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Work Order Plus Management Manual 1

Work Order Plus Management Manual

Introduction

Chapter 1: Monitor Interfaces

Work Center Operation/Inquiry

Application Overview

Views

Production-Related Operation

Department Operation/Inquiry

Application Overview

View

Work Order Inquiry

Application Overview

Views

Production Inquiry for Work Order

Application Overview

Views

Production Inquiry for Operation

Application Overview

Views

Production Activity Maintenance/Inquiry

Application Overview

Views

Production Detail

Application Overview

Inquiry Mode

Add Mode

Reporting Mode

Maintenance Mode

Operator Time Clock Inquiry/Maintenance

Application Overview

Views

Chapter 2: Reports

Production Schedule Report

Application Overview

Run Instructions

Work Center Rough Cut Report

Application Overview

Run Instructions

Single Level Where Use Report by Order

Application Overview

Run Instructions

Production History Report for WO+

Application Overview

Run Instructions

B/M Distribution Report

Application Overview

Run Instructions

WIP Report

Application Overview

Run Instructions

WIP Variance Report

Application Overview

Run Instructions

Labor Performance Report

Application Overview

Run Instructions

Production Hours Variance Report

Application Overview

Run Instructions

Production Cost Variance Report

Application Overview

Run Instructions

Exception Report

Application Overview

Run Instructions

 


Introduction

The ultimate goal of Work Order Plus is to manage the manufacturing process.  There are many tools to assist a plant manager with monitoring and analyzing.  These tools come in the form of screen programs and reports.



Chapter 1: Monitor Interfaces

Work Center Operation/Inquiry

How to Access:

Main Menu è Distribution è Bill of Material Processor è Maintenance è Work Center Operation

Or drill-down from another interface

 

(Figure 1) Work Center Operation/Inquiry

 

 

Application Overview

This is an operation interface for a work order that can be used to inquire the status.  An ID and password may be required for security.  This interface monitors all production and labor in one work center and handles exceptions.  It can also display the production history of one work order.  The interface provides an alternative way to start and report a production, as opposed to reporting through Work Order Production.  This is a powerful interface which can change many of the production values and time-clock related data, so access should be limited.

 

This interface has 3 stages:

  1. Enter a Work Center ID.  Use the F7 Key to search Work Center IDs.
  2. Enter the Operator ID and password to sign in.  Use the F1 Key to toggle between scanning mode and typing mode.
  3. Inquire or modify information in this work center.

Drill down from another interface and the system will skip the first and second stages when the Work Center ID and Operator ID are given.

 

Once you are signed in, the system will display useful information; basic work center statistics on the top three rows and the ID of the operator who is using this interface.  The work center statistics include the number of operators, the number of active/suspended productions and the number of machines in the work center.  Below the double-line is a list of details about this work center.  Take figure 2 as an example.  It lists all the operators who are currently working in this work center.  The interface has four information modes that can be toggled through the F1 Key:

 

  • Use the F1 Key to toggle among different views and inquire the work center’s current status and history.
  • Start a new Production, report for an unfinished Production, suspend a Production or resume a Production.  Some options are not available, depending on the work center setting.  This will be discussed later.
  • Drill down detail of the highlighted record.
  • Maintain production records or production transaction records.
  • Handle exceptions for this work center, like an operator’s time clock logoff or changing production activity.

 

 


Views

There are five inquiries available in this interface.  We call them Views of a work center in WO+.  They include Current Labor, Started Production, Complete Production, Cancelled Production and Work Center Activity.  Use the F1 Keyto toggle between the views.  The system will display a list of available options.  Select one and switch to a certain view.  The Operator file controls which views this operator can see, so some operators may see fewer options or may not have access to this interface.  Each view provides an aspect of this work center’s labor, production progress and history.

 

Current Labor

 

(Figure 2) Work Center Operation, Current Labor View

 

This view shows all operators who are currently working in this work center and will display today’s performance of each operator.  The system will evaluate today’s performance in productive hours, non-productive hours and break time.

