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Visual EstiTrack ™ - Chapter 6 Production

Rev. 10/2005 6-1

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PRODUCTIONPRODUCTIONPRODUCTIONPRODUCTION

Chapter 6 Production.....................................................................................................................................................1 Production Management ..................................................................................................................................................2

Job Card Maintenance .................................................................................................................................................3 Adding New Job Card...................................................................................................................................................4

Job Card Maintenance Overview.............................................................................................................................5 Inventory Usage Worksheet...............................................................................................................................13

Inventory Usage Detail....................................................................................................................................16 Inventory Lot Number Selection.................................................................................................................19

Batch Job Card Processor .....................................................................................................................................21 Quick Job Card Entry..............................................................................................................................................23 Recalculate Job Cards............................................................................................................................................27 Pan Ticket Maintenance.........................................................................................................................................29

Creating a New Pan Ticket.................................................................................................................................32 Pan Ticket Add Mode Description..................................................................................................................33

Pan Tickets for Secondary Operations......................................................................................................36 Pan Tickets for Assembly Operations........................................................................................................38

Batch Pan Ticket to Job Card Maintenance..........................................................................................................40 Creating Job Cards for Primary Operations via Batch Pan Ticket Entry..........................................................42 Creating Job Cards for Secondary Operations via Batch Pan Ticket Entry.....................................................45

Daily Production Monitoring........................................................................................................................................48 Daily Production Monitoring....................................................................................................................................49 Production Detail.....................................................................................................................................................51

Daily Operator Monitoring...........................................................................................................................................52 Daily Operator Monitoring.......................................................................................................................................53 Production Detail.....................................................................................................................................................55

In-Process Monitoring.................................................................................................................................................56 Remote Time Administration......................................................................................................................................58 Attendance Monitoring................................................................................................................................................59 Attendance Tracking Monitoring ................................................................................................................................61 Attendance Tracking Maintenance ............................................................................................................................63 Disciplinary Actions Maintenance...............................................................................................................................65 Lot Tracking.................................................................................................................................................................67

Inventory Lot Information........................................................................................................................................68 Reserving an Inventory Lot for a Specified Shop Order .......................................................................................71 Inventory Lots/Transfer Notes................................................................................................................................74

Production Reports .....................................................................................................................................................75


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PRODUCTION MANAGEMENT

Visual EstiTrack’s Production Management Subsystem filly manages all daily production activities such as Job Card Maintenance, Batch Processing, Pan Tickets and a number of monitors including In Process, Production and Attendance to name a few. All functions are fully integrated with the key Visual EstiTrack Subsystems therefore providing accurate real-time updates of all divisions.

Figure 6.1 Visual EstiTrack’s Production Management Menu

Chapter

6


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JOB CARD MAINTENANCE

The Job Card Maintenance subsystem is considered the heart of Visual EstiTrack’s production tracking system. The Job Card Maintenance form allows for daily job card entry for each workcenter running in the shop floor. Each time a job card is entered, Visual EstiTrack automatically updates inventory, calculates daily operation/production efficiencies, and tracks parts produced per hour to any associated scheduling/shop order records. It also recalculates the schedule end date and recalculates remaining material requirements.

The illustration below exemplifies the relationship of the Job Card and its full integration with other Visual EstiTrack subsystems.

Figure 6.2 Integration of the Job Card with to the other Visual EstiTrack subsystem

Everytime a

Job Card is

entered all

records

related

to the job

are updated.

Shop Order

Inventory

Daily

Production

Schedule

Releases

Job Card

Remote Job Card

Data Collection


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ADDING NEW JOB CARD

The function of Job Cards remains the same regardless of the method a Job Card is created. Job Cards are used to collect direct labor and material usage.

The method a Job Card is entered highly depends on the company’s business process procedure for Job Card data collection. Some companies opt to work with paper job cards that are collected and entered into the system via batch data entry processing. Others opt to have the operator directly enter his/her job into the system via Remote Time Entry. A description of each of the available options is given below.

Method Description

• Job Card Maintenance

New Job Cards maybe added using the Job Card Maintenance form. However, the form is extensive and the user may find the entry tedious and time consuming.

The Job Card Maintenance form’s main function is to maintain existing Job Card records. In addition to updating and deleting Job Card records, the user may also access the Inventory Usage Worksheet for the material consumed for the given operation/workcenter.

• Batch Job Card

Processing

The Batch Job Card Processing form allows the user to enter and subsequently create one or more job cards at a time. Records are retrieved for creation according to the first scheduled record of each workstation.

The quantities produced, scrapped, and hours (setup, production, and downtime) can all be entered into the retrieved list of shop order operations and workcenters.

Once the Job Cards are created, they are further maintained using the Job Card Maintenance form.

• Quick Job Card

Entry

The Quick Job Card entry form is the preferred method of batch job card data entry. A simple data entry format provides the user the means to enter in the job card specifics via a quick concise format.


• Remote Time Entry The Remote Time Entry system is a separate program used by operators to clock in and

out of shop orders using bar coded travelers.

During the logout procedure, information regarding the parts produced must be entered into the system. The system calculates the total production time and subsequently creates the job card record using the information logged by the operator.

Once the Job Cards is created, it maybe further maintained using the Job Card Maintenance form.


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Job Card Maintenance Overview

The information in the Job Cards can be captured manually as well as automatically via the Run Code. Run Codes are issued when a Shop Order Release is scheduled via the Scheduling system. Once a Run Code is entered, the relevant Shop Order information is automatically defaulted into the Job Card.

Figure 6.3 Job Card Maintenance

Menu Selection

• Left click on the sixth menu heading labeled “Orders”

• Select “Job Card Maintenance” from the drop down list.

Shortcut: Quickly enter this module by left clicking on the displayed “Job Card Maintenance” icon on the toolbar.

Security

The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option.

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Production �� Job Card Maintenance

Field Required Field Type Description

Job Card Definition

Run Date YES DATE The system automatically populates the run date with the current computer date. The date does NOT come from the server computer unless a Job Card is added at the Server/Workstation.

Note: The run date can only be modified prior to saving the Job Card.

Employee YES DROPDOWN Enter the Employee ID of the person that operated the Machine/Operation for the defined Job Card.

Shift YES DROPDOWN The system automatically populates with a shift of “1” when the Run Code is entered in the Run Code Field.

Note: The system will NOT allow the user to save the Job Card until a Shift is defined. It is important to validate that the correct shift is defined for the employee.

Number of Machines YES NUMBER The number of machines the employee operated at the same time. The system will divide the hourly rate equally among the defined number of machines to determine the labor costs for work in process. The system automatically defaults the field with “1” machine.

Run Code YES ALPHANUMERIC Enter the Run Code issued to the shop order after the order was scheduled via the Visual EstiTrack scheduling system. The Run Code is a unique identifier for a scheduled shop order record.

Run Code N/A PUSHBUTTON Activate pushbutton to un-scheduled a completed shop order if applicable.

Shop Order Number YES ALPHANUMERIC Enter in the Shop Order Number for the defined Job Card.

If the Shop Order was scheduled via the Visual EstiTrack Scheduling system, the system automatically displays the Shop Order Number based on the selected Run Code.

Release Number YES DROPDOWN The system automatically displays the Release Number based on the selected Run Code record if applicable. If the shop order is not scheduled, select the Release Number from the dropdown list.


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Operation Number YES DROPDOWN Select the Operation Number from the dropdown menu.

If the Shop Order is scheduled, the system automatically displays the Operation Number based on the entered Run Code.

Workcenter YES DROPDOWN Select the Workcenter from the dropdown list.

If the Shop Order is scheduled, the system automatically displays the Machine/Operation type Code based on the entered Run Code.

Job Card ID YES ALPHANUMERIC A unique system generated number identifying the Job Card for the operation performed.

Action Request N/A PUSHBUTTON Activate pushbutton to retrieve the Action Request subsystem. Please refer to the Quality chapter for additional information regarding Action Requests.

Part Number N/A DISPLAY Displays the Part Number used in the selected shop order

Revision N/A DISPLAY Displays the Part Revision used in the selected shop order number.

Operation Complete NO CHECKBOX Activate checkbox to indicate that the selected operation is fully complete.

Labor Hours

Setup NO NUMBER Enter in the total quantity of hours spent to setup the machine/workcenter including any overtime hours. The portion of overtime hours should be included in this field and are further defined in the Setup Overtime/Double Overtime fields.

Note: The system tracks setup hours separately from production hours.

Setup Overtime NO NUMBER Enter in the total quantity of overtime hours spent to setup the machine/workcenter.

Note: The system calculates the employee’s pay rate by time and a half when determining the Labor Hours in Work In Process.


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Setup Double Overtime NO NUMBER Define the number of double overtime hours spent on setup. These are setup double time hours only and should not include any overtime or setup hours.

