system overview

What is a task?Definition of task says it is an elemental value-adding activity. In simple terms it means an activity that is advisable and desirable to be performed in one-go and can be performed on one work center (a machine or persons or any combination).

What is a task?Definition of task says it is an elemental value-adding activity. In simple terms it means an activity that is advisable and desirable to be performed in one-go and can be performed on one work center (a machine or persons or any combination).


Basic terminology of the system

What is a component?A Component is something that is produced by a "task" or consumed by a task. It is both tangible and measurable.

What is a component?A Component is something that is produced by a "task" or consumed by a task. It is both tangible and measurable.

What is a work center?Any assemblage of machine(s) or persons or any combination is a work center. In simple words, a work center can execute tasks.

What is a work center?Any assemblage of machine(s) or persons or any combination is a work center. In simple words, a work center can execute tasks.

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Job StudyWizard

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File

WORK CENTRE

WORK CENTRE

WORK CENTRE

Shop floorInterface

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Factory dB

SchedulingEngine

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Shop floorInterface

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Shop floorInterface

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How the system works?

Quick & easy to define an entire job with detailed workflow including estimation of time, cost & wastages.

Jobs can also be simulated to find out when they would be ready for delivery considering entire existing load in the factory.

FileOn maturity the pre-defined

job file can be scheduled whenever and as it is

Individual activities are allotted in real-time to relevant Work Centers. Whereas progress & completion is notified back.

A new activity gets automatically allotted once current is over. This cycle continues 24x7.

FACTORY DB MANAGER (FDM)

The system is generic and can work for any kind of manufacturing / project setup. What changes from one setup to another are specifics of tasks, work centers, components and there associated properties. These are user configurable and all this information resides in one database called the factory dB. For the experienced person it is possible to populate manually the factory dB or using help from an excel work sheet. However, we provide an extensive UI to enable easy factorydB configuration with detailed validation to ensure what gets created is error free.

FACTORY DB MANAGER (FDM)

The system is generic and can work for any kind of manufacturing / project setup. What changes from one setup to another are specifics of tasks, work centers, components and there associated properties. These are user configurable and all this information resides in one database called the factory dB. For the experienced person it is possible to populate manually the factory dB or using help from an excel work sheet. However, we provide an extensive UI to enable easy factorydB configuration with detailed validation to ensure what gets created is error free.


JOB STUDY WIZARD (JSW)Provides complete facility to the Sales Executive on the move to manage his/her jobs that include:

• Quick job definition both one time & periodicals.

• Simulating jobs to estimate cost, time of delivery with extensive “what if” analysis

capability.

• Scheduling of jobs.

• Complete job status monitoring, editing of various job parameters, and adding of

shipping instructions even at a later date.

• Remove or hold jobs already scheduled.

• Make of quotes Maintain details of business development forays, enquiries made,

quotes submitted and their outcome.

• Monitoring for Sales Executives’ budget and profit.

• Client interaction record: number of trips made, phone calls made, expenditure

incurred, etc.

JOB STUDY WIZARD (JSW)Provides complete facility to the Sales Executive on the move to manage his/her jobs that include:

• Quick job definition both one time & periodicals.

• Simulating jobs to estimate cost, time of delivery with extensive “what if” analysis

capability.

• Scheduling of jobs.

• Complete job status monitoring, editing of various job parameters, and adding of

shipping instructions even at a later date.

• Remove or hold jobs already scheduled.

• Make of quotes Maintain details of business development forays, enquiries made,

quotes submitted and their outcome.

• Monitoring for Sales Executives’ budget and profit.

• Client interaction record: number of trips made, phone calls made, expenditure

incurred, etc.


WORK CENTER CONSOLE (WCC)

Can handle one or more Work Centers. Major work centers may have a dedicated WCC whereas smaller ones could be serviced by just one WCC. It is users choice. Akin to a supervisor that-

• Assigns and allows notification of tasks to be done electronically.

• Uses the statistics collected in real-time to cross verify figures entered by the Operator

• Graphical display of tasks running and yet-to-come with all details

•Work Center efficiency and utilization graphs available online with auto-updations.

WORK CENTER CONSOLE (WCC)

Can handle one or more Work Centers. Major work centers may have a dedicated WCC whereas smaller ones could be serviced by just one WCC. It is users choice. Akin to a supervisor that-

• Assigns and allows notification of tasks to be done electronically.

• Uses the statistics collected in real-time to cross verify figures entered by the Operator

• Graphical display of tasks running and yet-to-come with all details

•Work Center efficiency and utilization graphs available online with auto-updations.


SCHEDULING ENGINECONTROL CENTER CONSOLE (CCC)

Though the control centre per se is a black box for the User (a secured room with one or more Servers running several daemons 24x7x365) one would still need to control the control center as well as cull out MIS reports of sorts. All such activities are handled by the CCC.

• Costing and billing of completed jobs.

• Generation of various kinds of reports giving details of different job aspects, Work

Center utilization, efficiencies, etc.

• Registering of various consoles Password, User Code Words and privilege level

management in addition to other administrative activities concerning the Control Centre e.g.

start and stop, etc.

