Académique Documents
Professionnel Documents
Culture Documents
Manufacturing
Discrete Manufacturing
Automobiles, computer, dishwasher and washing machines
Flow Manufacturing
Lean or JIT
Process Manufacturing
Food, pharmaceuticals, etc.
Formulator
The Formula Management module facilitates entering information about how products are manufactured. Formula:
This helps us in pre define the quantities of ingredients we
need to make the product
Process Engineer
Routing:
This helps in define the steps, operations, resources and sequences of all these to make the
product.
Recipe:
This is to combine Formula with Routing and specify when this combination is valid. Formula + Routing Recipe
Formula
Scaling Allowed checkbox is to scale the product and ingredient quantities up & down. Packing checkbox is to just differentiate production formula from packing formula. Calculate Product Quantity: ingredient input quantities and their yields to calculate final product quantity.
Formulator Formulas
Entering Products
Quantity, UOM, Scale Type, Yield Type, Cost Allocation
Entering By-products
Quantity, UOM, Scale Type, Yield Type, By-product Type
Quantity, UOM, Substitution Effective Date, Scale Type, Scale Multiple, Scale Rounding Variance, Rounding Direction, Consumption Type, Contribute to yield, Contribute to Step Quantity, Phantom Type, Buffer, Scrap Factor
Entering Ingredients
Formula Statuses
Formula Status is changed as per the use of the formula. -Approved for Laboratory Use, Approved for General Use, Obsolete/Archived
Formula Statuses
1. New to make changes at any time, assuming you have security access. Default. New is default and we can change it to 2,3,4 statuses
2. Approved for Laboratory Use for use in laboratory batches and cost rollups for the laboratory. 3. Approved for General Use for use in production batches. 4. Obsolete/Archived to specify the object can no longer be used unless the status is changed. 5 & 6 statuses are usually after it is assigned to status 2,3,4 5. On Hold to specify the object cannot be used until the status is changed. 6. Frozen to prevent any further changes to the object and any dependent data.
Routing is an optional setup in OPM. It is very important and useful in detail study of the process and improvising it through activities and planning and scheduling the Resources to use them in optimum way. A routing is a sequenced set of operations to perform to complete a production batch. The operations are presented in a series of steps that organize these operations into an orderly set of activities that have individual resources associated to them.
Routing
Routing
Step (Operation)
Resource
Activity
Activity
Process Engineer Setup Activities
Activities are the actions performed during the production process and are set up to divide a manufacturing process into logical breakpoints. By analyzing and refining the granularity of activities, businesses can improve their work methods and reduce time to manufacture so that activities performed in operations are completed in the shortest possible time with the least effort to deliver the appropriate level of quality.
Generic Resource
Process Engineer Setup Plant Resources
Resources are assets used for production like Production Equipment & Employee Labor Define all the resources generally (eg. Blenders) or specifically (Blender1, blender 2) Resource class are for grouping the same kind which is optional Cost component class are for costing purpose (kind of cost for the resource)
Process Parameters
Process Parameters are resource parameters that are used to use the resource in safe and optimum level like temperature, speed of the spindle and pressure. We specify the target value, minimum and maximum values with units.
Plant Resource
Process Engineer Setup Plant Resources
A single resource can be used for different purposes in different inventory organizations and this might vary the capacity of the resource from one organization to another. So a resource should be defined at every inventory organization separately and should be enabled to make it available for the scheduling and planning. Resource Information window is used to enter the specific resource information for the inventory organization. Resource information window contains
Costing information Resource usage UOM Capacity Planning availability of resource in each Inventory organization for scheduling and planning. Process parameters can also be defined for specific inventory organizations.
Resource Information
Inventory organization information in the header
Process Operation
New Operation
Process Engineer Process Operations
Cost Information
Routing
Process Engineer Routing
Recipe
Process Engineer Recipes
Recipe
Process Engineer Recipes
Production Supervisor
This is to record the information regarding the production scheduling and actual production through FPO(Firm Planned Order) and Batches FPO:
This is to make schedules for the production depending on the requirement like make to order and stock
Batch
This records the actual production in batches
FPO is converted into one or more batches or we can make a new batch directly.
FPO Details/Actions
FPO status
The status of EPO remains as pending till the whole quantity is converted to batches. The remaining quantity will be reflected when you try to convert to batch again. The Planned Qty is the remaining Qty available as per FPO for making the batch.
Batch Details
Batch details form showing the Recipe, Dates, Ingredients, Products, By-Products and their quantities with other parameters.
Releasing a Batch
Releasing a Batch is actually making it available for production. This will change batch status into WIP
Batch Steps are the steps/operations defined in the routing. Batch is made based on a recipe and a recipe is attached to routing.
Batch Steps
Material Transaction
This window is used to WIP Issue the ingredients (consume from the inventory) and WIP Complete the Products and By-Products (Generate the Product into inventory).
While issuing an ingredient, we can use this form that displays the availability of the item in the inventory as shown below. Defining picking rules will help in picking the items using pre defined strategies.
Material Exceptions
Once we are done with Select Available Inventory, the Material Exceptions window allows us with proceeding with the transactions with all the details as shown below.
Batch Completion
After all material transactions and completing the steps, when the production is done, the batch is completed. Batch completion ways
Complete from WIP: In this the batch is first released where the start date is mentioned and then while completion the completion date is mentioned. Direct complete: in this the batch is directly changed to status complete. Here we should mention the start and completion dates at a time and the application directly guides us to the material transaction window.
Batch Release
Direct Complete
Quality
Quality: It is conformance to standards or requirements. Standards are set based on the need. Anything that is manufactured or any service that has been delivered posses a need for it. When there is a need there is even a measure of need and the quality is all about how good that need is met. The point is customer is only satisfied when his needs are fulfilled. The quality of a product or service is not just meeting the physical standards but it also depends on the time frame. The needs are to be fulfilled in the way they are needed and the time they are needed. The most important part of quality management is the successful communication of quality requirements from receipt of incoming materials to the shipment of finished goods. OPM Quality Management provides notification and approval workflows to control quality throughout the supply chain. There should be proper sampling plans made to pick the samples at stages of material where they are needed which is error prone due to the complexity of tracking. OPM Quality enables us to make sampling plans attached to specification.
Test
Specification
In quality, the tests, sample plans are defined in general and are not assigned to any organization in particular. There is 1 to 1 mapping for test and test methods. Test Methods can be optionally defined for single organization and Item if required. The purpose of Specification is to ensure the quality conformance of materials, such as an item or a lot, or for environmental conditions, such as a resource or a subinventory locator. The process of quality conformance needs one or more tests to be performed at a time on different samples. So we need to group tests and sampling plans as required either for a item or a resource or a subinventory locator.
Specification
Specification
Monitoring
Item (Item/Lot)
Resource
Locator
Specification - Item
Product Samples
Results Entry