 

The following functions are available in this view:

  • Use Up, Down, Page Up and Page Down to navigate the highlighted bar.  The screen will refresh each time the highlighted bar is moved.
  • Press the Enter Key to drill down to Time Clock Inquiry for the highlighted operator.
  • Use the F1 Key to toggle to another view
  • Use the F2 Key to add a new Production.  This will be discussed in the next section.
  • Use the F3 Key to bring up Advanced Options.  These options include adding a new production and drilling down to time clock inquiry.
  • Use the F4 Key to handle exceptions, like entering the end time of the highlighted operator if they forgot to log off.
  • Use the F5 Key to bring up the legend.

 

Started Production

 

(Figure 3) Work Center Operation, Started Production View

 

This view shows all work-in-progress productions.  These productions are operations for one or more work orders[1].  They have been started, but not yet reported.  They include currently active and suspended productions[2].  The order and operation information of each production will be displayed as well as the plan quantity and labor hour variance[3].

 

The following functions are available in this view:

  • Use Up, Down, Page Up and Page Down to navigate the highlighted bar.  The screen will refresh each time the highlighted bar is moved.
  • Use the Enter Key to inquire production detail.
  • Use the F1 Key to toggle to other views.
  • Use the F2 Key to report a production.  This will be discussed later.
  • Use the F3 Key to bring up Advanced Options.  These options include various drill-down selections for the highlighted production, like Production Inquiry for the order.  A production can be added or maintained through Production Detail.
  • Use the F4 Key to handle exceptions.  The exceptions include canceling a production.

 


Complete Production

 

(Figure 4) Work Center Operation, Complete Production View

 

This view displays all reported productions.  Each production should have a production transaction or a transaction history record[4].  The order and operation information of each production will be displayed, along with the reported quantity[5]and labor hour variance.

 

The following functions are available in this view:

  • Use the Up, Down, Page Up and Page Down to navigate the highlighted bar.
  • Use the Enter Key to inquiry Production Detail.
  • Use the F1 Key to toggle to other views.
  • Use the F2 Key to bring up the legend.
  • Use the F3 Key to bring up Advanced Options.  These options include various drill-downs for the highlighted production.  The number of days of records to display can be changed and reported transaction data can be maintained.
  • Use the F4 Key to handle exceptions.  The exceptions include canceling a production.
  • Use the F5 Key to refresh the screen.  This view is history-oriented and the data will not refresh when the highlighted bar
is moved.

Cancelled Production

 

(Figure 5) Work Center Operation, Complete Production View

 

This view lists all the cancelled productions.  These productions can be cancelled because of a mistake or a change in plan.  A production can be cancelled through Exception Handling and will appear in this view.  The screen will show brief information of each cancelled production as well as the cancel date.

 

The following functions are available in this view:

  • Use the Up, Down, Page Up and Page Down to navigate the highlighted bar.
  • Use the Enter Key to inquiry Production Detail.
  • Use the F1 Key to toggle to other views.
  • Use the F3 Key to bring up Advanced Options.  These options include various drill-downs for the highlighted production.  Also, the number of days of records to display can be changed.
  • Use the F5 Key to refresh the screen.  This view is history-oriented and the data will not refresh it when the highlighted bar is moved.

 


Work Center Activity

 

(Figure 6) Work Center Operation, Work Center Activity View

 

This view provides all production history in one work center.  Production activities are time transactions when the production was active.  A production is active when an operator is working on it or machines are automatically processing it.  For each activity record, the order and brief information about the operation will be displayed, along with the operator[6] who worked on this activity and the total hours.  

