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ENGINEERING AND MANUFACTURING PREPRODUCTION PLANNING

Work in Clobbi should be started with reference data  input, this is the system’s backbone.

Most of data must be added to documents from pre-completed reference books which minimizes or eliminates the chances for duplicate data from various sources.

 

Engineering preproduction planning, printing of engineering bills of materials

 

The main task of preproduction engineering activities is to create the register of specifications for products manufactured by a company (BOM means Bill of Materials to the MRPII standard). As a rule, this work is done by design departments staff. However, depending on functions distribution at a particular company, the preparations may be handled by staff of manufacturing engineering or production planning departments.

The system features the following options for operations with specifications:

  • Generation of BOMs used by the system up to the standards (ESKD – the GOST-based Unified System for Design Documentation). Printing (if needed) of specifications and sheets.
  • Generation of group specifications under A, B and E forms
  • Specifications for core and auxiliary production, design, engineering, process, repairs specifications
  • Support of alternative content of specifications and their periods

Desktop for this designer role looks as follows.

Desctop_of_designer

 

Main functions include specifications register, BOMs.

The key objective of the designer is to create and maintain updated specifications for all manufactured products. The most popular in terms of volumes of manufacture/sales items should be input into the specification database at first.

BOM Lines

BOM Lines

The designer can print specification reference standard shapes (e.g., Form A)

Bill of material A4

Bill of material A4

Manufacturing preproduction planning, printing of manufacturing process books

 

The main task of manufacturing preproduction is to have the up-to-date and unified information for all company services and units, that is:

  • Generation of multilevel bills of materials (BOM explosion)
  • Generation of route/operation flow for manufacturing of each part/assembly unit, detailing the operations sequence, material use standards, equipment utilization and labor standards.

 

The Clobbi system is able to generate different specifications at the different stages of the product life cycle, such as product specification / product checklist / precontract bill of materials, contracted bill of materials,
engineering and/or manufacturing bill of materials, planning  bill of materials for production order and other bills and specifications. In their production planning, most companies use engineering and manufacturing bill of materials for each production order that may be different from the baseline bill of materials, i.e. may be a modification of the basic product. See an example of a bill of materials in the figure below.

 

Structure of product

Structure of product

 

In order to reduce the engineering preproduction planning time, there is an option of creating a bill of materials taking advantage of Clobbi-CAD integration by importing the bill of materials directly from the 3D model designed in a CAD system.

You will then need to input route and operations manufacturing processes. In order to do so you will first need to fill in reference process data (job types, operations, machinery, worker jobs, …) and then input manufacturing processes, which handling is shown in the figure below. Upon input of each manufacturing process you can print the manufacturing process book to the
ESTD standard, with the book comprised of the title page, route and operations charts, sketch charts and tooling sheets,…) Bearing in mind that the Clobbi system is available for running on Android tablets and smartphones by workers, who receive tasks, it is recommended that videos of how to perform each process operation be recorded and added to each respective manufacturing process.

Quick input of process routes is available from the bill of materials.

 

Quick input of process routes

Quick input of process routes

 

This method of inputting process routes is rough-cut and requires additional control via design interface since some elements of the process route are not available in this interface.

See instructional video on quick input of the process route from the bill of materials

For more detailed description of operations of the process route use process route design interface featuring standards setting and recalculation modes as well as the possibility of linking additional printed forms of process documents.

Production engineering interface

Production engineering interface

 

After the process route has been assigned description, the route chart will be available for printing out, if required.

Photo - Route chart

 

Product process documents completeness and quality review

 

The integrity of product documentation can be analyzed using technical documentation completeness check mode. It helps to find unexploded assembly units, missing material use standards for a part, etc.

 

Testing completeness of technical documentations

Testing completeness of technical documentations

See the video “Testing of technical documentation completeness”

Many companies face a problem of substituting materials or purchased components that do not make an adequate match as intended by the designer or the process engineer. In order the replacement was possible, you should fill in the relevant registry. Upon approval the substitution becomes accessible to all interested roles – procurement staff, storekeepers, the planner, etc.