SCHEDULING ENGINECONTROL CENTER CONSOLE (CCC)

Though the control centre per se is a black box for the User (a secured room with one or more Servers running several daemons 24x7x365) one would still need to control the control center as well as cull out MIS reports of sorts. All such activities are handled by the CCC.

• Costing and billing of completed jobs.

• Generation of various kinds of reports giving details of different job aspects, Work

Center utilization, efficiencies, etc.

• Registering of various consoles Password, User Code Words and privilege level

management in addition to other administrative activities concerning the Control Centre e.g.

start and stop, etc.


Overall features• Execute more orders using existing resources. How?

• Cut cost of production drastically. How?

• Quickly know when new orders can be delivered without disturbing existing commitments. How?

• Always ensure 100% on-time deliveries. How?

Overall features• Execute more orders using existing resources. How?

• Cut cost of production drastically. How?

• Quickly know when new orders can be delivered without disturbing existing commitments. How?

• Always ensure 100% on-time deliveries. How?


Execute more orders using existing resources.

An order is an abstraction. What we actually execute are individual tasks or activities. If one really decides to list them individually, then even a simple order can have several elemental tasks. The more orders we deal with, higher is the number of individual tasks involved making things immediately very complex. It would be a painstaking endeavor to create an efficient schedule in the first place and well impossible to re-schedule all activities all over again as things change on the shop floor with an intention to maximize utilization of available resources.

We provide a solution that –

• Enables one to quickly break down an order in form of individual activities that also captures the work flow details comprehensively. It is this same representation that is used to estimate the cost, wastage and host of other details about the order. • A fully automatic scheduling engine accepts this definition as input and thereafter schedules / reschedules the job until it is over. At any point-in-time one has full visibility of how the future may unfold in detail with expected completion times for all orders known.• Re-scheduling is truly automatic and happens at a phenomenal speed (more than 90,000 tasks / minute) and is responsive to changed situation with guaranteed maximization of available resources where each allotted task can be executed. In a nutshell, if an activity can be done, and it should be done then it will be done maximizing throughput from existing resources.

Execute more orders using existing resources.

An order is an abstraction. What we actually execute are individual tasks or activities. If one really decides to list them individually, then even a simple order can have several elemental tasks. The more orders we deal with, higher is the number of individual tasks involved making things immediately very complex. It would be a painstaking endeavor to create an efficient schedule in the first place and well impossible to re-schedule all activities all over again as things change on the shop floor with an intention to maximize utilization of available resources.

We provide a solution that –

• Enables one to quickly break down an order in form of individual activities that also captures the work flow details comprehensively. It is this same representation that is used to estimate the cost, wastage and host of other details about the order. • A fully automatic scheduling engine accepts this definition as input and thereafter schedules / reschedules the job until it is over. At any point-in-time one has full visibility of how the future may unfold in detail with expected completion times for all orders known.• Re-scheduling is truly automatic and happens at a phenomenal speed (more than 90,000 tasks / minute) and is responsive to changed situation with guaranteed maximization of available resources where each allotted task can be executed. In a nutshell, if an activity can be done, and it should be done then it will be done maximizing throughput from existing resources.


Cut cost of production drastically.

The cost of coordinating order execution is comparable or may be even more than the actual cost of performing all tasks comprising the order. Breaking individual orders into elemental tasks to perform, deciding what tasks to execute, getting feedback, follow-up and revising original schedule accordingly and communicating information to all stakeholders concerned involves expensive personnel and is time consuming.

We provide a solution that-

•Automatically reschedules all activities for all orders and allocate tasks for execution to the concerned operators’ who in turn directly notifies task progress back to the scheduling engine, all in real time, to trigger the next reschedule. This process continues 24x7 unhindered.

•Offers complete transparency and visibility of the current schedule to all stakeholders in real time

Cut cost of production drastically.

The cost of coordinating order execution is comparable or may be even more than the actual cost of performing all tasks comprising the order. Breaking individual orders into elemental tasks to perform, deciding what tasks to execute, getting feedback, follow-up and revising original schedule accordingly and communicating information to all stakeholders concerned involves expensive personnel and is time consuming.

We provide a solution that-

•Automatically reschedules all activities for all orders and allocate tasks for execution to the concerned operators’ who in turn directly notifies task progress back to the scheduling engine, all in real time, to trigger the next reschedule. This process continues 24x7 unhindered.

•Offers complete transparency and visibility of the current schedule to all stakeholders in real time


Quickly know when new orders can be delivered without disturbing existing commitments

Any business is an on-going concern – existing orders get completed and new ones keep coming in. We must be in a position to quickly commit when a new order can be delivered given the existing load in-hand without disturbing any existing commitments. We provide solution where –

One can directly add a new order at end of the existing order queue and get to know delivery dates or perform extensive what-if analysis to see how best to accommodate the new order. All this with just a few button clicks.

Quickly know when new orders can be delivered without disturbing existing commitments

Any business is an on-going concern – existing orders get completed and new ones keep coming in. We must be in a position to quickly commit when a new order can be delivered given the existing load in-hand without disturbing any existing commitments. We provide solution where –

One can directly add a new order at end of the existing order queue and get to know delivery dates or perform extensive what-if analysis to see how best to accommodate the new order. All this with just a few button clicks.


