Maintain flow time standards for each work step or operation
Maintain process routings for product groups and part types. These routings should be modular in design to accommodate alternate processing steps for certain jobs.
Maintain work center definitions for all work centers
Maintain standard routing operation process times to accommodate:
Setup time
Run time
Queue time
Move time
Wait time
Machine time
Maintain input/output standards by:
Routing operation
Work center
Measure standard to actual input/output by:
Routing operating
Qork center
Maintain work center resource capacity data
Use same routing for multiple part numbers
Maintain routing and work center data online
Provide an audit trail of all routings and work center maintenance transactions
List routings by part number and revision
Provide a primary and alternate routings for the same part number
Provide alternate operations and/or work centers for a given routing operation
Provide routing effectivity control by:
Revision level
Date effectivity
Rrelease flags
Specify different routing operation types and separately track labor hours and material charged to each type:
Standard
Rework
Outside processing
Inspection
Other
Maintain routings operation effectivity by:
Create routings similar to others through a sameasexceptfor(copy) transaction
Express production rates for operations as standard hours/unit, or hours for the operations.
Maintain open work order file that:
Shows detailed routing for all open orders both online or in a printed report
Accept Work Order status maintenance (add, change or delete) online with proper security
Accept operation feedback maintenance
Generate move tickets
Accept changes to work order due date
Provide for splitorder capability
Accept changes to work order quantity
Display online the status of all open work orders. Data elements should include:
Provide an audit trail of all shop floor transactions for reconciliation
Report performance of scheduled versus actual output by:
Part number
Order number
Employee
Work center
Machine
Provide order status and tracking online for all orders released to production.
Track workinprocess by:
Report volume of work in queue by work center and identifying work in the preceding work center
Issue shop packet documents (e.g., picklist, work order routing, etc.) when the order is released to production
Track rework operations and rework orders and separately account for the labor and material charges
Display online status of all open work orders by:
Transfer quantities from one order to another while both orders are in process
Automatically identify the required tooling for the work order
Estimate actual material, labor, overhead and burden cost at any time after work order has been released
Develop ad hoc routings unique to a work order
Accommodate both repetitive and discrete manufacturing orders
Report labor, setup and run variances by operation on work orders
Check availability of material and capacity prior to releasing work orders to production
Report downtime levels by:
Report:
Report percent of capacity utilized by various resources:
Machines
Work centers
Employees
Generate reports which identify deviations from planned routings
Identify the individual who reported completion of an operation on the work order
Generate and schedule rework orders on the shop floor for warranty returns. This should include linking the rework orders to the customer return order and separately tracking these rework type orders
Report scrap and record the labor and material related thereto for assessment of scrap costs
Identify and report over-production and record labor and material related theretofore assessment of the financial impact on inventory valuation
Interface to automated data collection devices to record work under transactions including quantity movement, and scrap. The reader devices may be independent and separate from the video display terminals/keyboards
Track lot numbers of raw material from stockroom through shipment and allow for history accumulation. The lot numbers must provide an audit trail to the work order numbers, item numbers, and customers. NOTE: Work orders may contain more than one lot number.
Track item serial numbers from stockroom to work orders and onto customer shipment
Track lot quantities separately for split orders
Track work orders which require some outside processing by a subcontractor
Compare actual yield to standard for work orders and to trigger revision to subsequent work orders for the same part number and sales order to insure sufficient quantity for shipment
Designate a minimum percent yield for a work order and provide an online flag if this yield is not obtained
Write additional rework and outside processing operations into the existing work order routing
Replace a given operation with one or multiple operations on a work order routing
Utilize either a primary or alternate routing for the work order assembly
Identify alternate operations when reporting on actual work order material, labor and outside processing charges.
Enter via a work order transaction the item number and revision level of the documents and software used to build and test the work order assembly (e.g., assembly procedure, test procedure, test software, etc.)