See the video for working with the permissions of the replacement materials

 

Specify tipe of norms

Specify tipe of norms

 

Process engineers will also have access to calculation and analysis of various consumption and other standards. A part of them is filled in at the time of creation of process routes and is available in a more convenient view by using the function Standards. Generic call. For example, you can easily find all parts made of a specific material or all parts and assembly units machined using particular machinery.

 

The second part of standard types is called summary standards. They are filled out with calculations based on bills of materials and relevant standards input. As a result we get e.g. summary standards of material and components consumptions per manufactured item.

Combined consumption rates of basic and auxiliary materials

Combined consumption rates of basic and auxiliary materials

 



Reference data

Read about reference data »

Reference data is kept in the directories described below. Please feed the directories following the described sequence. It is also advisable to assign an employee (or a team) to feed and maintain these directories.

Desctop of designer

Desctop of designer

Units Directory

 

This is a directory of company’s units. It should be fed with the list of major units of your enterprise (warehouses, shops, lines, branches, divisions, …). The start packet of the system has a pre-populated directory for simpler operation. You just need to adapt it to your company’s structure.

Structure of devisions

See the video how to operate the unit directory

HR Directory

 

Data about staff involved in Clobbi operation (design engineers, manufacturing engineers, seniors, workers, warehouse keepers, …) should be entered here. The Clobbi start packet has a pre-populated directory to make it simpler. Please enter the data of your employees following the available entries.

See the video how to operate the HR directory

 

Contractor Directory (purchasers and suppliers)

 

The list of major purchasers and suppliers should be entered into this directory.

See the video how to operate the organizations directory
See video how to add organizations’ contacts

 

Manufacturing Resource Directory (Classifier)

 

This directory is central in the system. It should be fed with all manufacturing resources: products, items, semi-finished products, parts, assembly units and their modifications, supplies, raw materials, standard items, equipment, fixtures, specifications etc.

When working with this directory, Clobbi has following active functions:

 

  • Hierarchical and faceted coding support when making the classifier
    • Hierarchical classification has up to 14 nested hierarchy levels
    • Faceted classification inside resource groups. There are random facets with set valid values (e.g. Steel Makes facet and the list of makes, or Metalware Quality Class facet and the list of quality classes, etc.).
    • Automated code generation for manufacturing resources following the set parameters and facet values
  • Supports of up to six units of measure per each code and unit conversion factors
  • Within the classifier, management of information about standard agents, counterparts in terms of materials, semi-finished products, parts, assembly units
  • Manufacturing resource description following set standards and calculation formulas
  • Registration of design parameters in the database (e.g. length, width, coating thickness, weight of an item, etc.)
  • Classified data consistency management, cascade information updates support
  • Management of access and zoning of design engineering services following the resource groups and user roles in classifier access
  • Classifier multi language support. English, Russian and Ukrainian are already available
  • Corporative classifier support: harmonization of classifications of different enterprises and entering of different parameters of enterprises for unified corporate code of resource.
  • Classifier implementation routines: managing harmonization, adding and modification of mix of materials, items, semi-finished products, fixtures …

For simple operation, the start pack has a pre-populated general engineering directory with over 1 000 facets covering almost all basic materials for the majority of manufacturing enterprises. You just need to add your products, assembly units and semi-finished products, special materials and equipment.

Groups_of_resources

For the first time, please feed the directory with your data with scrupulous care. You may update the directory later with the following system features.

Resources_classifier

See the video how to work with the resource classifier
Resources used in the finished products (assembly units, parts, materials and bought-in components) may be added to the resource classifier based on the previously created algorithm when Importing of BOM from a CAD-designed 3D model

 

 

After engineering and manufacturing preproduction planning has been completed, we can proceed to production planning and records.

 

Please also see other sections:

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