PRODUCTION RECORDS AND FLOW OF PARTS, SEMI-FINISHED PRODUCTS, FINISHED PRODUCTS
Recording of production events is an important part of the production management cloud service. In order to enjoy all benefits of use of MRP algorithms and APS\MES planning one has to find solutions to the problem of work output recording, movement and issue of materials and components, accounting of production-in-progress at production units and warehouses – the tasks easily handled by Clobbi.
The use of material flow accounting offers answers to the following questions:
- Which orders are currently in production?
- What operation is being performed on the part for each order in the production floor now?
- What is going on at each work center?
- Where, when defects was found? What was the amount?
All actions regarding production records can be carried out using a PC (a Windows desktop or laptop computer) and an Android mobile device (a smatphone or a tablet).
The Clobbi.Manufacture application is designed for online assignment of tasks and recording of information on the progress the manufacturing process.
The users of the application receive a convenient and handy tool allowing them to:
- Receive job assignments online
- Receive information of the status of production orders and production tasks
- Review drawings, process flows, output quota
- Record actual start and end of job processing in real time
- Record idle time of machinery including the reasons of downtime
- See the history of events on route charts
- Monitor the manufacturing process inside the shop
The start and the end of each operation must be recorded in Clobbi. There are several ways to do so: using manual input of job start/end note in the shift task and the route chart, using barcoding, etc.
Recording of completion of an operation involves inputting information regarding actual amount of work performed – the quantity of machined parts and assembly units, parts spent for process needs, rework and scrap.
It also involves recording of movement of batches of parts and assembly units between work centers and production units as well as work centers idle time.
Material flow production records
Clobbi applies the desktop-oriented approach to production records, i.e. once information on production progress is recorded it further automatically calculates stock of materials in process, recording of different process events and monitoring of production plans.
Traditionally, a company will have three, normally independent of each other, types of production records:
- production records as records of production and transfer of of semi-finished products between company units (parts and assembly units)
- records of availability and issue of raw materials, materials, parts
- records of labor and payroll for main direct labor and matching them with the output of products/semi-products/parts and assembly units
The primary production documents here are:
- Operations per part work output report containing retirement lines
- Transfer note
- Defects reporting and handling documents
The above documents are formed by the service upon running online registration of process events automatically.
The basic document of production records is output report, which combines several functions –
both that of recoding operations per part work output, and materials/constituents used for output, and standard wages accounting, and costs accrual. This eliminates any possible discrepancies, doctoring and conflict of different accounting and reporting systems.
The work with the work output report is done in several stages:
- Creation of the document heading
- Creation of work output lines
- Creation of retirement lines
- Stock selection, substitution
- Document posting
Production records process shall start with the work output reports of blank production shops and followed on along the process route by machining and, ultimately, assembly departments.
Parts and Assembly Units Transfer Notes are used to move them between the shops. Work with them is similar to work with Requisition Request for issue of materials and components.
Once the process of recording of output of parts, minor components and their transfer to assembly facilities is up and running, we may proceed to running accounting in assembly shops themselves. Recording and posting of work output reports for all operations of the product manufacturing process route in the Clobbi service will result in an finished product entry in the card file of the assembly department.
The manufacturing process may not always run as it is supposed to. In this case a Reworking Report or a Scrap Report is drawn.
Finished products and all things we are to ship to customers must be shifted to the finished products warehouse by creating the document Transfer of Products to Finished Products Warehouse.
Work centers status analysis (3D shop)
To ensure sufficient speed of response to events in the production departments one needs to be able to get current information about the manufacturing situation in these units.
The Clobbi service has tools for tabular and visual representation of work centers with real-time display of events underway, while real-time accounting at the workplaces, tabular and visual representation of the work centers allow for all events going on in the production units to be displayed on the dispatcher’s monitor in a human-friendly style.
The 3D shop feature is provided for visual control of production units:
Each work center has a 3-color status bar and a note with more details about its status and its job on hands.
The main event instances in production include the start and the end of the batch for each part or assembly unit as well as the moment the work center goes idle.
Each work center is represented as a picture or a 3D model with the status bar (event indicator) and the note with details of the work center status nearby.
Tabular representation of work centers is provided to sort out and select work centers by different parameters:
Analysis of work-in-process stock balance
All plans have the Plan and Actual columns. The Actual columns are filled in automatically when execution of respective plans is calculated on the basis of production records and and work-in-process balance card files. There is no need for manual input of actual quantity. In addition to filling in the Actual column, this calculations also prepares analytical data regarding the need in current work-in-process balance and its workability for future periods.
Production records are an integral part of production planning and purchasing management since production records keep information on completed jobs and status of production units stocks up to date. In addition, the data obtained as a result of keeping production records serve as underlying data to maintain updated actual production costs.
Please see sections of Clobbi production management: