Monitoring Production

Monitoring production is used to follow up discrepancies in the production plan and so identify the orders that require corrective action. This is done on active orders, while information on closed orders is displayed in the production statistics.

Before you start

The process can be started when these prerequisites are met:

Description

Monitoring involves the continuous activities that show how well the plan is actually carried out. This action includes compiling and analyzing information from the shop floor to identify situations where the differences between actual and planned performance are large enough to require corrective action.

These exceptions from plan include comparing:

  • Actual time used to planned
  • Actual components issued against planned
  • Actual orders completed on time to total number of orders per work center.
  • Actual number of orders on time to the total number of orders
  • Actual input to a work center to planned input
  • Actual output from a work center to planned output
  • Unscheduled downtime per work center
  • Underloads and overloads per work center
  • Efficiency
  • Utilization rates
  • Quantity levels (per person and machine)

The section below describes the activities in this process.

Material

Information on the material issued against an order is displayed in the stock history file, and can be reviewed in such programs as Display Stock Transaction History (MMS070). Totals for quantity issued, quantity remaining for issue, estimated waste, etc. are displayed in program Work with Manufacturing Orders (PMS100) using option 11 = Comp/operation.

Operations

Information on the operations can be reviewed one of two ways in M3. When reported according to Reporting Operation Data, information is displayed in program Display Operation Transactions (PMS095). For operations reported according to Starting, Stopping, Validating and Attesting of Operation Time information is displayed in program Work with Reported Transactions (PMS400) or printed from program Print Operations - Day (PMS540). When these transactions are closed, they can only be displayed in program Work with MO Reporting - Operation (PMS070).

Quality inspection

The results from quality inspection are displayed differently depending on the type of inspection. For production without lot numbers, the results are displayed in program Display Inspection Results (PMS086). With lot numbers, the results are displayed in 'Lab Inspection Request. Open' (LIS200) (see Managing Laboratory Inspection ), or printed using program Print Lot Certificate (LIS660).

Manufacturing order

The order status indicates the progress of the manufacturing order in the order flow, from release to close. The status and other information can be followed in program Work with Manufacturing Orders (PMS100) or printed from program Work with MO - Overview (PMS620).

Work-in-progress

Work-in-progress (WIP) is printed from program Print WIP -Value (PMS605). The WIP value is obtained only if a costing model is created for the product. A to date can be specified when printing a WIP report to include all reported transactions up to and including that date in calculating the WIP value.

Scrap

Scrap is reported during operation reporting, so this information is displayed with the other operation information in programs:

  • Work with Manufacturing Orders (PMS100), option 11
  • Display Operation Transactions (PMS095)
  • Work with Reported Operation Transactions (PMS400).
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