Note: The system calculates the employee’s pay rate by 2 when determining the Labor Hours in Work In Process.

Available for Production NO NUMBER Enter in the total number of hours spent on production including any overtime hours. The portion of overtime hours should be included in this field and are further defined in the Production Overtime/Double Overtime fields.

Note: Downtime hours should also be included. They are deducted from the Available for Production hours when they are further defined in the corresponding Production Overtime/Double Overtime fields.

Production Overtime NO NUMBER Define the number of overtime hours spent on production. This is production hours only and should not include any overtime setup hours.

Note: The system calculates the employee’s pay rate by time and a half when determining the Labor Hours in Work In Process.

Production Double Overtime NO NUMBER Define the number of double overtime hours spent on production. These are production hours only and should not include any overtime or available for production hours.

Note: The system calculates the employee’s pay rate by 2 when determining the Labor Hours in Work In Process.

Tooling Downtime NO NUMBER Define the number of hours the amount of hours the Machine or Workcenter was not running as a result of tooling downtime. The total quantity of Tooling Downtime Hours for the selected Job Card.

The system deducts the downtime from the total number of production hours.

Note: Downtime reasons maybe defined using the Defect Code.


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Downtime NO DROPDOWN NUMBER

Enter in the total quantity of hours the Machine or Workcenter was not running in addition to any Tooling Downtime. The user can select a reason for the other downtime from the dropdown list. The following reasons are available: - Can’t hold tolerances - Machine Crashed - Tool Broke

Note: Any additional reasons maybe tracked using the Defect Code.

Production N/A DISPLAY The Production field is an automatic display of the calculated Net Adjusted Production hours based on the available, tooling down time and any other downtime reason defined for the selected Job Card.

Parts

Quantity 1 Quantity 2 Quantity 3

NO NUMBER The three quantity field columns are used in conjunction with Tracking Numbers to track lot quantities separately.

Note: The Quantity fields in conjunction wit the Tracking Numbers allow the user to create one Job Card for three separate Lots.

Produced YES NUMBER The Produced field is the total quantity of items produced.

Note: The system automatically displays the first total quantity of parts or products produced for or from a specified Tracking Number if applicable. This is performed for the selected Job Card record associated with a specified Run Date selected in the Daily Production Monitoring.

Review NO NUMBER Enter in the quantity of parts sent to the Material Review Board Inspection location.

Note: All locations and bins are user defined via the table: TABLES �� INVENTORY LOCATIONS


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Rework NO NUMBER Enter in the quantity of parts that need to be reworked.

Note: If applicable, the system automatically displays the first total quantity of parts or products produced for or from a specified Tracking Number that was reworked for a selected Job Card record associated with a specified Run Date selected in the Daily Production Monitoring.

Rework N/A PUSHBUTTON Activate pushbutton to include the rework quantity in the Good Parts Produced.

Scrap NO NUMBER Enter in the number of parts that were scrapped during production. This number is automatically deducted from the total number of parts produced.

Good N/A DISPLAY The system automatically calculates and displays the net amount of Parts or Products Produced.

If applicable, this field presents the first total quantity of Good parts or products produced for or from a specified Tracking Number based on the Produced, Rework and Scrap Quantities for the selected Job Card record associated with a specified Run Date selected in the Daily Production Monitoring.

Tracking Numbers NO ALPHANUMERIC Tracking numbers are an optional lot control. A unique number maybe assigned to each job card. The number maybe used to keep lots separate.

The system automatically displays the unique identifying tracking number when the Job Card is associated with a specified Run Date selected in Daily Production Monitoring.

Inventory Used

Inventory Used N/A PUSHBUTTON Activate pushbutton to retrieve the Inventory Usage Worksheet. This worksheet is used to define any material used for the production of the goods.

Zero Previous WIP NO CHECKBOX Activate checkbox to zero out the balance of the Work In Process Inventory number. Using this checkbox is a quick way to update the inventory records.


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Lot Number NO ALPHANUMERIC The inventory maybe reduced from a specific lot when a user specific lot number is assigned in the field.

If the field is left blank, normal FIFO rules are applied in pulling inventory from storage.

Inventory Produced

Inventory Number NO ALPHANUMERIC Enter in the inventory number produced by the completion of this Job Card.

Note: This field is automatically populated if the Job Card record is associated with a specified Run Date selected in Daily Production Monitoring.

Lot Serial Number NO ALPHANUMERIC The Lot serial number is an automatically generated step-up lot number assigned to the inventory produced via the Job Card.

Move to Stock NO CHECKBOX Activate checkbox to automatically update the available inventory.

Heat Number NO ALPHANUMERIC If applicable, enter in a previously defined heat number or use the search key for selection.

Add N/A PUSHBUTTON Activate pushbutton to retrieve the Heat Details form used to capture the General and Warranty Information as well as the chemical analysis of the Heat.

Update N/A PUSHBUTTON Activate pushbutton to retrieve the Heat Details form to update the selected Heat Number.

Location NO DROPDOWN Select the current inventory location of the items produced using the Job Card.


Bin NO DROPDOWN Select the inventory bin used to store the items produced from the Job Card from the dropdown list.



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Defect Codes N/A PUSHBUTTON Activate pushbutton to retrieve the Job Card Defects form. Any defects found during production can be individually defined along with the corresponding defected quantity, and any additional defect notes. Additional information regarding this form is further provided in the chapter below.

Inspected By NO DROPDOWN Select the employee that inspected the parts produced from the dropdown list.

Job Card ID NO NUMBER In Progress…

Add N/A PUSHBUTTON Activate pushbutton to add a new Job Card to the system. Job Card Maintenance form is refreshed for entry.

Save N/A PUSHBUTTON Activate pushbutton to save any changes made to the current open Job Card.

Cancel N/A PUSHBUTTON Activate pushbutton to cancel any changes.

Delete N/A PUSHBUTTON Activate pushbutton to delete the open job card. After the delete validation is confirmed, the record is permanently removed from the system.

Exit N/A PUSHBUTTON Exits the Job Card Maintenance form back to the main Visual EstiTrack menu system.

Palm Based Operating Interface

N/A PUSHBUTTON Activate pushbutton to initiate communication between the palm based operating system and the Visual EstiTrack system.

Scroll to First N/A PUSHBUTTON Scrolls to first record.

Scroll Back N/A PUSHBUTTON Scrolls back one record.

Scroll Forward N/A PUSHBUTTON Scrolls forward one record.

Scroll to Last N/A PUSHBUTTON Scrolls to last record.

Bin Ticket N/A PUSHBUTTON Activate pushbutton to print a Bin Ticket. The Bin Ticket identifies the parts produced from the Job Card and provides all relevant information such as lot number, shop order number, inventory number, workcenter, employee, inspector and quantities.


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Inventory Usage Worksheet

The Inventory Usage Worksheet is used to track the raw material consumed for the shop order. Entries can be automatically inserted and tracked via the Job Card if the material was allocated in the “Material Requirements” tab of the Shop Order Maintenance subsystem.

Using the Shop Order allocation method, the raw material can be automatically reduced as the shop order parts are produced in the Job card. This can be accomplished by the following two methods:

• Configuring the Visual EstiTrack company tables to auto-reduce Inventory in Job Cards. This configuration is made in the table: TABLES �� COMPANY �� Inventory Tab �� “Auto Reduce Inventory in Job Cards” checkbox.

Figure 6.4 Configuring company tables to auto-reduce inventory

• Activating the “Automatically Calculate Inventory Usage Based on Quantity Produced” checkbox of the Inventory Usage Worksheet displayed in figure 6.5.


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The form is divided into two distinct sections. Section one displays the raw material added either automatically or manually to the Job Card. Section two displays the Inventory Lot Information regarding to the highlighted material consumed in section one of the form below.

Additional information regarding the fields and parameters included in the form is provided in the corresponding table below.

Figure 6.5 Inventory Usage Worksheet

Section 1 �

Section 2 �


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Production �� Job Card Maintenance �� Inventory Usage Worksheet


Automatically Calculate Inventory Usage Based on Quantity Produced

NO CHECKBOX Activate checkbox to automatically calculate the inventory usage based on the quantity produced associated with the Job Card operation.

This can be bypassed if the user configures the Visual EstiTrack company table to auto-reduce the raw material inventory for a Job Card

Order Production Monitoring N/A PUSHBUTTON Once activated, the system automatically retrieves the Order Production Monitoring subsystem for the associated shop order number. The subsystem is opened to the “Operations” tab displaying the operation number of the current Job Card.

Inventory Monitoring N/A PUSHBUTTON Once activated, the Inventory Monitoring form is retrieved for the associated Shop Order Part Number.

Add N/A PUSHBUTTON Activate the pushbutton to add a new inventory to the Inventory Usage form. The Inventory Usage Detail form is retrieved in “Add” mode for further entry. Additional information regarding the form is further provided within the chapter below.