 

The following functions are available in this view:

  • Use Up, Down, Page Up and Page Down to navigate the highlighted bar.  The data will automatically refresh when the highlighted bar is moved on the first page since this shows the most recent activity.
  • Use the Enter Key to inquiry Production Detail.
  • Use the F1 Key to toggle to other views.
  • Use the F2 Key to bring up the legend.
  • Use the F3 Key to bring up Advanced Options.  These options include various drill-downs for the highlighted production.  The number of days of records to display can be changed and reported transaction data can be maintained.
  • Use the F4 Key to handle exceptions, including canceling productions and activities.
  • Use the F5 Key to bring up the legend.

Production-Related Operation

In Work Center Operation you can start a new production, report for a production, suspend an active production, resume a suspended production and maintain production details.  Suspending a production means to stop working on the production, like at the end of the day.  Resuming a production means to continue working on a suspended production.

 

Normally these activities are performed through Work Order Production, but direct labor[7] is required to report whether a work order has started or ended.  Productions that do not direct labor, like a CNC Machine (Computed Numerically Controlled machine) which can run automatically without an operator, can be manipulated through Work Center Operation.  This is an alternative way to report production, so evaluate your needs before using it.  Most of these production-related operations require the work center to be configured properly, like “Machine Hrs Calc Method” should be set to “S” for Separately Tracking.

 

Start a New Production

 

From Current Labor View, you can press the F3 Key to bring up Advanced Options and select “Start A New Operation” or bring up the window directly by pressing the F2 Key.  The Advanced Options in Started Production View also has this option.  Enter the operation information and the production will be started without an operator.  The machine hours for this work center should be calculated separately from Direct Labor Hours.

 

(Figure 7) Start a New Production.

 


Report for a Production

 

From Started Production View, you can press the F3 Key to bring up Advanced Options and select “Report For a Production” or bring up the window directly by pressing the F2 Key when the production to report is highlighted.  The system will pop up the screen to report quantity, material, serial/lot numbers, etc.  Operators can only report productions which have no direct labor, active or not.  Otherwise, the operator should report through the Work Order Production interface.

 

(Figure 8) Report for Production.

 

Suspend an Active Production

 

To suspend an active production, use Advanced Options in Started Production View on a currently active production.  Highlight an active production, as indicated by an “A” to the right side of the data line.  Press the F3 Key to bring up the Advanced Options menu. Select “Suspend Production” and the system will prompt a confirmation.  Click “Yes” to suspend this production, however can not have direct labor reported.  The machine hours for this work center should be calculated separately from Direct Labor Hours.

 

Resume a Suspended Production

 

To resume a suspended production, use Advanced Options in Started Production View.  Highlight a suspended production, indicated by an “S” to the right of the data line, and press the F3 Key to bring up the Advanced Options menu.  Select “Resume Production” and the system will prompt a confirmation.  Click “Yes” and this production will resume with an active status.  The machine hours for this work center should be calculated separately from Direct Labor Hours.


Maintain Production Detail

 

If an operator entered a wrong work order number or reported a wrong completed quantity, the production detail would need to be changed.  There are two stages to make a change, maintaining production detail and maintaining transaction detail.

 

If the production has not been reported, changes can be made to the order number, operation number and plan quantity. A single transaction production can be made into a batch production.  To maintain these details, use Advanced Options in Started Production View.  Highlight a production and press the F3 Key to bring up the Advanced Options menu.  Select “Production Detail Maintenance” and the Exception Handling screen will appear to verify if the operator has authority to continue.  A supervisor can enter credentials to continue.  A screen will appear to allow the order number, operation number and plan quantity to be changed.  The new operation from the new work order must remain in the same work center.

 

If production has been reported but the transaction has not been posted, changes can be made to the transaction detail, like complete quantity, issued material, serial numbers, etc. To maintain these details, use Advanced Options in Complete Production View.  Highlight a production to maintain and press the F3 Key to bring up Advanced Options.  Select the “Production Maintenance” option and the Exception Handling screen will appear to verify if this operator has the authority to continue.  A supervisor can enter credentials to continue.  The system will display the production detail maintenance screen.

 

(Figure 9) Exception Handling Checking for Production Detail Maintenance


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