days respectively 5 days. The remaining lead times are all derived the same way.

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Lead time used for MRP, that should be matches those in the routing file. If the MRP time for Part E was set at 10 days instead of 5 days, goods shall constantly be released 5 days early.

Lead times are typically made up of four elements: Run Time: Operation or machine run time per piece x lot size. Setup Time: Time to prepare work center, independent of lot size. Move Time: Delay waiting to be moved plus time spent moving from one work center to the next. Queue Time: Time spent waiting to be processed at a work center, which depends on workload and schedule. Queue Time: Frequently accounts for 80 percent or more of total lead time, its the element most capable of being managed.

Daily Route Availability (Grant Chart):

Gantt chart like those in below the screenshot shows a schedule. It too is a schedule for when to make

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each of the parts based on lead times that include move and queue times. The more usual practice is to prepare the detailed work center schedule without move and queue times. The typical approach is a schedule board with racks to hold pieces of paper. Each paper is a job and its length represents the setup plus run time required. The primary problem with this kind of system is updating. Actual data must be captured and integrated into an ongoing re-planning cycle. In eresource ERP you have provision to see daily route availability chart for Product name wise, Formulation name based, Machine name based, Labour name based. Again if it a labour then he comes under which category weather he is Skilled, Semiskilled, Unskilled, Skilled and Semiskilled, Semiskilled and unskilled or All. This chart shows you a clean picture on the availability of Machine, Labor, Formulation, Product for MRP.

Priority Sequencing Rules:

Priority Sequencing Rules determine which job to run next at a work center. To some extent, these rules can be seen as producing a loading of jobs onto individual machines, but usually only one job is committed at a time; That is, the job to run next is determined only near the time when the prior job has been completed. Some Sequencing Rules are: Order Slack Slack per Operation Critical Ratio Shortest Operation Next

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Production Configuration and Process

Processes and methods employed in transformation of raw materials or semi finished goods into goods or services. Here production is also done on the web based.

Planning
The term is also used to describe the formal procedures used in such an endeavor, such as the creation of documents diagrams, or meetings to discuss the important issues to be addressed, the objectives to be met, and the strategy to be followed. Planning is also a management function, concerned with defining goals for future organizational performance and deciding on the tasks and resources to be used in order to attain those goals.

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Product Process relation

Add To create a new Product Process Relation. For a given product different process are to be defined.

Name Product Name

Description Name of the product for which process relation is to be added Quantity of the output batch of the given product The unit of measurement of the output batch of the product The expected value for the given Quality Characteristics

Output Batch Qty Output UOM

Expected Value Grid Process Name Loading Time Unload Time

Name of the process that is to be related to the product The loading time of the product as per the process The Unload time of the product as per the process

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Process Time

The time required in the process, gets auto filled as per the entries in the loading time and unload time Used to add the process details entered by the user in the grid below Used to cancel the entries done by the user in the Process details sections

Add

Cancel

Grid Process Name Loading Time Unload Time Std. Time Required Control Name of the process that is related to the product The loading time of the product as per the process The Unload time of the product as per the process The Standard time required for the process User can edit or delete records in list using the Edit/Delete buttons in the control column This is the gross time required for all the processes listed in the grid This is the net time required for all the processes listed in the grid

Gross Process Time

Net Process Time

Reference Details Prepared By Approved By Checked By Name of the person who made the entries Name of the person who approved the entries Name of the person who checked the entries

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Search/Edit of PPR Used to search all the product process relation that are already defined. The product process relation can be searched as per the Product Name or Process Name.

Name Product Name Wise Product Name Product Name

Description

The user has to select it to search according to Product Name Dropdown from which the user can select the name of the product for which the process relations are to be searched.

Product Name Wise Product Name Wise The user has to select it to search according to Product Name.

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Product Name

User can the name of the product from the dropdown and then search the products related to that process.

Machine Process Relation

Add Define a relation between a machine and the products. A machine can be used for processing on different products. This form is used to define these relationships.

Name Entry No.