Update N/A PUSHBUTTON Activate the pushbutton to update the highlighted inventory record. The Inventory Usage Detail form is retrieved in Update mode for further entry. Additional information regarding the form is further provided in the chapter below.

Delete N/A PUSHBUTTON Activate the pushbutton to delete the highlighted inventory record. After the delete validation is confirmed, the record is permanently removed from the system.

Exit N/A PUSHBUTTON Activate the pushbutton to exit the form and return to the Job Card Maintenance form.

Display - Order/Location/Bin - Lot/SN/Heat/Supplier

NO RADIOBUTTONS The display of the “Inventory Lot Information” section of the form (section two of figure 6.5) can be configured to either display one of the two available display options by activating the appropriate radio button.


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Inventory Usage Detail

The Inventory Usage Detail form is retrieved when a material is added or updated within the Inventory Usage Worksheet. The user may perform the following functions within the form:

• Specify the Inventory Quantity by either manually entry or calculated quantity computed via the Inventory Calculator.

• Designate the exact material lot/location of the material consumed during the operation.

• Return material to stock. The Quantity on-hand is increased in Inventory Maintenance for the Inventory number returned.

Additional information regarding the fields and parameters included is provided in the corresponding table below.

Figure 6.6 Inventory Usage Detail

Production �� Job Card Maintenance �� Inventory Usage Worksheet �� Inventory Usage Detail


Inventory Quantity Used

Inventory Number YES ALPHANUMERIC Enter in the Inventory Number of the material to be consumed via the associated Job Card operation or use the attached search key for selection.

Quantity Used NO NUMBER Enter in the quantity of material used.

The Inventory Calculator may be used in replace of manually entering in the quantity.


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UOM YES DROPDOWN Select the material’s Unit of Measure from the dropdown list.

The Inventory Calculator may be used in replace of manually entering in the UOM.

Calculator N/A PUSHBUTTON Activate pushbutton to retrieve the Inventory Calculator pop-up. The calculator is used to calculate the material required based on the Required Length, Width and Quantity Needed.

Note: The system automatically converts the pieces required in to the material’s Stock Unit of Measure used in Inventory Maintenance to reduce the inventory quantity on-hand.

Return of Used Item(s) NO CHECKBOX Activate checkbox to alter the purpose of the form from entering material quantities consumed to entering the Material Quantity returned back to stock.

The Material’s Quantity On-Hand is increased by the returned quantity in Inventory Maintenance.

Override Calculated Quantities

NO CHECKBOX Activate checkbox to allow the user to override the calculated quantities.

Quantity Cut The “Quantity Cut” display box is present when a raw material is defined in the Material Item Definition of a Shop Order. The cut specifications defined are displayed for the material.

Pieces cut NO NUMBER The system displays the calculated number of pieces to be cut. This field maybe overridden if necessary.

Use From The “Use From” display box allows the user the opportunity to select a specific material lot.

Location YES DROPDOWN Select the material’s location from the dropdown menu.

Bin YES DROPDOWN Select the material’s bin from the dropdown menu.

Lot/SN Number NO DROPDOWN Select the material’s lot / serial number from the dropdown menu.


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Heat Number Enter in the material’s heat number or use the attached search key to retrieve the Heat Number Selection form to aid in heat selection.

Select Lot/Serial Numbers N/A PUSHBUTTON The materials lot can be easily selected by activating the associated pushbutton. The Inventory Lot Number Selection form is retrieved displaying a list of the material’s lot stored in the system.

The user can select the exact lot and from the list of available lots. The location, bin, lot/serial number and heat number of the material are all automatically updated according to the selection made.

Save N/A PUSHBUTTON Activate pushbutton to save any changes made.

Cancel N/A PUSHBUTTON Activate pushbutton to cancel any changes made.


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Inventory Lot Number Selection

The Inventory Lot Number Selection form is used when adding a new material that was consumed during operation. The form is accessed from the Inventory Usage Detail form and allows the user to select the exact lot of material used during the production.

The form is divided into two sections. Section one lists the selected inventory number’s lots and corresponding locations, heats and quantities. Section two of figure 6.7 lists the inventory lots selected by the user for operation consumption. Once the user selects the lot from the list, the SELECT pushbutton transfers the lot to the bottom half of the form (section two of figure 6.7). The quantity of can be adjusted for the selected lot prior to saving it to the system.

Additional information regarding the fields and functions included in the form are provided in the corresponding table below.

Figure 6.7 Inventory Lot Number Selection

Section 1 �

Section 2 �


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Production �� Job Card Maintenance �� Inventory Usage Worksheet �� Inventory Usage Detail �� Inventory Lot Number Selection


Display -- All Lots -- Stock Only -- Order Only

YES RADIOBUTTON Activate the appropriate radio button to display the type of lots to include in the list displayed in section one of figure 6.7.

The user can choose to display all lots, lots that are in stock only, or lots that are on order only.

Select N/A PUSHBUTTON Activate the pushbutton to select the highlighted lot from section one of figure 6.7. Once the material lot is selected, it is removed from the section one list and added to the consumption list displayed in section two of figure 6.7.

Lot/Serial Number NO ALPHANUMERIC The user can also select the lot by entering in the lot/serial number of the desired inventory number. Once entered, the lot is removed from the top half of the form and added into the list displayed in section two of figure 6.7.

Change Quantity N/A PUSHBUTTON Activate pushbutton to change the quantity used of the highlighted lot from section two of figure 6.7.

An Enter Inventory Quantity pop-up prompts the user to enter in the quantity of the inventory’s unit of measure that was consumed during the operation. The user is also provided a “Piece to Stock Unit of Measure” calculator that may aid in consumption quantity calculation.

Once the changes are SAVED, the quantity for the lot record displayed in section two of figure 6.7 is modified with the new quantity.

Remove from List N/A PUSHBUTTON Activate the pushbutton to remove the highlighted inventory lot from the consumption list displayed in section two of figure 6.7. The lot entry is subsequently re-inserted into the top half of the form.

Save N/A PUSHBUTTON Activate pushbutton to save any changes made to the form.

Cancel N/A PUSHBUTTON Activate pushbutton to cancel any changes made to the form.


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Batch Job Card Processor

The Batch Job Card Processing form allows the user to enter and subsequently create one or more job cards at a time. The records are retrieved for job card creation according to the first scheduled record of each workstation.

The quantities produced, scrapped, and hours (setup, production, and downtime) can all be entered into the retrieved list of shop order operations and workcenters.


Figure 6.8 Batch Job Card Processor

Menu Selection


• Select “Batch Job Card Processor” from the drop down list.

Security



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The Batch Job Card Processor is used to add Job Card entries and then batch create the entries in one step by activating the “Create Job Cards” pushbutton.

The records included in the grid can be individually entered or can be auto-populated by activating the “Auto-Populate” pushbutton. The grid is then populated with the first scheduled record of each workcenter. Entries are therefore populated into the grid based on the shop orders scheduled and assigned corresponding Run Codes.

Prior to allowing the user to actually create the Job Cards, the user is prompted to enter an “Employee ID” for each record populated into the grid. The user can also update fields included in the grid for each Job Card record. Once the Job Cards are actually created, they can be further maintained using the Job Card Maintenance form.

Production �� Batch Job Card Processor


Automatically save Job Card when created.

NO CHECKBOX Activate checkbox to automatically save the job card when it is created.

If it is not checked, the Job Card Maintenance form is populated with the information included in the grid. The Job Card Maintenance form is left opened for further update. The user must manually SAVE each Job Card record to the system to complete the creation process.

Derive Production Hours from Quantity Produced

NO CHECKBOX Activate checkbox to automatically calculate the production hours based on the entered quantity produced and the cycle time defined for the operation/workcenter.

Default Hours NO NUMBER Enter in the default production hours to be used for all of the records included in the grid.

Add N/A PUSHBUTTON Activate pushbutton to add a new Job Card entry to the grid.

Auto Populate N/A PUSHBUTTON Activate pushbutton to auto populate the grid with the first scheduled record of each workcenter. Entries are therefore populated into the grid based on the shop orders scheduled and assigned their assigned Run Codes.

Delete N/A PUSHBUTTON Activate pushbutton to remove the entry from the grid.

Create Job Cards N/A PUSHBUTTON Activate pushbutton to create a Job Card record for every record included in the grid. Job Cards are created when all the mandatory fields are populated.

Exit N/A PUSHBUTTON Activate pushbutton to exit form back to the main Visual EstiTrack menu system.


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Quick Job Card Entry

The Quick Job Card entry form is the preferred method of batch job card data entry. A simple data entry format provides the user the means to enter in the job card specifics via a quick concise format.


Figure 6.9 Quick Job Card Entry

Menu Selection


• Select “Quick Job Card Entry” from the drop down list.

