Shop Floor Control in Eresource Erp
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Transcript of Shop Floor Control in Eresource Erp
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Shop Floor
control
Shop Floor Control Management in eresource
(SFC)
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2 2010 eresource Infotech Private Limited. All rights reserved
An essential and concise guide to
understanding and implementing eresource
Release 2.8
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3 2010 eresource Infotech Private Limited. All rights reserved
Copyright
Copyright 2011 ERESOURCE. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or for any purposewithout the express permission of eresource Infotech P. Ltd. The information contained herein may bechanged without prior notice.
Microsoft, WINDOWS, NT, EXCEL, Word, PowerPointand SQL Serverare registeredtrademarks of Microsoft Corporation.
HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C, World WideWeb 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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4 2010 eresource Infotech Private Limited. All rights reserved
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): .......................................................................................................... 7Priority 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 reduceproduct 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, anddetermine 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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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
Move
time
Queue
time
Total
time
Rounded
time
Part D routing
1 101 1.4 0.4 0.3 2.0 4.1 4.0
2 109 1.5 0.5 0.3 2.5 4.8 5.0
3 103 0.1 0.1 0.2 0.5 0.9 1.0
Total lead time = 10 days
Part E routing
1 101 0.3 0.1 0.2 0.5 1.1 1.0
2 107 0.2 0.1 0.3 0.5 1.1 1.0
3 103 0.3 0.2 0.1 1.5 2.1 2.0
4 109 0.1 0.1 0.1 0.5 0.5 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.
End Item A
Lead time = 1
Part ELead time = 1
Part DLead time = 2
Part C
Lead time = 2
Part B
Lead time = 3
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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 elementmost 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 integratedinto 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 Description
Product Name Name of the product for which process relation is to be
added
Output Batch Qty Quantity of the output batch of the given product
Output UOM The unit of measurement of the output batch of the
product
Expected Value The expected value for the given Quality Characteristics
Grid
Process Name Name of the process that is to be related to the product
Loading Time The loading time of the product as per the process
Unload Time 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
Add Used to add the process details entered by the user in the
grid below
Cancel Used to cancel the entries done by the user in the Processdetails sections
Grid
Process Name Name of the process that is related to the product
Loading Time The loading time of the product as per the process
Unload Time The Unload time of the product as per the process
Std. Time Required The Standard time required for the process
Control User can edit or delete records in list using the
Edit/Delete buttons in the control column
Gross Process Time This is the gross time required for all the processes listed
in the grid
Net Process Time This is the net time required for all the processes listed in
the grid
Reference Details
Prepared By Name of the person who made the entries
Approved By Name of the person who approved the entries
Checked By 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 Description
Product Name Wise
Product Name The user has to select it to search according to Product Name
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 Description
Entry No. System generated Entry number for the new Machine Product
Relation
Entry Date The date on which entry was made
Machine Name The name of the machine for which the product relations are to
be defined
Product Name Name of the product that is related to the machine
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Batch Qty Quantity of the product processed in the batch
UOM Unit of measurement of the product quantity
Base Name Base name of the product
Base Qty Quantity of the base required in the process
Process Name Used to select the process name that is carried out on the
machine for the given product
Loading Time Auto filled as per the process selected for the product
Unload time Auto filled as per the process selected for the product
Cleaning time Time required in cleaning of the machine after bath is processed
Actual processing
time
The actual time required in the product processing, that is sum of
loading time, unload time and the cleaning time.
Add Used to add the details entered by the user in the grid below
Cancel Used to clear the fields entered by the user in the product details
fields
Product Name Name of the product that is related to the machine
Batch Qty Quantity of the product processed in the batch
UOM Unit of measurement of the product quantity
Base Name Base name used for the product
Base Qty Quantity of the base required in the process
Grid
Process Name Process name that is carried out on the machine for the given
product
Loading Time Loading time required for the process
Unload time Unload time required for the process
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Cleaning time Cleaning time required after the process
Actual processing
time
The actual time required in the product processing, that is sum of
loading time, unload time and the cleaning time.
