Shop Floor Control Features and Functions
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Work Center Setup
Work Center Setup: The first task when setting up a Shop Floor Control system is defining each workgroup. This question lists some of the variables that would define any given work center.
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Overhead Rate Structure
Overhead Rate Structure: In some instances the overhead rates charged to a Work Center may be quite significant, and cannot be ignored when evaluating the efficiency of the Work Center. This question tries to identify how overhead will be charged to a Work Center.
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Scheduling Technique
Scheduling Technique Supported: There are several ways to look at scheduling. It could be based upon an assumption that there are no constraints, in which case jobs are scheduled as they become available. Alternately, the required completion date of the job could be taken into consideration, in which case the required start date for each operation is based upon the required completion date(s) further down the line. Here scheduling works backward from completion date to start date. Some people would prefer to exercise some degree or complete control of the scheduling process (manual). Finally, scheduling may be based upon a combination of a forward and backward analysis where potential bottlenecks are identified.
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Included in Lead Time Tracking
Lead Time Tracking Includes: If jobs are to be completed in a timely manner, manual or computer-assisted planning systems have to take into consideration lead times as well as actual production times. Setup and production times are easily understood. Queues are backups normally associated with specific pieces of machinery. Wait time may be thought of as the time when no work is performed on a job between operations. It may be travel time to get from one machine or work station to another, or it could be due to any other expected delay that is not directly associated with a machine or operation (like setup and queues).
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Outside Processing Controls
Outside Processing Controls Supported: Many manufacturing facilities rely upon outside specialists to perform certain functions. It could be applying special coatings to parts, or any other operation, and it could come at any point in the production cycle. In some cases an item could be partially manufactured in-house, then sent to the outside partner for a particular operation, and finally placed back into production in-house. In these cases the planning and control functions have to recognize that the outside processing operations are a critical link in the manufacturing process. Although users may not have direct control of the outside partners production cycle, those processes have to be taken into consideration and controlled as closely as practical. This question lists several steps users might want to take as they try to establish better control of these outside processes.
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Just-in-Time Planning
Supports Just in Time Planning: Just in time production control techniques cut lead times dramatically so that inventory arrives from the manufacturer as it is needed on the shop floor. This reduces the need for stocking material drastically, and increases working capital significantly. This question tries to identify the degree to which the system supports just in time production planning.
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Serial/Lot Tracking
Supports Serial/Lot Tracking: Serial and lot tracking are important in many instances. Only the serial number of the finished item may be important (single level), or all serial numbers of components may be important (multi-level). Finally, the lot numbers may be important.
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Component Backflushing
Supports Component Backflushing: There are two ways to look at when components are officially used. Once a sub-assembly is completed, the system could deduct all components from inventory. Alternately the components would not be officially withdrawn from inventory until the work order is completed.
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Shop Floor Control (General)
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Manufacturing Features and Functions
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