Requirements - Shop Floor Control (SFC)

Overview

The principal objectives of a Shop Floor Control system are to monitor work-in-process inventory with the minimum amount of money, time and effort invested, and provide current shop floor information to assist management in its efforts to control production effectively. To accomplish this, a complete shop floor control system should satisfy each of the following criteria:

• A shop floor control system should track and status work in process inventory as it passes through the shop.
• A shop floor control system should schedule manufacturing work orders in a desired priority and issue dispatch lists to control shop priorities.
• A shop floor control system should provide timely and accurate feedback on plant activities that are not proceeding according to plan.
• A shop floor control system should provide factory labor efficiency and machine utilization statistics.
• A shop floor control system should provide manufacturing accounting information so that plant operations reflected in company financial statements are derived from the same sources as manufacturing operating statements.

The system monitors the actual events on the shop floor in support of the capacity plan. It must also maintain a routing file to be used in printing work orders and developing standard costs. The system must provide for online reporting of labor inputs as well as material movement.

Routings and Work Center

• 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:
• Date
• Revision letter
• Create routings similar to others through a sameasexceptfor(copy) transaction
• Express production rates for operations as standard hours/unit, or hours for the operations.

Production and Scheduling

• Maintain shop order priority system which dates the orders and allows for tracking and revising priorities
• Process infinite loading of shop orders
• Process finite loading of shop orders
• Provide online a daily dispatch list shoring the shop schedule and priorities:
• By planner
• By work center (including outside contractors)
• Reschedule past due orders so the revised dates can provide feedback to the master schedule
• Automatically back schedule orders based upon the job routings
• Automatically forward schedule orders based upon the routings
• Automatically establish work order priorities based on the "critical ratio" calculation. This calculation measures the standard time remaining to complete the job compared to the time remaining to reach the due date; jobs with the smaller ratio of time remaining to standard hours remaining receive a higher priority.
• Generate repetitive daily production schedules as a:
• Rate (units/hour)
• Total units required
• Provide overlap operation scheduling to start a job in an operation before all quantities have completed the previous operation.

Work Order Tracking/Status/Processing

• 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:
• Order status
• Order location (quantity per work center)
• Component shortages
• Rejections by operation
• Close short
• Quantity in rework/repair status
• Quantity completed
• 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:
• Operation
• Group of operations (report one operation and all preceding operations are reported)
• 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:
• Work order number
• Part number
• Planner
• Sales order (reference) number
• 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:
• Work center
• Machine
• Report:
• Run variances by work center
• Set up variances by work center
• 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:
• New work order number is generated to replace the original
• Split-order is generated from the parent work order
• Move work order assemblies to stock, MRB, rework, scrap or another work order by the designated serial and/or lot number

Work order material tracking

• Generate kit lists for a work order using the appropriate bill of material:
• Upon release
• Reprint ondemand
• Generate kit lists for a work order using the appropriate as-planned configuration effectivities by:
• Date
• Serial number
• Lot number
• Via a single transaction to issues all kit-list required quantities by:
• Work order number
• Work order and operation number
• Work order and work center
• Issue a single item number by work order (used for issuing shortages, individual serial number and/or lot number quantities)
• Maintain shortages by:
• Work order
• Work order operation (work center)
• Maintain inventory allocations based on release work order required (unissued) quantities
• Track and report on the issue of unplanned material by:

• Work order

• Work order operation (work center)
• Work center
• Transfer material from a work order to stock or other inventory location (e.g., MRP, scrap, etc.) from any operation on the routing
• Maintain all of the material issue, transfer and return transactions history for a work order
• Perform a material transfer from one work order to another also transferring the corresponding material cost.

Work order serial number and lot tracking

• Transfer material from a work order to stock or other inventory location (e.g., MRB, scrap, etc.) and automatically maintain contract cost integrity
• Maintain all of the material issue, transfer and return transactions history for a work order by:
• Serial number
• lot number
• Move work order assemblies to stock, MRB, rework or scrap by the designated serial and lot number
• Perform a material transfer from one work order to another and automatically maintain contract cost integrity
• Record serial number(s) or lot number(s) on all work order material transactions:
• Issues
• Returns
• Moves
• Transfers
• Have multiple serial or lot numbers for the same component item number on a shop order (e.g., for item number to have issued from Lot Number A and from Lot Number B)
• Validate serial number and lot numbers on all work order material transactions
• Track/disposition the work order assembly quantity at each operation as being accepted, rework, scrap or sent to MRB by:
• Quantity
• Serial number
• Lot number
• Reason code
• "To" operation
• "To" stockroom.

Reports

• 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
• Lead Time Report – Automatically calculates the lead time roll up for all orders at a work center and builds new lead times for setting due dates on new orders, sequenced by item.
• 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.

Interfaces

• Work Center and Routings – The routing work center files are used in tracking work orders.
• Master Production Schedule – SFC provides completion dates to the MPS.
• Material Requirements Planning – Firm and planned work orders are shared information between MRP and SFC.
• Inventory Control – Material transactions and allocation requirements interface with the SFC work orders.
• Bill of Material – The Bill of Material required to support the production of the parent part is required information for SFC.
• Manufacturing Cost – The SFC open work order status is used to calculate the value of workinprocess.

Routing Field Sizes

• Routing name
• Routing description
• Routing revision level
• Routing type (standard, rework, outside processing, etc.)
• Routing ineffectivity date
• Routing outeffectivity date
• Operation number
• Operation description
• Operation sequence number
• Operation ineffectivity date
• Operation outeffectivity date
• Operation work center
• Alternate operation number(s)
• Changeover hours
• Setup hours
• Run hours
• Move/queue hours
• Labor grade required
• Tool number
• Special instructions.
• Operation overlap factor
• Group technology indicator.

Work Center Field Sizes

• Work center number
• Work center description
• Number of shifts
• Number per shift
• Number of machines
• Number of people
• Capacity
• Efficiency
• Labor rate
• Overhead rate
• Run hours at standard
• Run hours at actual.

Work order field sizes

• Work order number (W/O)
• Sales order number(s)
• Part number
• Part description
• Unit of measure
• W/O status
• W/O quantities
• W/O scheduled start date
• W/O scheduled completion date
• W/O actual start date
• W/O actual completion date
• W/O completed quantity
• W/O scrap, quantity
• W/O priority
• Lead time
• Planner code
• Product code
• Work order comment codes
• For each operation necessary to complete the work order
• Operation quantity started
• Operation quantity completed
• Operation quantity scrapped
• Operation standard changeover time
• Operation standard setup time
• Operation standard run time
• Operation actual changeover time
• Operation actual setup time
• Operation actual run time
• Operation scheduled start date/time
• Operation actual start date/time
• Operation scheduled completion date/time
• Operation actual completion date/time
• Operation employee code.