Control Used to edit or delete records in the list using Edit/Delete buttons
Reference Details
Prepared By Name of the person who made the entries
Approved By Name of the person who approved the entries
Checked By 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 The user has to select it to search, according to machine name
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 The user has to select it to search, according to product wise.
Product Name 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 Description
MPS Id System generated Master Production schedule code.
MPS Date The Date on which MPS is generated.
Based On The type on which MPS is based such as forecast or Inline
orders
From Date The Form date of the DMRP
To Date The To date of the DMRP
Finished Material Requirement
Reference Type The type of reference such as Forecast or inline orders
Reference No. The reference number of finished material
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Item Name Name of the Item
Formulation Name The size of the item
Required Quantity The quantity required by the supplier
Required Date The time before which the finished material is required
Requirement Item Name
Wise
The requirement of the material according to item name
Requirement Formulation
Wise
The requirement of the product according to formulation
wise.
Generate Batch Pan Generation of the Batch Plan according to the
requirements.
Remarks Remarks if any
Reference Details
Prepared By Name of the person who prepared the entries
Checked By Name of the person who checked the entries
Approved By 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 Description
MRP Id System generated MRP code.
MRP Date The Date on which MRP is generated.
MPS Id The MPS Id according to the MRP code.
MPS Date The Date on which MPS is generated.
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Consolidated Requirement Item Name Wise
Item Name Name of the Item
Formulation Name The size of the item
Required Quantity The quantity required by the supplier
Required Date The time before which the finished material is required
No of production Days The no of days required for production
Requirement Filtration
Type
The type of filtration required
Remarks Remarks if any
Reference Details
Prepared By Name of the person who prepared the entries
Checked By Name of the person who checked the entries
Approved By Name of the person who approved the entries
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ShiftMaster
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 Explanation
General Details
Shift Plan ID System Generated Plan Id
Shift Plan Date The date on which Plan was generated
Form Date The Form Date of the Plan
To Date The To date of the plan
Control The control given to the employee for a particular shift
Shift Name Name of the Shift
Check For Cancel To be check for cancellation of the shift for a particular
employee
Remarks Remarks if any
Reference Details
Prepared by Name of the person who prepared the form
Approved by 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 Description
General Details
Entry No. Displays the Auto populated process entry id
Entry Date The date on which the entries were made
Product Name The product of which the daily yield entries are made
Raw Material Details
Raw Material Name Displays the raw material name that is required in the
process
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BOM Qty Displays the bill of material quantity of the raw material
UOM Displays the unit of measurement of the raw material
Input Qty The quantity of raw material used in production
Remark Remarks about the raw material used
Wet Qty Wet quantity of raw material used in production
Dry Qty Dry quantity of raw material required in production
QC Rejection Qty The Rejected quantity by QC
Semi Finished Transferred
to Store
Used to transfer the yield quantity details after deducting QC
Rejection quantity to stores
Reference Details
Prepared By The person who made entries
Approved By The person who approves the process
Checked By 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 Description
Batch Details
Batch No. System Generated Batch No.
Batch Date Date on which Batch is generated.
Batch Req. Issue Slip No. Issue Slip Number
Product Name Name of the product
Batch Size The Size of the batchPacking Size The size of product after packing
Date of Commencement The date at which commencement is given.
Date of Completion The date of completion
WIP Check List Work in Progress Check List
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Cleaning Details
Name of Equipment Name of the equipment
Date of Cleaning The date on which cleaning is done
Cleaned By Name of the person who had done the cleaning
Analysed By Name of the person who had done the analyses
Result The result of equipment after cleaning
Line Clearance DetailsDate Of Clearance The date of clearance
Previous Product The name of the previous product
Stage of Clearance Name of the stage
Checked by QA Name of the person who has checked
Remark Remarks if any
Reference Details
Prepared by Name of the person who has prepared the form
Approved by 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.