The Manufacturing Order contains all the information needed to begin production activity: the list of materials involved and the work process cycle, indicating what centres the work processes are to be done on.
The list of materials and the work process phase can be modified within the manufacturing order without changing its definition of the bill of materials. Such flexibility permits to manage extra or different discharges from the ones projected in the bill of materials so as to swiftly manage rushes or stocks; it also permits toset up any reprocessing phases in the event of finished products not compliant with quality requirements.
The discharge of a component only takes place when it is actually used : this is particularly useful when working materials with average-long production Lead Times.
The production order can be created using a number of procedures, but the MRP procedure is definitely the most efficient and complete.
The Picking List is the document that summarises the quantities to discharge and discharged for each component included on the list of materials, indicating the storehouse and location of the discharge.
It also indicates from which “lot” the inventory component is to be discharged from in order to have full Lot Traceability.
Beginning from the discharge voucher it is possible to know which inventory entries are linked to it.
Production development and confirmation
Using the Progress procedure that analyses availability of inventory materials, it is possible to decide which phases to send to production. The list of phases selected for a given production order and/or on a work centre forms the Work processing List.
The works progress can be constantly monitored using special control reports, which report differences in projected and already completed work processing times and quantities.
Even when work processing has already started, it is possible to change the work centre assigned to deal with an urgent job or unavailability for example. The new work centre can pass from in-house to outsourced or vice-versa, or the reference outsourcer may change.
The final balance of work processes provides us with the details of all the final balances made for each single phase of a given production order (dates, quantities, work process times etc…).
The control panel is an interactive tool that can be used, beginning from a job order, to enable a production order, item or combination of these to graphically display production status and the documents generated.
Manufacturing Advanced - Control Panel
Through the control panel the user can execute several operations without ever accessing the menu to retrieve the different procedures. For example, it is possible to launch the production order in production, execute progress, final balance, recalculate production costs, generate the subcontracting costs.
The management of Subcontracting makes it possible to consider the outsourcer part of your own set of production resources, thus providing maximum freedom in the organisation of the work cycles. So, in a single cycle we can find both in-house and outsourced work processing phases; each in-house phase can be executed by a different work centre and each outsourced phase can be executed by a different outsourcer.
The procedure recognises the need to prepare the additional documents necessary for the outsourcer:
- Supplier order for work processes to perform
- Transport document to send components to process
For the generation of the transport documents, Mago.net provides more than one simple procedure: this is a real tool to analyse the quantities available at outsourcers with possible proposal for reintegration.
It is possible to issue delivery notes also only for the quantities needed for production, or send higher or lower quantities to the outsourcer. Every time the delivery note is generated the quantities available at the outsourcer are indicated and it proposes reintegration of the quantities necessary to process the production orders that have been sent.
By registering the packing list of the material processed, the balance of the work processing phases of the associated production order will be automatically completed.
Manufacturing documents maintenance
It is known that work processes that were initially considered in-house for manufacturers have to be outsourced and vice-versa; it is also possible for material to be substituted at the last minute or other needs may arise: there is no situation that cannot be put right.
Mago.net provides the user with a series of procedures so they can manage the unexpected. For example, the RollBack procedure can be used to avert an erroneously balanced production order.
The need of streamlining both of manufacturing procedures and documents led to the definition in Mago.net of this new feature called Kanban because already oriented to management and scheduling of future production processes by using and monitoring of "Kanban-Cards".
It is possible to configure a less costly production in term of management for the desired items only defining them as Kanban, and ensuring uniformity of treatment in term of inventory entries, production processes and subcontracting management.
Simply through the characterization of a Bill of Materials as "Kanban type" when used inside other ones of higher hierarchy level it will be possible not create any linked production order, avoiding the resulting manufacturing management and planning, but going to manage the load, transfer, unload and cost of its materials and keeping track of time and cost of its routing steps and operations.