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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    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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    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.