Manufacturing Workflows

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Manufacturing workflow (Routing) is a tool which allows to define the required activities to fabricate a product taking into account the process sequence, how long does it take the node (operation) and where it should be done.

To use ADempiere Workflows gives you a great flexibility for describing the production process.

It answers the question: How should the product be made?

Contents

Manufacturing Workflows(Routes and Processes)

To create Work Flows of Manufacturing double click on

  • Manufacturing
    • Manufacturing Rules
      • Manufacturing Workflow
        • Manufacturing Workflow.

The next window will be displayed.

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Figure 1.1.2.1

The Manufacturing Workflows Window allows you define the Workfow to fabricate a product in any Organization of the Client (organization *) or in a specific Organization.

You must use the Manufacturing Workflows tab to enter the general information, Type the Name to identify this specific workflow. If the workflow name is the same as the product name this WF will be the default Wf for the product. Then enter a Description if you wish.

Tick the Is Routing chek box and the Process Type and Resource fields are displayed.

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Figure 1.1.2.1.1

The Process Type is selected among several options depending on the characteristics of the process you want to manage. The Process Type is only a reference and has the next valid options according with the APICS classification:

Continuous Flow: Continuous flow usually refers to the production or processing of fluids, wastes, powders, basic metals, and other bulk items. An oil refinery crude oil into various petroleum products or a pipeline for water, oil, or natural gas are examples of continuous flow manufacturing and distribution processes.

Dedicated Repetitive Flow: Discrete parts such as shafts and connecting rods and discrete assemblies such as microcomputers may be produced by a repetitive flow process. The term dedicated implies that the production facility produces only one product, including product variances (such as color) that require no setup delay in the manufacturing process.

Batch Flow: Is functionally the same as the continuous or the repetitive, except two or more products are manufactured in the same facility. Because of long setup times in the batch flow shop, manufacturing runs for each product typically last several hours or several days.

Repetitive Flow Mixed Model: It is also used to manufacture two or more models. However, the changeover time between models is minimal, and the different models are intermixed on the same line.

Job Shop: is characterized by the organization of similar equipment by function (such as milled,drilled, turned, forging, and assembly). As jobs flow from manufacturing resource to manufacturing resource a different type of operation is performed in each manufacturing resource.

Fixed Site (Project): It has the main characteristic that the materials, tools and personnel are brought to the manufacturing resource where the product is going to be fabricated.

The Resource field is a reference of the manufacturing resource where the work will be made (Plant).


In Batch Size you give the product quantity witch can be done by each batch. If we are going to produce more than 1 batch the system will schedule several batches in the manufacturing resource (production line), the quantity of each one will be taken from the pack size quantity to get the MO quantity required.


Data Access Level field shows the access level to this record.


In the Work Flow Responsible field you enter the person, rol or organization in charge of the Work Flow.

Priority indicates how important is this entity, the valid entries are Hight, Medium or Low.


In the field Valid From-To is registered the time period into which the Workflow is valid.

The Document Number is allocated by the system and it comes from the sequence defined in the Document Sequence menu option.

Author is the person that created the record.


The Starting Node shows the first activity (node) of the work flow.


Finally, in the Manufacturing Work Flow Tab you can see the fields group Time, the fields included in this group are:


Accumulated Time: currently is a reference where you enter the total time required to to accomplish every node of this WF.


Queue Time: Currently is a reference where you enter the accumulated queue time for this WF. The Queue time is the time usually taken since the previous operation is finished, or the components were issued from the warehouse, until the current operation in a manufacturing order starts its process.


The Setup Time Currently is a reference where you enter the accumulated Setup time for this WF. The Setup time is the time required to execute the necessary activities in a manufacturing resource to be able to start the manufacturing process.


Duration WF: Currently it is a reference where you enter the accumulated Duration for this WF. The Duration WF is the normal duration of a job, in duration units.


Duration Unit is the time unit of measure for this group of fields (e.g. hours, minutes etc). Every time recorded in this work flow will be referenced at this Duration Unit.

Waiting Time: Currently is a reference where you enter the accumulated Waiting time for this WF. The Waiting Time is the time a job remains at a manufacturing resource until it is moved to the next operation or to the warehouse it the operation is the last one.

Move Time: Currently is a reference where you enter the accumulated Move time for this WF. It is the estimated time to move the material thought the manufacturing resources.

Clicking on the bottom Validate Work Flow it verifies that the work flow does not have errors.

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Figure 1.1.2.1.2

When the process validation is finished it shows the message correct (OK) if the work flow is correct (with a limited verification).

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Figure 1.1.2.1.3

Next you must introduce each one of the operations that take part in the the product manufacturing, for this you use the Node Tab.


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Figure 1.1.2.1.4

In the Node Tab is introduced the Name to identify the operations from the manufacturing routing. If desired give a Description for operation.

From the selection list Resource select the manufacturing resource (previously defined) where you want to execute the operation. For the product costing, the Resource rate is taken from the cost element introduced in the window Product Costing.

If the check box Is Control Operation is selected it will indicate that in this operation you will report the real time used in the operation and that for all the previous operations, until the last control operation, the standard time will be used as real time. (this feature will be used in the Shop Floor Control Module).

If the check box Is Subcontract is selected, it indicates that this operation will be executed by an external Resource.


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Figure 1.1.2.1.5

When you enter dates in the fields Valid From – To we give the the period of time where this operation will have to be considered for the elaboration of the product.


In the Workflow Responsible field you enter the responsible for this node. It can be one of the following types; Human, Organization or Rol.

Unit Cycles is the number of products that can be produced in the time unit of measure from the manufacturing resource. This data is used instead the Duration field where you enter the required time to execute an operation for one product.