Always ensure 100% on-time deliveries.

If it is possible to predict when each order in hand would be completed given the existing conditions in real-time, then it is rather a matter of just monitoring commitment dates. We provide a solution that –

Enables full future schedule visibility across all orders at task level until each order in- hand is not completed that is revised automatically as conditions change in real-time. One can thus monitor order completion dates and if need be adjust or in worst case re- negotiate a new committed date well in advance avoiding the embarrassment of doing so at the eleventh hour.

Always ensure 100% on-time deliveries.

If it is possible to predict when each order in hand would be completed given the existing conditions in real-time, then it is rather a matter of just monitoring commitment dates. We provide a solution that –

Enables full future schedule visibility across all orders at task level until each order in- hand is not completed that is revised automatically as conditions change in real-time. One can thus monitor order completion dates and if need be adjust or in worst case re- negotiate a new committed date well in advance avoiding the embarrassment of doing so at the eleventh hour.


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Overall system features

Virtual factory at customers’ disposalVirtual factory at customers’ disposal

Micro level incentive Plan Micro level incentive Plan

Built-in accountabilityBuilt-in accountability

Intelligent multi-unit schedulingIntelligent multi-unit scheduling

Salesman on wheelsSalesman on wheels

Fully scalable & easily configurableFully scalable & easily configurable

Extensive simulation facilityExtensive simulation facility

Plant at a glancePlant at a glance

Job StatusJob Status

What You See Is What You DO (WYSIWYDO)

What You See Is What You DO (WYSIWYDO)

Centralized customer databaseCentralized customer database


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Job execution & management

Automatic task telescoping to expedite

Automatic task telescoping to expedite

Minimize work-in-progressMinimize work-in-progress

One logical factory - multiple unitsOne logical factory - multiple units

Task feedback questionsTask feedback questions

Monitoring of customer committed dates

Monitoring of customer committed dates

Calculating safe windows for inputs & procurement items

Calculating safe windows for inputs & procurement items

Special job notesSpecial job notes

Interleaving tasksInterleaving tasks

Defining & using HolidaysDefining & using Holidays

Minimize job cycle timeMinimize job cycle time

Minimize WIP movement across units

Minimize WIP movement across units

Factor in variable material movement time

Factor in variable material movement time

Attribute-wise switchover savings calculation

Attribute-wise switchover savings calculation

Intelligent task divisionIntelligent task division

Task spanning over short breaksTask spanning over short breaks

Auto-selection of appropriate Work Center(s)

Auto-selection of appropriate Work Center(s)


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Real-time control & monitoring of shop floor

Resource constraint identificationResource constraint identification

Dynamic resource adjustmentDynamic resource adjustment

Meaningful task-wise feedbackMeaningful task-wise feedback

Run-time micro level costingRun-time micro level costing

Is reported good-count OK to proceed?

Is reported good-count OK to proceed?

Schedule overriding facilitySchedule overriding facility

Task’s running status feedbackTask’s running status feedback

Locking a taskLocking a task

Input material trackingInput material tracking

Continuous monitoring of committed dates

Continuous monitoring of committed dates


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Ease of job definition

Pre-defined building blocksPre-defined building blocks

Enter data just once. Reuse facilityEnter data just once. Reuse facility

Relationship between final products

Relationship between final products

Automatic cost, wastage & delivery date calculation

Automatic cost, wastage & delivery date calculation


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Workflow validation

Check for task inputs before execution

Check for task inputs before execution

Automatic extent limit checking for tasks

Automatic extent limit checking for tasks

Selection of comparable work Centers

Selection of comparable work Centers

Thorough Job validationThorough Job validation


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Workflow representation

Grouping tasksGrouping tasks

Catalytic componentsCatalytic components

Cascading tasksCascading tasks

Splitting task output and controlling its creation

Splitting task output and controlling its creation

Line-up of similar tasks of a jobLine-up of similar tasks of a job

Customer approvals and its outcome

Customer approvals and its outcome

Merging inputsMerging inputs


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Job scenario simulation

Simulating addition a group of jobs either en bloc or independently

distributed in existing priority list

Simulating addition a group of jobs either en bloc or independently

distributed in existing priority list

Simulate change in efficiency levelsSimulate change in efficiency levels

Simulate addition / deletion of Work Centers

Simulate addition / deletion of Work Centers

Manual re-ordering of tasksManual re-ordering of tasks

Add or delete NSTZsAdd or delete NSTZs

Historical analysisHistorical analysis

Assess theoretical minimum job cycle time

Assess theoretical minimum job cycle time


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THANK YOU

FOR MORE DETAILS PLEASE REFER TO OUR WEBSITE

www.etalika.in

THANK YOU

FOR MORE DETAILS PLEASE REFER TO OUR WEBSITE

www.etalika.in


system overview

Business

work sheet

major work centers

definition of task

quick job definition

job studywizard

complete job status

various job parameters

detailswork center efficiency