Description System generated Entry number for the new Machine Product Relation The date on which entry was made The name of the machine for which the product relations are to be defined Name of the product that is related to the machine

Entry Date Machine Name

Product Name

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Batch Qty UOM Base Name Base Qty Process Name

Quantity of the product processed in the batch Unit of measurement of the product quantity Base name of the product Quantity of the base required in the process Used to select the process name that is carried out on the machine for the given product Auto filled as per the process selected for the product Auto filled as per the process selected for the product Time required in cleaning of the machine after bath is processed The actual time required in the product processing, that is sum of loading time, unload time and the cleaning time. Used to add the details entered by the user in the grid below Used to clear the fields entered by the user in the product details fields Name of the product that is related to the machine Quantity of the product processed in the batch Unit of measurement of the product quantity Base name used for the product Quantity of the base required in the process

Loading Time Unload time Cleaning time Actual processing time Add Cancel

Product Name Batch Qty UOM Base Name Base Qty Grid Process Name

Process name that is carried out on the machine for the given product Loading time required for the process Unload time required for the process

Loading Time Unload time

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Cleaning time Actual processing time Control Reference Details Prepared By Approved By Checked By

Cleaning time required after the process The actual time required in the product processing, that is sum of loading time, unload time and the cleaning time. Used to edit or delete records in the list using Edit/Delete buttons

Name of the person who made the entries Name of the person who approved the entries Name of the person who checked the entries

Search/Edit of MPR

To search and edit machine product relations. User can search Machine product Relation as per name of the machine or as per the Product of the Machine. User can edit the Machine Product Relations already defined.

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Name

Description

Machine Name Wise Machine Wise Machine Name The user has to select it to search, according to machine name Dropdown from which the user can select the name of the machine for which the product relations are to be searched.

Product Name Wise Product Wise Product Name The user has to select it to search, according to product wise. User can select the name of the product from the dropdown and then search the machine product relations for the product selected.

Master Product Planning

Add The MPS is a translation of Business Plan into a product manufacturing schedule that covers what is to be assembled or made, when, with what materials acquired when and the cash is required. The master production scheduling is the key component to Material Requirement Planning. A Master Production Schedule (MPS) is a plan for production, staffing, inventory, etc. It is usually linked to manufacturing where the plan indicates when and how much of each product will be demanded.

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Name MPS Id MPS Date Based On

Description System generated Master Production schedule code. The Date on which MPS is generated. The type on which MPS is based such as forecast or Inline orders The Form date of the DMRP The To date of the DMRP

From Date To Date

Finished Material Requirement Reference Type Reference No. The type of reference such as Forecast or inline orders The reference number of finished material
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Item Name Formulation Name Required Quantity Required Date Requirement Item Name Wise Requirement Formulation Wise Generate Batch Pan

Name of the Item The size of the item The quantity required by the supplier The time before which the finished material is required The requirement of the material according to item name

The requirement of the product according to formulation wise. Generation of the Batch Plan according to the requirements. Remarks if any

Remarks Reference Details Prepared By Checked By Approved By

Name of the person who prepared the entries Name of the person who checked the entries Name of the person who approved the entries

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MPS based MRP (MRP II)

MRP II is the successor of the MRP I. Here, In MRP II, it integrates planning of all aspects of a manufacturing firm. MRP II includes function such as business planning, production planning and scheduling, capacity requirement planning, job costing, financial management and forecasting, order processing, shop floor control, time and attendance, performance measurement and sales and operating planning

Name MRP Id MRP Date MPS Id MPS Date

Description System generated MRP code. The Date on which MRP is generated. The MPS Id according to the MRP code. The Date on which MPS is generated.

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Consolidated Requirement Item Name Wise Item Name Formulation Name Required Quantity Required Date No of production Days Requirement Filtration Type Remarks Reference Details Prepared By Checked By Approved By Name of the person who prepared the entries Name of the person who checked the entries Name of the person who approved the entries Name of the Item The size of the item The quantity required by the supplier The time before which the finished material is required The no of days required for production The type of filtration required

Remarks if any

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Shift Master
This form contains the details of the timing shift for a particular period of a particular employee. The form contains Shift Plan ID, Shift Plan Date, etc.