Automatically carry over and maintain existing work order component transactions when:
Move work order assemblies to stock, MRB, rework, scrap or another work order by the designated serial and/or lot number
Daily Work Center Report – Lists by work center the item numbers, quantities and condition (e.g., rework/repair or good) of all work orders located at the work center
Production Order Status Report – Lists by item number with the status for all open orders. Typically, the due date, scrap and rework reported, and amount completed on the order provide the basic report elements.
No Activity Report – Lists each open order that has not had any activity reported since a specified date
Work Center/Department Workload Report – Lists all open orders on a priority or due date sequence which are in queue at the work center
Work Center Job Schedule Dispatch Report – A listing that provides detailed information on the quantity and status of all material at a work center listed in the priority sequence that the jobs should be worked.
Resource Utilization Report – Measures the utilization of equipment or machine groups by work center. The report could be formulated to display machine busy, idle, and down time
Detail Load Report – Lists each scheduled job within each work center broken down into weekly periods. This detail can be extended out to a meaningful horizon, typically two to four weeks. Data elements could include item number, order number, order status, operation start data, and capacity statistics
Employee Labor Performance Report – A weekly listing by employee showing the jobs worked on, total direct hours, total indirect hours, output in standard hours, percent efficiency, and percent utilization
Work Center Labor Performance – A report similar to the Employee Labor Performance except broken out by work center
Routing Master File Listing – Printed upon request, this report lists all routing information by operation within part number. The report should optionally be printed for either selected parts or the entire file.
Department/Work Center Master File Listing – Printed upon request, this report lists the contents of the Department/Work Center Master File
Labor Cost Variance Report – Printed upon request, this report lists standard labor cost and variance by Part Number/Work Order
Work Load in Outside Processing – Lists all work orders currently routed to outside contractors. It indicates the work order number, end item number, subcontractor, purchase order, job status, priority, due-out date, open quantity, and current status reason/remarks.
Slow Moving/Past Due Orders – Lists by responsible planner or work center all open work orders that have not been completed by the due date and/or have not had any reported activity (units completed or operations completed) within a specified time period. It indicates the work order number, job status, priority, due date, last activity date, remaining quantity, remaining standard hours, and current status reason/remarks.
Outside Processing Past Due – Lists all open work orders routed to outside contractors that have not completed the outside processing operation by the scheduled due date. It indicates the work order number, assembly number, job status, subcontractors, priority, due-out date, quantity and current status reason/remarks.
Material Shortages by Work Order – Lists by responsible planner all work orders that have component shortages. A shortage is a component item request against a work order for which a back order has been established. This report indicates by work order the component part number, description, quantity requested, quantity short, due-in date and status reason/remarks.
Material Shortage by Component – Lists by part number all component shortages. A shortage is a component item request against a work order or charge number for which a back order has been established.This report indicates by component part number, the work order (charge number), quantity short, due-in date and status reason/remarks.
Shortage Priority Monitor – Lists all shortages that are high priority. It indicates by work order (charge number) the component part number, quantity requested, quantity short, due-in date and status reason/remarks.
Work Center Completion Report – Lists by work center the work orders reported as having to completed assembly quantities. It indicates the work order number, item number, quantity completed, unit cost, total cost and status reason/remarks.
Rework Report – Lists by work center the work orders reported as having to rework assembly quantities. It indicates the work order number, item number, quantity reworked, unit cost, total cost and status reason/remarks.
Rework History – Lists by work center current week, monthtodate, quartertodate, and yeartodate, work orders with reworked assemblies. It indicates the item number, description, work center quantity reworked, unit cost and total cost.
Scrap Report – Lists by work center the work orders reported as having to scrap assembly quantities. It indicates the work order number, item number, quantity scrapped, unit cost, total cost and status reason/remarks.
Scrap History – Lists by work center current week, monthtodate, quartertodate, and yeartodate, work orders with scrapped assemblies. It indicates the item number, description, work center quantity scrapped, unit cost and total cost.