Security


Section 1 �

Section 2 �

Section 3 �


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The Quick Job Card Entry form is divided into two distinct divisions. The top half of the form (section 1 of figure 6.9), displays a list of added Job Card entries. The bottom half of the form (section three of figure 6.9) is used to input key job card elements. Additional information regarding the fields and functions included in the form is provided in the corresponding table below:

Production �� Quick Job Card Entry


Add N/A PUSHBUTTON Activate pushbutton to add a new Job Card entry. Once activated, the fields in section 3 of figure 6.9 are available for entry.

Update N/A PUSHBUTTON Activate pushbutton to update the highlighted Job Card entry. Once activated, the highlighted record is retrieved into the job card fields displayed in section three of figure 6.9.

Delete N/A PUSHBUTTON Activate pushbutton to remove the highlighted entry from the list of Job Cards to create.

Create Job Cards N/A PUSHBUTTON Activate pushbutton to create a Job Card record for every item included in the list displayed in section one of figure 6.9.


Date YES DATE Enter in the date. The interactive Visual EstiTrack calendar is available for date selection.

Employee YES DROPDOWN Enter the Employee ID of the person that operated the Machine/Operation for the defined Job Card.

Shift YES DROPDOWN Enter in the correct shift of the employee running the operation/workcenter of the Job Card entry.

The field is automatically defaulted to first shift “1”.

Number of Machines YES NUMBER The number of machines the employee operated at the same time. The system will divide the hourly rate equally among the defined number of machines to determine the labor costs for work in process.

The system automatically defaults the field with “1” machine.


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Runcode YES ALPHANUMERIC Enter the Run Code issued to the shop order after the order was scheduled via the Visual EstiTrack scheduling system. The Run Code is a unique identifier for a scheduled shop order record.

Shop Order YES ALPHANUMERIC Enter in the Shop Order Number for the defined Job Card.

If the Shop Order was scheduled via the Visual EstiTrack Scheduling system, the system automatically displays the Shop Order Number based on the selected Run Code.

Release YES DROPDOWN The system automatically displays the Release Number based on the selected Run Code record if applicable. If the shop order is not scheduled, select the Release Number from the dropdown list.

Operation YES DROPDOWN Select the Operation Number from the dropdown menu.

If the Shop Order is scheduled, the system automatically displays the Operation Number based on the entered Run Code.

Workcenter YES DROPDOWN Select the Workcenter from the dropdown list.

If the Shop Order is scheduled, the system automatically displays the Machine/Operation type Code based on the entered Run Code.

Produced YES NUMBER Enter in the total number of parts produced. This number should reflect all parts including any parts needing rework, review or scrap.

Review YES NUMBER Enter in the quantity of parts sent to the Material Review Board Inspection location.

Rework YES NUMBER Enter in the quantity of parts that need to be reworked.

Scrap NO NUMBER Enter in the number of parts that were scrapped during production. This number is automatically deducted from the total number of parts produced.

Lot Number NO NUMBER In Progress…


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Setup Hours NO NUMBER Enter in the total quantity of hours spent to setup the machine/workcenter including any overtime hours. The portion of overtime hours should be included in this field and are further defined in the Setup Overtime/Double Overtime fields.

Note: The system tracks setup hours separately from production hours. Setup Overtime and Double Overtime may be further defined for the Job Card using the Job Card Maintenance form after the Job Card is created.

Production Hours NO NUMBER Enter in the total number of hours spent on production including any overtime hours. The portion of overtime hours should be included in this field and are further defined in the Production Overtime/Double Overtime fields.

Note: Downtime hours should also be included. They are deducted from the Production hours when they are further defined in the field “Downtime Hours”.

Overtime and Double overtime may be defined to the Job Card using the Job Card Maintenance form after the Job Card is created.

Downtime Hours NO NUMBER Enter in the total number of hours the Machine or Workcenter was not running.

Note: Reasons for downtime may be added to the Job Card using Job Card maintenance.

Save N/A PUSHBUTTON Adds the entered Job Card information to the list displayed in the top half of the form.

Finish N/A PUSHBUTTON Activate pushbutton to complete the Job Card entry process. The pushbuttons displayed in section two of figure 6.9 are then made available for further Job Card processing.


Rev. 10/2005 6-27

Recalculate Job Cards

Since the Job Card is the basis by which raw material costs and labor and burden costs are calculated, it is necessary at times to rerun the Job Cards calculations for a series of Job Cards or for a specific Shop Order Number if there were any changes made to defined costs that may affect the shop order costing.

For example, if either a burden rate was not defined on a workcenter, or an employee’s hourly rate was not defined or has been changed, it may cause an understatement of the shop order costs. The Recalculate Job Cards routine would recalculate costs for the selected Job Cards when the user made the appropriate changes to the hourly or workcenter rates. Additional information regarding the fields and parameters included in the criteria window displayed is provided in the corresponding table below.

Figure 6.10 Recalculate Job Cards

Menu Selection


• Select “Recalculate Job Cards” from the drop down list.

Security



Rev. 10/2005 6-28

Production �� Recalculate Job Cards


Shop Order Completion Date Range

NO DATE Enter in the date range the Shop Orders were completed.

All created Job Cards that correspond to the Shop Orders completed within the defined date range are recalculated using the last updated material costs, burden and employee labor rates.

Job Card Creation Date Range

NO DATE Enter the date range the Job Cards were created.

All created Job Cards that were created within the defined date range are recalculated using the last updated material costs, burden and employee labor rates.

Shop Order Number NO ALPHANUMERIC Enter in the Shop Order number to recalculate all Job Cards created for the specified Shop Order.

Recalculate Job Cards with Inventory Usage Discrepancies

NO CHECKBOX Activate checkbox to recall and recalculate all job cards with inventory discrepancies.

If a Job Card creation date range is specified, all Job Cards created within the date range are reviewed/recalculated if Inventory Usage discrepancies exist. If the date range remains null, Inventory usage discrepancies are reviewed and recalculated for all created Job Cards.

Recalculate Selected Job Cards

N/A PUSHBUTTON Activate pushbutton to initiate the Recalculate Job Cards routine for all records that meet the specified filter criteria.

Clear N/A PUSHBUTTON Activate pushbutton to Clear the search criteria from the form.

Exit N/A PUSHBUTTON Exits form back to the main Visual EstiTrack menu system.


Rev. 10/2005 6-29

Pan Ticket Maintenance

Pan Ticket Maintenance is used to create pan tickets that maybe distributed to shop floor employees. The Pan Ticket predefines the scheduled shop order and therefore includes the Run Code, Shop Order, Release Number, Operation, Workcenter and Raw Material inventory number and lot. The information is used to tag a tray of manufactured parts. One Pan Ticket should be used for one tray of parts.

The Pan Ticket should accompany the tray of parts throughout the shop process so “Lot Control” is always maintained for the goods. Once the operation is complete, the operator normally writes the quantity completed on the Pan Ticket. At the end of the day this information gathered is used to create Job Cards for the Shop Order by either using the Batch Job Card Maintenance form or the Batch Pan Ticket to Job Card Maintenance form. Additional information regarding these steps is further provided in the chapter below.

Figure 6.11 Pan Ticket Maintenance

Menu Selection


• Select “Pan Ticket Maintenance” from the drop down list.

Security



Rev. 10/2005 6-30

The Pan Ticket Maintenance subsystem is divided into two tabulations – Data Tab and List by Ticket Number Tab.

The “Data” tab is used to display the selected Pan Ticket data. The user may edit the data within the form and may also reprint additional copies of pan tickets from within the form.

Note:

All of the available fields within the “Data Tab” maybe overridden if necessary via this form.

The “List by Ticket Number” tab displays a list of defined Pan Ticket numbers. The user may select the desired pan ticket to retrieve into the Data tab from the available list.

Production �� Pan Ticket Maintenance: Data Tab


Ticket Number N/A DISPLAY Displays the Selected ticket Number

Run Code YES ALPHANUMERIC Displays the Run Code of the selected Pan Ticket Number.

Part Number YES ALPHANUMERIC Displays the Part Number of the selected Pan Ticket.

Revision NO ALPHANUMERIC Displays the Part Revision of the selected Pan Ticket.

Shop Order Number YES ALPHANUMERIC Displays the Shop Order Number of the selected Pan Ticket.

Part Description NO TEXT Displays the Part Description of the selected Pan Ticket.

Release Number YES DROPDOWN Displays the Release Number of the selected Pan Ticket.

Operation Number YES DROPDOWN Displays the Operation Number of the selected Pan Ticket.

Operation Type YES DROPDOWN Displays the Operation Type of the selected Pan Ticket.

Workcenter YES DROPDOWN Displays the Workcenter of the selected Pan Ticket.

Issued to Employee YES DROPDOWN Displays the Employee who was issued the selected Pan Ticket.

Date Issued YES DATE Displays the Date issued of the selected Pan Ticket.

