To be able to talk about the subject we have to get acquainted with
the basic concepts and terminology. Thus let us take a look at
individual concepts.
When discussing this module we will basically deal with decomposition
(definition) of some product. The product represents the holder of the entire
structure. Here we always dismantle products top-down. Or to put it more simply:
First let us select a product and we can ask ourselvers what makes up the
product and which operations were used in assembly. A list of
materials, assemblies or components could be served as answer to the first
question. A to-do list of operations can be served as answer to the second one.
All data are thus divided to component (specifications) and procedure
data (procedures).
Specification
| A specification is an
individual product's blueprint. There are various different terms and
definitions used in specifications. Yet in practical use you can simplify
it. You need not for example differentiate between assemblies and components
because a component can be thought of as an assembly made of one material
fabricated or processed irreversibly.
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Structural specification
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Products are typically constructed from a great number of various
component parts which are not all directly integrated in the final
assembly stage. That is why you dismantle products to simple structured
semi-finished products, that is, subassemblies. This way you make it
easier to view product structure and at the same time enable use of one
and the same subasembly in multiple related products. It simplifies
preparation of standards decreasing cost of manufacturing because you
can create subassemblies for multiple products. Each subassembly can be
a product including its own specifcation and a list of operations or
procedures. Om the other hand, each product can be represented with a
tree-structure view of products, semi-finished products and materials.
Here we discussed structural specification. PANTHEON allows use of
unlimited number of levels.
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Semi-finished product
(assembly or component)
| A subassembly
can be an assembly or component and can in the same way as the product
contain semi-finished products and materials. Thus it is an object made
of one, two or multiple materials and/or semi-finished products. Besides
specific semi-finished product ID the other significant data is quantity
of required semi-finishe products, for example one product.
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Material (raw material)
| It
represents for example raw material or any other asset you purchase and
integrate it in your product at any level. The quantity required is one
of the most significant data just like with semi-finished products.
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Alternative
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The product need not be made only of one material. When there is a lack
of material some other requires to be used. So you can deconstruct
specification in some other way, that is, by entering an alternate.
Since using some other material also brings about a different
technological procedure, the operations also get the label of the
alternate with which they are linked.
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Procedure
| A procedure is
represented by a sequence of operations which are required when making a
new semi-finished product or product from material. What is very
importont in series production (mass production) is order. It is a bit
less important in on-demand production.
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Operation
|
The most detailed piece of data in technological product deconstruction
is operation. Operations can be internal or external (subcontracing).
Plus they can further be divided into working and controlling ones, etc.
Yet all operations have something in common: Every operation is limited
by its duration and it is related to some position.
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Duration
| Duration can be
calculated using three type of data. Production time (Tpr) is of
the foremost mportance. Then you enter set-up time (Tsu) and of
course quantity of products in operation.
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Capacities
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It is obtained after creating working calendar and data from the
Resources register. Veiw calendar to see whether it is a working day or
holiday. Net capacity is then calculated for each machine separately,
according to the following formula:net capacity = ((No. of machines *
No. of shifts * hours per shift) + exceeding norm %) - loss %; all data
are updated in the Resources register.
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Capacity requirements
| To obtain
this data is a bit more ardous task. First you have to enter
specification and quantity, plus specifying the period to include in the
plan. Entering this data starts working operations. Each operation
includes the following.
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Production time
|
It represents time requird for production of 1 product.
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Set-up time
| It represents time
required for preparation of resource before actually starting working
operation and returning to the initial original state after the
operation has finished. It can be used for one single operation adn for
the whole series.
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Intermediate time
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It represents time between two operation. Furthermore, it is related to
machine usage, that is, it represents time elapsed between the usage of
two machines.
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Cycle Time
| It represents time
which elapses between the start of the previous operation and the start
of the current one. It can be calculated in several ways!!!
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Optimum quantity
|
It represents product quantity in mass production. Furthermore, it is
used when calculating cylce time.
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Position
| Because operations
include more than just working operation, position (of employment) seems
to be too narrow a term. That is why we here rather use the term
technological division (resource). For a more detailed treatment of
technological division see the topic covering the Resources register or
follow-up dealing with planning and available capacities.
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Work Order
|
Work order is a type of internal document used in manufacturing for
issuing material requirements as well as working operation requirements
in production of products and semi-finished products. It is based on
specification and intended for preparation and delivery of all required
materials and semi-finished products used in production.
Furthermore, work order is a subsidiary account when observed from
the accounting aspect. Here you can post all production costs for
individual product. |
Order
|
We use the term order thus linking up the Sales and Manufacturing
modules using just one document. Besides the order there is also the
term for line in case of the same products being ordered using one
order.
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Plan
|
It groups together mulitple orders or work orders. We can differentiate
between the main production plan and finished plan.
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Operation No.
| Number of
operation is transferred to work slip from technological procedure. It
is used in identifying individual operations because all operations have
the same work order ID as well as the same order ID.
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Structural issue
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Use it for finished product and when trying to issue it documentation is
created for all levels. To put it differently, when issuing a product a
complete documentation is created for all semi-finished products and
components as well as for the product. This way there is a minimum
possibility of errors occurring. Before trying to start the first
operation, you have to know which product (variant) you want to
manufacture. With structural issue you can also automatically join equal
assemblies. This way you additionally optimize manufacturing. The type
is set by default which is useful in monitoring manufacturing. Such type
of issue is used in the basic edition. It is usefulfor on-demand
manufacturing, small series production and mass production where cycle
time is shorter, that is, where price of component and material is
exceeds your capability of manufacturing semi-finished products without
tracking demand as is the case with issue by levels. All work orders
that can be found wih one product (containing all semi-finished
products) are assigned the same status as the order. This way
they are linked together. Users can see the product in question right
away.
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Issue by level
| Using it creates
documentation for the first level. This way all semi-finished products
and components require to be issued separately. Here the user should
take care so as to really issue all correct components. Plus,
take care to issue correct quantity. Since issuing by level does not
enable any control for the afore-mentioned problems, users in charge of
monitoring manufacturing and planning must take great care. This type of
issuing is used in mass production. Here production cylce is greater
than the delivery deadline so that components have to be produced before
starting with production of products.
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MRP
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Material Resource Planning. Taht is, planning for material, raw
materials and semi-finished requirements.
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CRP
| Capacity Resource Planning.
That ias, planning for resource capacity requirements.
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MPS
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Master Production Schedule. That is, the master production plan based on
which you perform planning.
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