Shop Floor Control

The Shop Floor Control module supports the E2E process starting from the Manufacturing Order Creation to its Closure.

Master Data

The manufacturing Master Data has been enhanced.

 

Workcenter

•       Check to avoid to create work center duplicated based on its description and its code

•       indicator to allow partial quantity confirmation

•       indicator to allow starting workorder without component availability

•       document attachment feature

 

Bill of Materials

·       An operation can be set as a milestone one

·       Operation sequence for sequencing workorders in scheduling phase

·       Operations with the same sequence are scheduled in overlapping (parallel operations)

·       check no other operation can have the same sequence with a milestone one, so no operation can be in overlapping to a milestone one

 

 

Manufacturing Order Creation and its Confirmation

The planned pivot dates (Planned Start Pivot Date and Planned End Pivot Date) are determined based on Manufacturing Lead Time in product master data and Security Lead Time in settings at company level starting from the Planned Start date; this is performed in forward mode based on the working calendar set at warehouse level.

 

 

Workorders Scheduling and Work Center Capacity Loading

·       The scheduling phase involves the Scheduled Start Date and Scheduled End Date determination for each workorder.

·       Production Order Scheduled Dates (Scheduled Start Date and Scheduled End Date) are determined also to be compared to the Planned Dates.

·       Rescheduling is possible until the next phase, workorder confirmation, has not been started

·       The capacity requirements are created, hence capacity loading occurs for the corresponding Work Centers

 

Workorders Scheduling

The following logic has been implemented for workorders scheduling:

·       the Workorder Scheduled Dates determination is performed in forward mode and based on the following times:

o   cycle time for each operation in BoM

o   time before production in the work center for each operation in BoM

o   time after production in the work center for each operation in BoM

·       the scheduling is performed according the working calendar entered in the Work Center for each operation in BoM

·       the workorder sequencing is based on the sequence assigned to each BoM’s operation

·       parallel operations (operations with the same sequence in BoM’s operations) are scheduled in overlapping with the same start scheduled date

 

 

Capacity Loading

 

·       Workorder capacity requirements are calculated based on working hours determined in the scheduling phase;

·       the capacity requirements are to be compared with the available capacity in the subsequent capacity evaluation phase

·       the available capacity is calculated based on working calendar set at work center level; therefore, the effective availability of the related work center is taken into account in the capacity evaluation phase

 

Through the capacity load feature it is possible to evaluate the capacity feasibility at manufacturing order level.

 

Capacity Evaluation

To Evaluate the Manufacturing Plan feasibility for capacity point of view a Capacity Evaluation has to be performed for the bottlenecked Work Centers at least.

The following features are provided:

·       the weekly available capacity has to be compared with the capacity requirements over the time, week by week, at Work Center level;

·       the available capacity is calculated based on the workorder scheduled interval (from the scheduled start date to the scheduled end date) and the working calendar set at work-center level; the work-center capacity and the work-center time efficiency are both taken into account;

·       The capacity requirements are calculated by considering the scheduling interval also and the working calendar on work center level;

·       The work center capacity load in percentage and the remaining capacity are calculated for supporting the subsequent capacity leveling phase

·       The same report is useful for evaluating the effectiveness of the subsequent Capacity Leveling phase

 

 

Capacity Leveling with Mid-Point Scheduling

Capacity leveling is achieved by moving workorders over the time so the corresponding capacity requirement is moved also. The mid-point scheduling logic has been implemented for determining new scheduled dates for all the remaining active workorders.

 

In detail, we have as follows:

·       all the remaining active workorders are moved in backward or forward scheduling according to if they are preceding or following the concerned workorder

·       All the capacity requirements are moved also

·       Workorder in progress are not moved: check whether the new Mid-Point scheduling is not compliant with the start date of workorders in progress

·       Closed and cancelled workorders are not taken into account

·       Parallel workorders are scheduled with the same scheduled start date in forward scheduling logic or with the same scheduled end data in backward scheduling logic

·       Check to do not perform Mid-Point scheduling for workorders in progress status

·       Check to do not perform Capacity Leveling phase without having performed the Scheduling phase

 

 

Workorder Confirmation

new tool has been implemented for recording both actual times and quantities.

·       the following actual durations are to be entered:

◦     actual working duration (the planned one is suggested)

◦     actual setup duration (the planned one is suggested)

◦     actual teardown duration (the planned one is suggested)

·       therefore, the effective actual overall duration is calculated

·       workorder actual dates determination (Actual Scheduled Start Date and Actual Scheduled End Date) based on times declaration in forward mode by taking into account the working calendar set at Work Centre level

·       check to forbid partial quantity confirmation based on a Work Center indicator

·       check to avoid starting workorder without components availability (Forecasted Quantity available) based on a Work Center indicator

·       check to avoid to confirm produced quantity more than production quantity

·       check to produce quantity more than what already produced by the previous workorder

·       milestone operation can be confirmed and all the preceding workorders are canceled

·       check to avoid milestone operation confirmation if any preceding workorder is in progress status

 

 

·       all actual durations (i.e. Setup duration, Teardown duration, Working duration and Overall duration) are reported in time tracking section; the overall duration is determined (the Odoo standard provides the elapsed one only)

 

 

Production Order Closure

The following features have been implemented:

·       Actual dates (Actual Start Date and Actual End Date) are determined based on times declaration in Work Order Confirmation phase: the actual scheduled start date for the first workorder and the actual scheduled end date for the last workorder are taken into account

·       Actual Dates are determined for production orders without any workorder also

·       The manufacturing order closure cannot be performed if any workorder has not been performed

·       The components picking has to be performed

·       All the components are to be available, so the related quantities are reserved