Inventory Number YES DROPDOWN Displays the consumed Inventory Number of the selected Pan


Rev. 10/2005 6-31

Production �� Pan Ticket Maintenance: Data Tab


Ticket.

Lot Number YES DROPDOWN Displays the consumed inventory’s lot number of the selected Pan Ticket.

Reprint N/A PUSHBUTTON Activate pushbutton to reprint the Pan Ticket using the information displayed within the form.

Reprint Count NO NUMBER Enter in the number of Pan Tickets to reprint.

Search N/A PUSHBUTTON Activate pushbutton to retrieve the Pan Ticket Quick Search utility.

Add N/A PUSHBUTTON Activate pushbutton to create a new pan ticket. The Pan Ticket Add mode form is retrieved for entry.

Save N/A PUSHBUTTON Activate pushbutton to save any changes made to the form.


Delete N/A PUSHBUTTON Activate pushbutton to delete the retrieved Pan Ticket from the system. After the delete validation is confirmed, the record is permanently removed from the system.


Scroll to First N/A PUSHBUTTON Activate pushbutton to scroll to first record.

Scroll Back N/A PUSHBUTTON Activate pushbutton to scroll back one record.

Scroll Forward N/A PUSHBUTTON Activate pushbutton to scroll forward one record.

Scroll Last N/A PUSHBUTTON Activate pushbutton to scroll to the last record.


Rev. 10/2005 6-32

Creating a New Pan Ticket

The following steps are used when creating a New Pan Ticket:

• Retrieve the Pan Ticket Maintenance subsystem via the menu bar: PRODUCTION �� PAN TICKET MAINTENANCE.

• Activate the ADD pushbutton located on the bottom of the form displayed in figure 6.12 below.

Figure 6.12 Adding a new Pan Ticket

• The Pan Ticket Add Mode form is retrieved for further entry. Additional information regarding the fields and parameters included in the form are provided in the corresponding section below.


Rev. 10/2005 6-33

Pan Ticket Add Mode Description

The Pan Ticket Maintenance “Add Mode” is the medium used to create pan tickets for primary, secondary and assembly operations. The type of operation is controlled via the corresponding radio buttons provided at the top of the form. Additional information regarding the fields and parameters are provided in the table below.

The Primary Operation displayed in the figure below is the controlling operation. Once the primary operation is fully entered, the “Create Pan Tickets, and Print” pushbutton initiates the system to create one pan ticket number for all of the operations included in the shop order. A Pan ticket is printed out with the following information:

• Bar coded Pan Ticket Number • Part Number / Revision

• Finished Good Inventory Number/Employee • Shop Order Number / Qty Ordered

• Raw Material / Lot • Heat Number

• A list of Operations / Workcenters included in the Shop Order

• Shop Order Number • Employee

• Workcenter • Pan Ticket Number

• Date field for user entry • Count field for user entry

Figure 6.13 Pan Ticket Add Mode


Rev. 10/2005 6-34

Production �� Pan Ticket Maintenance �� Pan Ticket Add Mode: Primary Operations


Operation Selection

• Primary Operation

• Secondary Operation

• Assembly

YES RADIO BUTTON The user may select the type of pan ticket operation to add using the three available radio buttons.

The Primary Operation display window is available when the Primary Operation radio button is selected.

The Secondary Operation displayed in the bottom half of the form is available when the Secondary Operation radio button is selected.

The Assembly Operation radio button, when activated, reconfigures the fields included in the Primary Operation display window

Primary Operation The Primary Operation display window is available when the Primary Operation radio button is selected.

Run Code YES ALPHANUMERIC Enter in the Run Code generated during shop order scheduling.

Shop Order Number YES ALPHANUMERIC Enter in the Shop Order number.

Release Number YES DROPDOWN Enter in the Shop Order Release Number.

Operation Number YES DROPDOWN Enter in the Operation number or select from the dropdown list.

Override Workcenter NO CHECKBOX Activate checkbox to override the workcenter defined in the shop order.

Workcenter NO DROPDOWN The workcenter field is available for selection when the corresponding “Override Workcenter” checkbox is activated. Select the new workcenter from the dropdown list.

Raw Material Inventory Number

YES ALPHANUMERIC Enter in the Raw Material Inventory Number consumed during the operation. The search button is available for selection.

Raw Material Lot Number YES DROPDOWN Enter in the lot number of the selected raw material.


Rev. 10/2005 6-35

Production �� Pan Ticket Maintenance �� Pan Ticket Add Mode: Primary Operations


Issued to Employee YES DROPDOWN Enter the employee name that will be issued the pan ticket. The selected employee will complete the operation on the defined workcenter.

Number of Tickets to Issue

NO NUMBER Enter in the number of tickets to print. General procedure tags one pan ticket per each tray of parts being produced by an employee during a shift.

Create Pan Tickets and Print

N/A PUSHBUTTON Activate pushbutton to print the pan tickets using the information entered.

Clear N/A PUSHBUTTON Activate pushbutton to clear the form for reentry.


Rev. 10/2005 6-36

Pan Tickets for Secondary Operations

Individual pan tickets maybe printed for each secondary operation by using the second half of the Pan Ticket Add Mode form displayed below. The information included in the Secondary Operation pan tickets vary from the Primary Operation tickets outlined in the section above.

The following information is included in the Secondary Operation pan ticket:

• F/G Inventory Number

• Part Number/Revision

• Operation

• Workcenter

• Employee

• A blank count grid providing the operator to enter in the Primary Operations ticket number, count, scrap, review, and defect.

• F/G Inventory Number

• Employee

• Workcenter

• Date field for user entry

Figure 6.14 Pan Ticket Add Mode for Secondary Operations


Rev. 10/2005 6-37

Production �� Pan Ticket Maintenance �� Pan Ticket Add Mode: Secondary Operations


Secondary Operation The Secondary Operation displayed in the bottom half of the form is available when the Secondary Operation radio button is selected.

Finished Goods Inventory Number

YES ALPHANUMERIC Enter in the Finished Goods inventory number of the selected shop order.

Operation Number YES NUMBER Enter in the secondary operation assigned to the employee via the Pan Ticket.

Workcenter YES DROPDOWN Enter in the workcenter used during the operation.

Issued to Employee YES DROPDOWN Select the employee from the dropdown list assigned to the operation/workcenter.


YES NUMBER Enter in the number of tickets to print. General procedure tags one pan ticket per each tray of parts being produced by an employee during a shift.

Print Pan Tickets N/A PUSHBUTTON Activate pushbutton to print the pan tickets using the information entered.


Exit N/A PUSHBUTTON Activate pushbutton to exit form back to the “Data” tab of the Pan Ticket Maintenance subsystem.


Rev. 10/2005 6-38

Pan Tickets for Assembly Operations

Figure 6.15 Pan Ticket Add Mode for Assembly Operations

Production �� Pan Ticket Maintenance �� Pan Ticket Add Mode: Assembly Operations


Primary Assembly Operation

The Assembly Operation radio button, when activated, reconfigures the fields included in the Primary Operation display window.

Run Code YES ALPHANUMERIC Enter in the Run Code generated during shop order Scheduling.

Shop Order Number YES ALPHANUMERIC Enter in the Shop Order number.

Release Number YES DROPDOWN Enter in the Shop Order Release Number.

Operation Number YES DROPDOWN Enter in the Operation number or select from the dropdown.

Override Workcenter NO CHECKBOX Activate checkbox to override the workcenter defined in the shop order.

Workcenter NO DROPDOWN The workcenter field is available for selection when the corresponding “Override Workcenter” checkbox is activated. Select the new workcenter from the dropdown list.


Rev. 10/2005 6-39

Production �� Pan Ticket Maintenance �� Pan Ticket Add Mode: Assembly Operations


Quantity of Parts to Produce

YES NUMBER Enter in the quantity of parts to be assembled by the assigned employee.

Issued to Employee YES DROPDOWN Enter the employee name that will be issued the pan ticket. The selected employee will complete the operation on the defined workcenter.


YES NUMBER Enter in the number of tickets to print. General procedure tags one pan ticket per each tray of parts being produced by an employee during a shift.

Add Assembly Tickets, Lots and Print

N/A PUSHBUTTON Activate pushbutton to print the pan tickets using the information entered.



Rev. 10/2005 6-40

Batch Pan Ticket to Job Card Maintenance

Once daily operations are completed by the shop floor associates, the Pan Tickets associated with the employee and operations completed are used to create Job Cards. The Job Cards are used to track the raw material costs as well as labor and burden costs associated with the job.

The Batch Pan Ticket to Job Card Maintenance form is used to create Job Cards using the information entered on the Pan Tickets. The form is broken down into two distinct sections. Section one of figure 6.16 shown below, displays the list of added pan tickets to the system. Section two of the figure 6.16 is used for data entry while adding the pan tickets to the system.