Name General Details Shift Plan ID Shift Plan Date Form Date To Date Control Shift Name Check For Cancel

Explanation

System Generated Plan Id The date on which Plan was generated The Form Date of the Plan The To date of the plan The control given to the employee for a particular shift Name of the Shift To be check for cancellation of the shift for a particular employee Remarks if any

Remarks Reference Details Prepared by Approved by

Name of the person who prepared the form Name of the person who approved the form

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Checked by

Name of the person who checked the form

Daily Production Yield

Use to add the details of daily yield production of the product. The daily yield details can be added and then transferred to the store.

Name General Details Entry No. Entry Date Product Name Raw Material Details Raw Material Name

Description

Displays the Auto populated process entry id The date on which the entries were made The product of which the daily yield entries are made

Displays the raw material name that is required in the process

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BOM Qty UOM Input Qty Remark Wet Qty Dry Qty QC Rejection Qty Semi Finished Transferred to Store Reference Details Prepared By Approved By Checked By

Displays the bill of material quantity of the raw material Displays the unit of measurement of the raw material The quantity of raw material used in production Remarks about the raw material used Wet quantity of raw material used in production Dry quantity of raw material required in production The Rejected quantity by QC Used to transfer the yield quantity details after deducting QC Rejection quantity to stores

The person who made entries The person who approves the process The person who checked the entries

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Production
Production is a processes and methods employed in transformation of tangible inputs like raw materials, semi finished goods or subassemblies, etc. along with the intangible inputs like ideas, information, implementation, etc. into goods or products.

Daily Production Record

The form records the daily production of the product.

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Production WIP
Production of WIP is partially or completed goods; parts or subassemblies that are no longer part of the raw materials inventory and not yet part of the finished products details are seen in these forms. Work in Process inventory forms a part of the working or current assets of a firm and is usually at lower of cost and realizable value.

Name Batch Details Batch No. Batch Date Batch Req. Issue Slip No. Product Name Batch Size Packing Size Date of Commencement Date of Completion WIP Check List

Description System Generated Batch No. Date on which Batch is generated. Issue Slip Number Name of the product The Size of the batch The size of product after packing The date at which commencement is given. The date of completion Work in Progress Check List
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Cleaning Details Name of Equipment Date of Cleaning Cleaned By Analysed By Result Line Clearance Details Date Of Clearance Previous Product Stage of Clearance Checked by QA Remark Reference Details Prepared by Approved by

Name of the equipment The date on which cleaning is done Name of the person who had done the cleaning Name of the person who had done the analyses The result of equipment after cleaning The date of clearance The name of the previous product Name of the stage Name of the person who has checked Remarks if any Name of the person who has prepared the form Name of the person who has approved it

Job Card:
Job Card determines which job will be done by whom. Which are the process need to be done, which machine is required and who are the people who will be working on that processes and machines.

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This form shows you a very clear picture for reason for ideal, Material shifting, available time, Total time is required, time for ideal, time utilized for working etc.

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Job Work:
Weather you do job work for other or you get it done from outside. eresource ERP provides you both the provision. Outsourcing is subcontracting a process, such as product design or manufacturing,

to a third-party company. The decision to outsource is often made in the interest of lowering cost or making better use of time and energy costs, redirecting or conserving energy directed at the competencies of a particular business, or to make more efficient use of land, labor, capital, (information) technology and resources.

Job Work Issue/ Receive:

By the feeding details of party (job worker) details, its follow up criteria, raw item details for job work and job work finish item details you can easily issue job work to your job worker Or receive job work from other parties. Also you have provision to see the follow up dates for job work issued to job worker and job work received from out side.

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Job Work Follow up for Job work Issued/Received:

You can take regular follow up with the job worker whom you have issued any job or from the other party you received any job work.

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Batch Plan:
By the selection of Material Planning Scheduling you are capable to make a batch plan for any MPS. Also at the time of preparing any batch plan you have provision to check Machine availability for that

particular batch.

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Benefits of Shop Floor Control :

The eresource Shop Floor Control module provides real time labour and production reporting for online production visibility throughout the organization.

Gain control and improve efficiency at a single shop or at multiple locations throughout your enterprise. Accurate production data can be used by costing applications with real or standardized allocations. Eresource ERP shop floor control program readily integrates with automation for automatic counting The shop floor control program collects data and provides custom shop floor control by lot, job, schedule, product, work center etc.

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