Factory Control System
BUSINESS LAYER
Production Organigram                                           Production                                           Manag...
Production Processes                 Production &            Make Products                   Materials                   P...
Fabrication FlowRaw Material    Components        Semi Finished       Finished                                            ...
Logistics Processes    Store              Deliver       Store      Warehouses    Off-site  Custumer           Production  ...
Product Aggregation                                                         Manufacturing                                 ...
Shop Floor ControlProduction                              Shop Floor Control               Factory    Product             ...
Factory Process                      P roductio                       n Order                                             ...
Factory Material Flow                                                                           Production                ...
Factory Locations Map            Factory LocationsSuppliers                        Goods                                Wa...
Shop FloorProduction                            Shop Floor Control              Factory    Product                        ...
Job Shop Context                      (Parts/Lots/Routing Step                             Execution)               Routin...
Job Shop Locations MapJob Shop Services                                         Services                                  ...
Job Shop Process                    Factory                   WorkOrder                                                   ...
Job Shop Context                      (Parts/Lots/Routing Step                             Execution)               Routin...
Job Shop Services                        Job Shop                         ServicesInspection    Stores    Maintenance    T...
Inspection Process                                                                                                        ...
In Process Inspection                      Inspection                         Parts Approved        Parts Rejected        ...
Job Shop Services                        Job Shop                         ServicesInspection    Stores    Maintenance    T...
Stores Process Shop Order   Shop Order     Floor                       Material                               Picking List...
Material Assignment    Store Plan                                      Store ExceptionInventory Checking                  ...
Stores Process Shop Order   Shop Order     Floor                       Material                               Picking List...
Operator Material Picking                                           Container StatusPicking Work List   Container Loading ...
Stores Process Shop Order   Shop Order     Floor                       Material                               Picking List...
Material Storage        Incoming                                                   Raise            Container         Mate...
Job Shop Services                        Job Shop                         ServicesInspection    Stores    Maintenance    T...
Maintenance Process                       Examine PM Plan             Defect                       DefectPM Plan          ...
Maintenance OperationsRepair Order                                         Repair Part                        Machine     ...
Maintenance Process                       Examine PM Plan             Defect                       DefectPM Plan          ...
Repairman ActivitiesSign for m aterials     Turn in time tickets   Execute Repair    Mark last ticket                     ...
Maintenance Process                       Examine PM Plan             Defect                       DefectPM Plan          ...
Master Mechanic Activities                  Tools              Maintenance                Availability            Plan Mai...
Job Shop Services                        Job Shop                         ServicesInspection    Stores    Maintenance    T...
Tool Crib Process              Tool                              Tool from           Fabricated /                         ...
Tool Receiving Tool Crib        Space                       ContainerStore Space      Checking       If No Space   Queued ...
Tool Crib Process              Tool                              Tool from           Fabricated /                         ...
Tool Allocation Planning                                         Stock Checking                    Tool Inventory         ...
Tool Crib Process              Tool                              Tool from           Fabricated /                         ...
Tool issuingTool Crib Work     Container Loading     Loading Rate of     List                                    Flow     ...
Job Shop Services                        Job Shop                         ServicesInspection    Stores    Maintenance    T...
Transport Process                          Transport                          Resources                                   ...
Allocate ResourcesTransport Request                        Transport Plan Move Request                         Transport S...
Transport Process                          Transport                          Resources                                   ...
Move Executing Transport Plan    Materials & Tools    Container Status                  Transport                        S...
Shop FloorProduction                            Shop Floor Control              Factory    Product                        ...
Work Center Context            (Parts/Lots/Routing Step Execution)                   Work Orders from               Proces...
Work Center Locations Map  Work Center Locations                          Work Center                            Buffer   ...
Work Center Process    WorkOrder                                            Waiting for                                   ...
Work Center Decisions Making                    Work Center Decisions                          Making     Update Queue    ...
Schedule Job   Machines                      Machines  As signments                     As signments                      ...
Work Center Process    WorkOrder                                            Waiting for                                   ...
Monitor Buffer Operations                      Monitor Buffer                       Operations   Buffer Receiving         ...
Buffer Receiving                            Exception                       Wait for                            Reporting ...
Monitor Buffer Operations                      Monitor Buffer                       Operations   Buffer Receiving         ...
Buffer Picking                                                              Buffer Pickup                  Operator       ...