Once the user has added all completed pan tickets to the system, the job cards maybe subsequently created for all entries listed in section one of the form.

Both primary and secondary operations maybe added to the utility by using the appropriate operation tab provided. Additional information regarding the form and included fields and parameters are provided on the corresponding table below.

Figure 6.16 Batch Pan Ticket to Job Card Maintenance

Section 1 �

Section 2 �


Rev. 10/2005 6-41

Menu Selection


• Select “Batch Pan Ticket to Job Card Maintenance” from the drop down list.

Security



Rev. 10/2005 6-42

Creating Job Cards for Primary Operations via Batch Pan Ticket Entry

Job Cards can be quickly created for a list of completed primary operations. The Primary Operations are entered into the system using the “Primary Operations Tab” of the Batch Pan Ticket to Job Card Maintenance form.

Figure 6.17 Adding Batch Pan Tickets to Job Cards for Primary Operations

The following steps are used during the procedure:

• Activate the ADD pushbutton located in the Primary Operations tab displayed in the figure above. This action enables the input fields for further entry.

• Enter in the data into the input fields displayed in the figure above. Additional information regarding the available fields and parameters are provided in the corresponding table below.

• The SAVE pushbutton adds the record to the Primary Operation display list shown in section one of figure 6.17.

• Activate the FINISHED pushbutton to complete the entry process and to re-enable section one of figure 6.17.

• Activate the CREATE JOB CARDS pushbutton to initiate the Job Card creation procedure for all entries included in the list.

Section 1 �

Section 2 �


Rev. 10/2005 6-43

Production �� Batch Pan Ticket to Job Card Maintenance �� Primary Operations Tab


Add N/A PUSBUTTON Activate pushbutton to enter in a pan ticket for job card creation.

Update N/A PUSBUTTON Activate pushbutton to update the highlighted pan ticket. Once activated, the pan ticket information is retrieved into section two of figure 6.17 for further update.

Delete N/A PUSBUTTON Activate pushbutton to remove the highlighted pan ticket from the list. Once the delete validation is confirmed, the record is permanently removed from the system.

Create Job Cards N/A PUSBUTTON Activate pushbutton to create job cards for all of the pan ticket entries included in the list.

Exit N/A PUSBUTTON Activate pushbutton to exit the form back to the main Visual EstiTrack menu system.

Derive Hours from Quantity

NO CHECKBOX Activate checkbox to calculate a theoretical production time for the quantity produced by using the defined cycle times and the number of parts produced on the pan ticket.

Section 2 of Figure 6.17

Date NO DATE Enter in the date the pan ticket was completed by the operator.

Ticket Number NO NUMBER Enter in the Pan Ticket number.

Shift NO NUMBER Enter in the shift the operator completed the operation.

Number of Machines NO NUMBER Enter in the number of machines used to complete the operation.

Produced NO NUMBER Enter in the total number of pieces produced by the operator.

Review NO NUMBER Enter in the number of produced pieces that went to the material review board for inspection.

Rework NO NUMBER Enter in the number of produced pieces that needed to be reworked.

Scrap NO NUMBER Enter in the number of produced pieces that were scrapped by the operator.


Rev. 10/2005 6-44

Production �� Batch Pan Ticket to Job Card Maintenance �� Primary Operations Tab


Setup Hours NO NUMBER Enter in the total number of setup hours for the given machine/workcenter.

Production Hours NO NUMBER Enter in the total number of production hours.

Downtime Hours NO NUMBER Enter in the total number of downtime hours.

Save N/A PUSHBUTTON Activate pushbutton to save the entries to the Pan Ticket list.

Finished N/A PUSHBUTTON Activate pushbutton to complete the pan ticket entry process.


Rev. 10/2005 6-45

Creating Job Cards for Secondary Operations via Batch Pan Ticket Entry

Job Cards can be quickly created for a list of completed secondary operations using the “Secondary Operations” tab of the Batch Pan Ticket to Job Card Maintenance form.

Figure 6.18 Batch Pan Ticket to Job Card Maintenance – Secondary Operation

The following steps are used during the procedure:

• Activate the ADD pushbutton located in the Secondary Operations tab displayed in the figure above. This action enables the input fields for further entry.

• Enter in the data into the input fields displayed in the figure above. Additional information regarding the available fields and parameters are provided in the corresponding table below.

• Activate the SAVE pushbutton to add the record to the Secondary Operation display list shown in gray above.

• Activate the FINISHED pushbutton to complete the entry process and to re-enable section one of figure 6.18.

• Activate the CREATE JOB CARDS pushbutton to initiate the Job Card creation procedure for all entries included in the list.

Section 1 �

Section 2 �


Rev. 10/2005 6-46

Production �� Batch Pan Ticket to Job Card Maintenance �� Secondary Operations Tab


Add N/A PUSHBUTTON Activate pushbutton to enter in a pan ticket for the secondary operation.

Update N/A PUSHBUTTON Activate pushbutton to update the highlighted pan ticket. Once activated, the pan ticket information is retrieved into section two of figure 6.18 for further update.

Delete N/A PUSHBUTTON Activate pushbutton to remove the highlighted pan ticket from the list. Once the delete validation is confirmed, the record is permanently removed from the system.

Create Job Cards N/A PUSHBUTTON Activate pushbutton to create job cards for all of the pan ticket entries included in the list.

Exit N/A PUSHBUTTON

Activate pushbutton to exit the form back to the main Visual EstiTrack menu system.

Derive Hours from Quantity

NO CHECKBOX Activate checkbox to derive the production hours from the quantity produced.

Plating Posting NO CHECKBOX In Progress…

Date NO DATE Enter in the date the pan ticket was completed by the operator.

Employee NO TEXT Enter in the Employee code of the operator that completed the operation.

Shift NO NUMBER Enter in the shift the operator completed the operation.

Number of Machines NO NUMBER Enter in the number of machines used to complete the operation.

Operation NO NUMBER Enter in the secondary operation number.

Pan Ticket Number NO NUMBER Enter in the original pan ticket number assigned to the shop order’s primary operation.

Workcenter NO ALPHANUMERIC Enter in the workcenter used to complete the operation.

Produced NO NUMBER Enter in the total number of pieces produced by the operator.

Review NO NUMBER Enter in the number of produced pieces that went to the material review board for inspection.


Rev. 10/2005 6-47

Production �� Batch Pan Ticket to Job Card Maintenance �� Secondary Operations Tab


Rework NO NUMBER Enter in the number of produced pieces that needed to be reworked.

Scrap NO NUMBER Enter in the number of produced pieces that were scrapped by the operator.

Setup Hours NO NUMBER Enter in the total number of setup hours for the given machine/workcenter.

Production Hours NO NUMBER Enter in the total number of production hours.

Downtime Hours NO NUMBER Enter in the total number of downtime hours.

Save N/A PUSHBUTTON Activate pushbutton to save the entries to the Pan Ticket list.

Finished N/A PUSHBUTTON Activate pushbutton to complete the pan ticket entry process.


Rev. 10/2005 6-48

DAILY PRODUCTION MONITORING

The Daily Production Monitoring form provides the user the ability to scroll through all job cards and review operational/production efficiencies.

Additional information maybe analyzed for a selected Job Card by using the available Production Detail form. The user may review the available hours, production hours, downtime hours and reasons and part counts within the Production Detail form. Additional information regarding both the Daily Production Monitoring form and the Production Detail form is provided in the chapter below.

Figure 6.19 Daily Production Monitoring

Menu Selection


• Select “Daily Production Monitoring” from the drop down list.

Security



Rev. 10/2005 6-49

Daily Production Monitoring

The Daily Production Monitoring form is broken down into two divisions. The Criteria display box provides the user a production filtering means. The user can filter the results according to the parameters defined within the display box.

The second half of the form displays the results of the search defined in the criteria window. The results are listed in a table format displaying the key shop order details along with a calculated percent efficiency.

The following efficiencies are calculated by the system.

Actual Operational Pcs/Hour Operational Machine

Efficiency % =

Gross Estimated Pcs/Hour

Actual Production Pcs/Hour Production Job

Efficiency % =

Net Estimated Pcs/ Hour

Additional information regarding the input fields and parameters are provided in the corresponding “Daily Production Monitoring” table below.

Production �� Daily Production Monitoring


Criteria

Date Range NO DATE Enter in the date range of the job card entries to retrieve from the system.

Employee NO DROPDOWN Select the name of the employee from the dropdown list to retrieve a list of job cards records issued to the selected employee.

Inventory Number NO ALPHANUMERIC Enter in the finished good inventory number to retrieve a list of job cards associated with the defined number.

Workcenter NO DROPDOWN Select the workcenter from the dropdown list to retrieve a list of job card records created for the defined workcenter.


