Progress Reporting in Repetitive Manufacturing

Progress reporting in repetitive manufacturing is done using these sessions:

  • Work List (tirpt4602m000)
  • Report Shift (tirpt4636m200)

Work list reporting

Reporting from the Work List (tirpt4602m000) session is done during a shift, in 'real time'. You can configure the Work List (tirpt4602m000) session to accommodate your preferred procedures using the Work List Settings (tirpt0141m000) session; you can define parameters for schedule line completion, quantity reporting and rejects processing.

After you specify the work cell, the current shift is selected and the production schedule lines for this time period are shown. You can view the status, due date, start and end dates and quantities of items for each line.

You can maintain completed and rejected quantities in the Report/Progress/Inventory part of the Work List (tirpt4602m000) session by reporting additional quantities completed on the selected schedule line. Every time a quantity is reported completed on a schedule line, the bookings for the shift are automatically updated to the work cell cost document.

During a shift the actual work cell hours are calculated by LN based on the work cell status. The labor hours are based on the quantities reported completed in combination with the labor resources and TAKT time defined in the production model. After all quantities are booked, you can report a schedule line complete.

Shift reporting in Repetitive Manufacturing

The Report Shift (tirpt4636m200) session is used to manage and report the final results at the end of each shift.

In this session you have the option to amend preliminary bookings from the Work List (tirpt4602m000) session. If all data is correct, you can complete the shift, and update the related cost document.

You report a shift completed by specifying a work cell and selecting the applicable shift. Once the shift is selected, an overview of the estimated work cell hours, labor hours, and quantities are displayed based on the production schedule lines planned for the shift along with the quantities and hours already booked.

Set- up, run, and down times can be reported using the options available in the Work List (tirpt4602m000) session, or calculated based on the quantities reported. The time booked may be less than the time available for the shift. This may occur due to booking discrepancies and can be corrected by the shift supervisor before the shift is reported complete after booking the set-up time and down time for the work cell.

If the hours are still less than the shift time after correction, the remainder of available hours is booked as wait time. Labor hours are booked similarly, however the exception is that the wait time for labor hours must be entered manually by the shift supervisor.

When a shift is closed, the related work cell cost documents can also be closed.

Note: 
  • A shift may contain multiple bookings, for example if backflushing occurs for each transport quantity the quantity, completed is booked every time the transport quantity is reached.
  • Hours are books as generic labor for the work cell, not for each employee.
  • If additional material quantities are used, you must manually book the quantities to the point of usage, that is linked to the material in the work cell cost document.

Work cell cost document reporting

A work cell cost document stores the cumulative results for a specific work cell over a period of time. These actions lead to bookings:

  • Reporting end item quantities completed
  • Reporting end item quantities rejected
  • Report labor hours and machine hours
  • Backflushing materials
  • Reporting additional materials directly on the work cell cost document.

Once the period specified in the cost documented has past, the document can be closed. You can use the Close Cost Document (tirpt7201m100) session to select the cost documents you want to report closed.

Work station progress reporting

When additional detail is required in progress reporting, you can implement reporting for each work station. You can report completed and rejected quantities for each work station if the following parameters are selected:

  • The Report on Work Stations check box in the Repetitive Manufacturing Parameters (tirpt0100m000) session must be selected.
  • The Report on Work Stations check box selected in the Production Model (tirpt2100m100) session is selected.

If the previous parameters are selected for the production model, these options are available:

  • Work station is count point

    If the Work Station Is Count Point check box in the Schedule Line Work Stations (tirpt4111m000) session is selected during scheduling, quantities of product completed and rejected are reported based on the active schedule lines of the selected work station. Reporting quantities rejected on a count point leads to an update of the work cell schedule line.

  • Work station is inspection point

    Each inspection point includes an inspection schedule defined based on the specified inspection protocol. There are two quality inspections option for Repetitive Manufacture:

    • A basic in-process inspection protocol

      The process inspection protocol is similar to the process variables functionality in Job Shop Control. You can set up inspections by specifying process variables in the Process Variables (tirpt4112m000) session, and view the results in the Inspection Results (tirpt4112m100) session.

    • An item inspection protocol using the Quality Management module

      Quality
Note: The work cell layout must accommodate reporting for each work station.
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