Overlap Units, is the minimum number of products you need to finish in the current node before you can continue with the next node.

Working Time: Work Flow simulation execution time. Currently is just a reference field.

The Queue time is the time usually the product will have to wait at this node before starts to be processed.

Setup Time is the required time to execute the actions of preparation of the resource specified in the node to be able to start the manufacturing process. To make the manufacturing schedule using the technique both forward and backward, the setup time is considered only once for every node in the manufacturing order.

Duration: The planned standard time to produce one unit of product in a node.

Waiting Time: Is the time a job remains at a manufacturing resource after the node is finished until it is moved to the next operation. or to the warehouse. (e.g. for drying)

Move Time is the time that a job spends in transit from one node to another in the plant.

Once all the required nodes (operations) have been entered for a manufacturing process you must set the node sequence, this is done selecting the Transition Tab.

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Figure 1.1.2.1.6

The required information to establish the sequence of the nodes is in the Node Tab and in the field Start Node field introduced in the Workflow Tab.

To be able to do a Manufacturing Schedule both forward or backward, the system uses the characteristics set in the Node tab and the sequence from the Sequence tab.

Work Flow Editor

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Figure 1.1.2.2

By Work Flow Editor it is possible to visualize in a graphic mode the operations of the production process and its execution sequence. At the same time you can see the information registered in the fields: Name, Description and Help from the Work Flow window.

When you select the zoom icon you get the Workflow window.


Bills of Material & Formula

It is a list of all the subassemblies, intermediates, parts and raw material that go into a parent assembly showing the quantity of each required to make an assembly. There are a variety of display formats of bill of material, including single level bill of material, indented bill of material, modular (planning), costed bill of material, etc. May also be called “formula,”, “recipe”, “ingredients list” in certain industries.

It answers the question, what are the components of the product?

Bills of Material &Formula

When you click the menu option Manufacturing < Manufacturing Rules < Bill of Materials & Formula < Bill of Material the Bill of Material Windows is displayed.

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Figure 1.1.3.1

In the Bills of Material Tab the following fields are required to identify in a specific way the bills of Material: Client, Organization, Search Key and Name.

Additionally with the Engineering Change Document number you can track the modifications made to the BOM. The sequence of the ECD is allocated by the system using the Sequence entered for this Document Type.

In the Bill of Material tab the following fields are required: Client, Organization, Search key and Name to identify in a unique way the bill of material and the Engineering Change Document Number used to track the modification.

The Revision field shows the number of revision you have made for this BOM and the Valid from and Valid to indicates the valid period for this BOM (In that period you can use de BOM in a manufacturing order).

The product field along with the product instance identify the parent product. The manufacturing Unit of Measure is also introduced and it will be taken into account for the quantities entered for the components.

The BOM Type is the same one used in the Product Window, in the BOM tab for the parent product. The valid options are Optional Products, Alternative Groups and Standard Part. To get more information around BOM please refer to the Chapter 5 of the Compiere User Manual.

Then you introduce the detailed information around the BOM for every component using the BOM tab.

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Figure 1.1.3.2

The required information in the Bill of Materials is the Product child and the Attribute Set Instance.

The Valid From and Valid To dates indicate the valid time period to use the BOM in a Manufacturing Order.

The Component Type Selection List has the next options:

Component: identify a raw material, ingredient, part, or subassembly that goes into a higher level assembly, compound or other item. Byproduct: This entity is a non scheduled product gotten as a consequence of another production process. It has a sales value but it is minimum.

Phantom: indicates the product is a fictitious assembly, that is to say, a set of components that are grouped only to make easier the analysis in a separated way from the rest of the BOM. When the MRP generates a requirement of the phantom and the projected on hand is not available, the process goes to the lower level and start a new MRP cycle but does not create Planned Orders for the phantom product.

Packing: This product will not be taken into account to calculate the total quantity of components when the IsQtyPercentage check box is ticked.

Planning: The parent product will be used for the planning process of the different options of similar products. (e.g. 30 % bread with fiber and 70 % bread without fiber)

Tools:The product is a tool which is going to be used in a production operation.

If you click the IsQtyPercentage it means you need to introduce the quantity of the componenet as a percentage of all the components. If you do not click the IsQtyPercentage checkbox then you need to introduce in the Qty field the quantity of the component to produce a unit of measure of the parent product.

If you click IsCritical checbox, a Manufacturing Order will not be released to the shop floor if this component is not on hand.

In the Assay field you enter a percentage of components that will be used to make a test.

The Scrap field is introduced as a component percentage factor that is expected not to be useful as a part of the parent production.

he Issue Method field permit you to select between Issue or Backflush, if you choose issue you need two steps, first you issue the components from the warehouse and after production you need a second warehouse movement of receiving the finished product into the warehouse.

If you choose backflush in one single movement you receive the finished product in the warehouse and automatically you issue the components required from the warehouse.

The Backflush Group is used in order to group components that you want to issue together in a Backflush process.

Lead Time offset is the number of days after you start to produce the finished product when you need this component.

Forecast is the percentage we expect to use of this component to produce the finished product. It is used to make plans of getting components and it has a BOM type of Planning BOM and you can not use this BOM for a manufacturing order.


Bill Of Material & Formula review

The BOM & Formula Review option menu shows in two different panels the parent-component relationship for the product entered in the Product field.

You need to introduce the parent product you want to see its components then click the OK button, next drag the left margin of the panel to the right and you will have the two panels.

When you need to consult an implosion, click the implosion check box and enter the component you wish to consult and tick the Implosion check box.

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Figure 1.1.3.3

The left panel shows the BOM hierarchies in a tree form. The right panel shows the information connected with the BOM for every product in it. To get more information around the meaning of the fields please refer to the upper section of this Chapter.

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