Rev. 10/2005 6-50

Production �� Daily Production Monitoring


Exclude Zero Efficiency Job Cards from Weighted Averages

NO CHECKBOX Activate checkbox to exclude the job cards with a calculated zero efficiency from the weighted average calculation.

Shop Order Number NO ALPHANUMERIC Enter in a shop order number to retrieve a list of job cards created specifically for the selected shop order.

Operation Number NO NUMBER Enter in an operation number to retrieve a list of created job cards assigned with the defined operation number.

Options

Search N/A PUSHBUTTON Activate pushbutton to activate the retrieval process according to the specifications defined within the Criteria display box.

Clear N/A PUSHBUTTON Activate pushbutton to clear the Criteria fields for reentry.

Exit N/A PUSHBUTTON Activate pushbutton to exit the form back to the main Visual EstiTrack menu system.

Production Detail N/A PUSHBUTTON Activate pushbutton to retrieve the Production Detail form for the highlighted Job Card record. Additional information regarding the Production Detail form is provided in the chapter below.


Rev. 10/2005 6-51

Production Detail

The Production Detail form displayed below can be retrieved for a selected job card record by either double-clicking the record from the Daily Production Monitoring results list or by highlighting the record and further activating the PRODUCTION DETAIL pushbutton displayed in figure 6.19.

The Production Detail form provides the user insight into the job cards labor hours and parts produced. Any product defects can be reviewed via the DEFECT CODES pushbutton displayed in the figure below.

Figure 6.20 Production Detail


Rev. 10/2005 6-52

DAILY OPERATOR MONITORING

The Daily Operator Monitoring form provides the user the ability to observe daily production for a defined operator. The form provides useful insight to a manager regarding an employees performance and production efficiencies.

The user may also review the available hours, production hours, downtime hours and reasons and part counts for a selected shop order with the Production Detail form.

Figure 6.21 Daily Operator Monitoring

Menu Selection


• Select “Daily Operator Monitoring” from the drop down list.

Security



Rev. 10/2005 6-53

Daily Operator Monitoring

The Daily Operator Monitoring form is broken down into two divisions. The Criteria display box provides the user the ability to filter the results according to the parameters defined within the display box. The second half of the form displays the results list of the search defined in the criteria window. The results are listed in a table format displaying the key job card details along with the calculated operator efficiency.

The following efficiency is calculated by the system.

Adjusted Net Pieces /Hour Operator Efficiency % =

Gross Estimated Pcs/Hour

Production �� Daily Operator Monitoring


Criteria

Date Range NO DATE Enter in the date range of the job card entries to retrieve from the system.

Employee NO DROPDOWN Select the name of the employee from the dropdown list to review their calculated efficiencies for each job card assigned to the employee that fall within the defined date range.

Inventory Number NO ALPHANUMERIC Enter in the finished good inventory number to retrieve a list of job cards associated with the defined number.

Workcenter NO DROPDOWN Select the workcenter from the dropdown list to retrieve a list of job card records created for the defined workcenter.

Efficiency Based On

• Gross Cycle

• Net Cycle

YES RADIOBUTTON Select from either the Gross cycle or Net Cycle times to use for the efficiency calculation.

Department NO DROPDOWN Select the department from the dropdown list to retrieve a list of all job cards issued to the employees associated with the selected department.

Shop Order Number NO ALPHANUMERIC Enter in a shop order number to retrieve a list of job cards created specifically for the selected shop order.

Operation Number NO NUMBER Enter in an operation number to retrieve a list of job cards assigned with the defined operation number.


Rev. 10/2005 6-54

Production �� Daily Operator Monitoring


Options

Search N/A PUSHBUTTON Activate pushbutton to activate the retrieval process according to the specifications defined within the Criteria display box.

Clear N/A PUSHBUTTON Activate pushbutton to clear the Criteria fields for reentry.

Exit N/A PUSHBUTTON Activate pushbutton to exit the form back to the main Visual EstiTrack menu system.

Production Detail N/A PUSHBUTTON Activate pushbutton to retrieve the Production Detail form for the highlighted Job Card record. Additional information regarding the Production Detail form is provided in the chapter below.


Rev. 10/2005 6-55

Production Detail

The Production Detail form displayed below can be retrieved for a selected job card record by either double-clicking the record from the Daily Operator Monitoring results list or by highlighting the record and further activating the PRODUCTION DETAIL pushbutton displayed in figure 6.21.

The Production Detail form provides the user insight into the job cards labor hours and parts produced. Any product defects can be reviewed via the DEFECT CODES pushbutton displayed in the figure below.

Figure 6.22 Production Detail


Rev. 10/2005 6-56

IN-PROCESS MONITORING

Figure 6.23 In-Process Monitoring

Menu Selection


• Select “In-Process Monitoring” from the drop down list.

Security



Rev. 10/2005 6-57

Production �� In– Process Monitoring


Criteria

Run Date NO DATE In Progress….

Shop Order Number NO ALPHANUMERIC In Progress….

Open Only NO CHECKBOX In Progress….

Workcenter NO DROPDOWN In Progress….

Employee NO DROPDOWN In Progress….

Shift NO DROPDOWN In Progress….

Shift Group NO DROPDOWN In Progress….

Options

Sort by Employee NO CHECKBOX In Progress….

Sort by Efficiency NO CHECKBOX In Progress….

Search N/A PUSHBUTTON In Progress….

Clear N/A PUSHBUTTON In Progress….

Exit N/A PUSHBUTTON In Progress….

Display

• Shop Order

• Part Number

NO RADIOBUTTON In Progress….

Drill Down In Progress….

Time Detail N/A PUSHBUTTON In Progress….

Operation Activity N/A PUSHBUTTON In Progress….


Rev. 10/2005 6-58

REMOTE TIME ADMINISTRATION

Please refer to Chapter 11 “Remote Time Collection” for Remote Time Administration operating instruction.

Figure 6.24 Remote Time Administration

Menu Selection


• Select “Remote Time Administration” from the drop down list.

Security



Rev. 10/2005 6-59

ATTENDANCE MONITORING

Figure 6.25 Attendance Monitoring

Menu Selection


• Select “Attendance Monitoring” from the drop down list.

Security



Rev. 10/2005 6-60

Production �� Attendance Monitoring


Criteria

Date Range NO DATE In Progress….


Shift Code NO DROPDOWN In Progress….

Supervisor NO DROPDOWN In Progress….

Department Code NO DROPDOWN In Progress….

Exclude Temporary Employees

NO CHECKBOX In Progress….

Show Temporary Employees Only


Late Only NO CHECKBOX In Progress….

Results List Options

• Here Now

• Scheduled but not here

• Scheduled Off

NO RADIOBUTTON In Progress….

Options In Progress….




View Time Card In Progress….

Time Detail N/A PUSHBUTTON In Progress….


Rev. 10/2005 6-61

ATTENDANCE TRACKING MONITORING

Figure 6.26 Attendance Tracking Monitoring

Menu Selection


• Select “Attendance Tracking Monitoring” from the drop down list.

Security



Rev. 10/2005 6-62

Production �� Attendance Tracking Monitoring


Criteria





Reason Code NO DROPDOWN In Progress….




Temporary Employees Only


Exceptions Only NO CHECKBOX In Progress….

Options





Rev. 10/2005 6-63

ATTENDANCE TRACKING MAINTENANCE

Figure 6.27 Attendance Tracking Maintenance

Menu Selection


• Select “Attendance Tracking Maintenance” from the drop down list.

Security



Rev. 10/2005 6-64

Production �� Attendance Tracking Maintenance


Criteria






Reason Code NO DROPDOWN In Progress….



Temporary Employees Only


Exceptions Only NO CHECKBOX In Progress….

Options



Print N/A PUSHBUTTON In Progress….

Update Detail N/A PUSHBUTTON In Progress….

Time Card N/A PUSHBUTTON In Progress….

Schedule Card N/A PUSHBUTTON In Progress….

Set Exceptions N/A PUSHBUTTON In Progress….



Rev. 10/2005 6-65

DISCIPLINARY ACTIONS MAINTENANCE

Figure 6.28 Disciplinary Actions Tracking

Menu Selection


• Select “Disciplinary Actions Tracking” from the drop down list.

Security



Rev. 10/2005 6-66

Production �� Disciplinary Actions Tracking


Criteria

Month YES SCROLL In Progress….

Year YES SCROLL In Progress….


Unissued Actions Only NO CHECKBOX In Progress….

Include Temporary Employees


Include Terminated Employees



Update Allotted Hours and Actions

N/A PUSHBUTTON In Progress….

Update Late/Early Leave Actions

N/A PUSHBUTTON In Progress….

Set Actions N/A PUSHBUTTON In Progress….



Rev. 10/2005 6-67

LOT TRACKING

Visual EstiTrack’s Lot/Serial Number Tracking form is a multifunction form provides the user with two main functions – the ability to access information regarding inventory lots and the ability to reserve lots for a specified shop order via the Inventory Transfer Detail form. Additional information regarding the two functions is provided in the chapter below.

Figure 6.29 Lot/Serial Number Tracking

Menu Selection


• Select “Lot/Serial Number Tracking” from the drop down list.

Security


Section 1 �

Section 2 �

Section 3 �


Rev. 10/2005 6-68

Inventory Lot Information

The form is divided into three main sections. Section one of figure 6.29 is used as a filtering means. The user has the opportunity filter the results according to the definitions entered into the form. The user can choose to review information regarding a specific lot number, or choose to review all of a defined inventory number’s lots and Job Card Transactions. Additional information regarding the filtering options available is provided in the corresponding Lot/SN Tracking table.

Section two of figure 6.29 lists the lot numbers retrieved according to the defined search criteria. Section three of figure 6.29 displays all Job Card transactions associated with the retrieved inventory lots.

Production �� Lot/Serial Number Tracking


Search Criteria

Lot/Serial Number NO ALPHANUMERIC Enter a lot/serial number to retrieve information regarding the specified lot number.

Enable Lot Tracing N/A PUSHBUTTON In Progress….

Workcenter NO DROPDOWN Select the workcenter from the dropdown list to retrieve a list of inventory lots and job cards associated with the specified workcenter.

Heat/War No NO ALPHANUMERIC Enter in a Heat number to retrieve a list of associated lots and their corresponding Job Card transactions.

Inventory Number NO ALPHANUMERIC Enter in an Inventory Number to retrieve the inventory number’s lots and any associated Job Card transactions.

Tracking Number NO ALPHANUMERIC Enter in a Pan ticket tracking number to retrieve a list of any corresponding inventory lots and all associated Job Card transactions.

Part Number NO ALPHANUMERIC Enter in a Part number to retrieve the part number’s corresponding lots and any associated Job Card transactions.

Shop Order Number NO ALPHANUMERIC Enter in a Shop Order number to retrieve a list of any corresponding inventory lots and all associated Job Card transactions.

Location NO DROPDOWN Enter in a warehouse location to retrieve a list of inventory lots currently located in the specified location. A list of associated Job Cards also is retrieved for any corresponding lots.


Rev. 10/2005 6-69



Display YES RADIOBUTTON Select the type of information to display in section two of figure 6.29

• Shop Order Shop Order – displays any associated shop order number, transaction type inventory location

• Heat Notes Heat Notes – displays any additional defined lot notes, or heat numbers.

Exclude Completed Operations

NO CHECKBOX Activate pushbutton to exclude any completed operations from the results list.

Non-Reserved Lots Only NO CHECKBOX Activate checkbox to retrieve a list of non-reserved lots only.

Include Zero Quantity Lots

NO CHECKBOX Activate checkbox to display zero quantity lots with the results list.

Exclude Negative Lots NO CHECKBOX Activate checkbox to exclude any negative lots from the results list.

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Reserve/Transfer Lot N/A PUSHBUTTON Activate pushbutton to reserve the highlighted inventory lot for a specified shop order number. Once activated, the Inventory Transfer Detail form is retrieved allowing the user to specify a shop order, a transfer quantity and add any additional details regarding the lot transfer.

Additional information regarding the Inventory Transfer Detail form is provided further in the chapter below.

Review Certifications N/A PUSHBUTTON Activate pushbutton to retrieve the Document Manager subsystem. Any captured certifications can be reviewed within the subsystem for the selected inventory lot.

Review Heat Warranty N/A PUSHBUTTON Activate pushbutton to review any associated Heat/Warranty records.

Lot Control Tickets N/A PUSHBUTTON Activate pushbutton to print the “Production Routing Instructions” for the highlighted inventory lot and its associated shop order number.

Lot/SN Tracking Report

N/A PUSHBUTTON Activate pushbutton to print a “Lot/SN Tracking Report”. The records retrieved into section two of figure 6.29 are included into the report.


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Options

Search N/A PUSHBUTTON Activate pushbutton to retrieve a list of results according to the specifications defined within the Search Criteria display box.

Clear N/A PUSHBUTTON Activate pushbutton to clear the Search Criteria display box for reentry.

Exit N/A PUSHBUTTON Exits the Lot/SN Tracking form back to the main Visual EstiTrack menu system.

Drill Down Production Detail Report

N/A

PUSHBUTTON

Activate pushbutton to retrieve the Production Detail Report for the highlighted Job Card Record.


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Reserving an Inventory Lot for a Specified Shop Order

The purpose of the Inventory Transfer Detail form is to reserve a material lot for consumption by a specified shop order. Additional details regarding the included fields and parameters are further provided in the corresponding table below.

The following steps are used to access to the form for a specified inventory number:

• Retrieve a list of material lots into section two of the Lot Tracking form.

• Highlight the selected material lot

• Activate the RESERVE/TRANSFER LOT pushbutton located below section two of figure 6.29.

Figure 6.30 Inventory Transfer Detail form


Rev. 10/2005 6-72

Production �� Lot/Serial Number Tracking �� Inventory Transfer Detail


Inventory Number N/A DISPLAY Displays the Inventory Number of the selected lot number.

Part Number N/A DISPLAY Displays the Part Number of the selected lot number.

Part Description N/A DISPLAY Displays the Part Description of the selected lot number.

Revision N/A DISPLAY Displays the Part Revision of the selected lot number.

Date Received N/A DISPLAY Displays the date the selected lot was received into the system.

Supplier N/A DISPLAY If applicable, the field displays the name of the supplier who provided the selected material lot.

Reserve for Shop Order NO ALPHANUMERIC Enter the Shop Order number or user the search key for selection. A quantity of the selected material lot maybe reserved for the defined Shop Order.

Producing Shop Order N/A DISPLAY If applicable, displays the shop order use to create or treat the selected material lot.

Last Operation Number NO DROPDOWN ?If applicable, displays the last operation used by the Producing Shop Order to create or treat the selected material lot.

Lot/Serial Number NO ALPHANUMERIC Enter in the lot/serial number. If the form was accessed from the Lot/Serial Number Tracking form, the highlighted material lot number is automatically transferred into the field.

Heat Number NO ALPHANUMERIC Enter in the material’s heat number if applicable.

Current Location N/A DISPLAY Displays the current location of the selected material lot.

Bin N/A DISPLAY Displays the current bin of the selected material lot.

Quantity Transferred NO NUMBER Enter in the amount of the selected material lot to transfer/reserve to the specified shop order number. The entire quantity of the selected material lot is automatically defaulted into the field in the material’s UOM.

Pc to Stock UOM N/A PUSHBUTTON Activate pushbutton to use the pieces to stock calculator provided. The user is provided with the calculator to quickly


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Production �� Lot/Serial Number Tracking �� Inventory Transfer Detail


Calculator calculate the material lot’s UOM by entering in the number of pieces required.

Lot Quantity on Hand N/A DISPLAY Displays the current available amount of the selected material lot.

Inventory Location NO DROPDOWN Select the “transfer to” inventory location from the dropdown list.

Bin NO DROPDOWN Select the “transfer to” inventory bin from the dropdown list.

Revision Number NO ALPHANUMERIC In Progress….

Revision Level NO DROPDOWN In Progress….

Lot/Transfer Notes NO TEXT A free form text field used to capture any additional Lot/Transfer notes.

Save N/A PUSHBUTTON Activate pushbutton to save the changes made to the form.



Rev. 10/2005 6-74

Inventory Lots/Transfer Notes

Additional material lot or lot transfers notes can be captured or viewed within the Inventory Lots/Transfer Notes form displayed in the figure below. This form can be accessed by the user from the Lot/SN Tracking form. A double-click on a retrieved material lot in section two of figure 6.29 retrieves the below form where any notes maybe stored. Any associated inventory transfer information is also displayed for the user.

Figure 6.31 Inventory Lot/Transfer Notes


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PRODUCTION REPORTS

Figure 6.32 Production Reports


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Menu Selection


• Select “Production Reports” from the drop down list.

Security



Rev. 10/2005 6-77

Report

• Daily Production Report

• Daily Productivity Report

• Daily Operator Report

• Average Operational/Efficiency

• Production Tracking Report

• Daily Log Report

• Downtime Problems Report

• Scrap Summary Report

• Scrap Summary Detail Report

• Defects Report

• Rework Summary Report

• Review Summary Report

• Daily Efficiency Report

• Weekly Efficiency Report

• Daily Production Report

• Shop Order Hours Report

• Assigned vs. Unassigned Hours report

• Daily Employee Report

• Weekly Employee Report

• Labor Hours Report

• Indirect Costs Report

• Earnings Rate History Report

• PPM Defects Report


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Report

• Schedule vs. Time Card Variance Report

• Operation Days in Queue Report

• Production Tickets

• Lot Control Tickets

cccchapter hapter hapter 6666 productionproduction

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