Shop FloorProduction                            Shop Floor Control              Factory    Product                        ...
Machine Context                         Work Orders             Processing                            from                ...
Machine Process                                                                                                           ...
Machine SetupPrevious Setup  Teardown            Store Old Tools               in Buffer                                  ...
Machine Process                                                                                                           ...
Load / Run / Remove Work Piece                                Process Plan Job Step Analysis                     Process P...
Machining ProcessPart Setup             Chip Making                           Tool Change                                 ...
Machine Process                                                                                                           ...
Operator Inspection                                              Lot not Completed                                        ...
APPLICATION LAYER
Batch Manufacturing                   Batch                ManufacturingManufacturing      Shop Floor         Mfg Automati...
Manufacturing Engineering                                   Mfg                                EngineeringProcess      Rob...
Batch Manufacturing                   Batch                ManufacturingManufacturing      Shop Floor         Mfg Automati...
Shop Floor Control                                                         Shop Floor                                     ...
Production ControlProduction Costs             Product                 Production Plan    Facility                        ...
Production Order Control Purchase Order     fulfills                     Production ControlPurchasing                     ...
Inventory Control                                            Inventory ControlPurchasing                Purchase Order    ...
Production ControlProduction Costs             Product                 Production Plan    Facility                        ...
Factory to Production Flow                      Material Usage                Accounting DataFacility Usage               ...
Production ControlProduction Costs             Product                 Production Plan    Facility                        ...
Work Order FlowProduction                 Factory Control                          Job Shop                 Work Center Co...
Work Order Data StructureProduction Work    Factory Work Order         Job Shop Work Order    Work Center Work    Order   ...
Shop Floor Control                                                         Shop Floor                                     ...
Factory Control Context    Product                       Factory to                Production to               Work Order ...
Factory Data Structure                                                                              Factory Empirical Data...
Manufacturing Costs                                    Manufacturing CostsMaterial Cost          Material       Resource C...
Factory Control Sub-functions                     Receive Product    Product Manufacturing   Parts Completion Date   Explo...
Factory Control Context    Product                       Factory to                Production to               Work Order ...
Production to Factory FlowManpower Budget                  Production to   Equipment & Facility                    Factory...
Factory Control Context    Product                       Factory to                Production to               Work Order ...
Factory to Job Shop Flow                                                          Raw Material AvailabilityPart Reqmt     ...
Factory Control Context    Product                       Factory to                Production to               Work Order ...
Job Shop to Factory Flow                    Material Usage                 Manpower                                       ...
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The author of this presentation has created the virtual model of a batch manufacturing factory, using an enterprise architecture tool. Processes, applications, infrastructures, data models, etal, are stored in a repository called encyclopedia. Due to the impossibility of publishing the encyclopedia I decided to publish at least the diagrams, that constitute only one facet of the whole. This presentation is the collection of such diagrams.

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Fcs - Encyclopedia

  1. 1. Factory Control System
  2. 2. BUSINESS LAYER
  3. 3. Production Organigram Production ManagerManufacturing Production Factory Engineering Planning & Control Production Production Manufacturing Manufacturing Job Shop Assembly Planning Control Costs Control Shop Floor Work Job Shop Center Services Work Job Shop Maintenance Center Stores Operations Mfg Unit ToolCrib Transportations Operations Machine Operator Inspections
  4. 4. Production Processes Production & Make Products Materials PlanningAssemble / Package Products Plant Inventory Management PrductionManufacturing Processes Oversight Manufacturing Strategy Setting Make or Buy Subcontracting Manufacturing Planning Materials Procurement
  5. 5. Fabrication FlowRaw Material Components Semi Finished Finished ProductsReceive Make Make Sub- Make Final DeliverMaterial Components Assemblies Assemblies Logistics Processes
  6. 6. Logistics Processes Store Deliver Store Warehouses Off-site Custumer Production Customer Design and Services Returns Material Returns Layout Execution Logistics ReceiveStrategy Setting Custumer Returns Logistics Processes Maintain Warehouse Logistics Mgmt InformationStore Products Assortment Logistics Inventory Receive and Space Mgt Planning Planning Products
  7. 7. Product Aggregation Manufacturing Engineering creates creates Routing Routing Step Process Plan performs performs performsProduct Assembly Part Piece Processing monitors makes makes makes makesmonitors Factory Job Shop W ork Center Machine
  8. 8. Shop Floor ControlProduction Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  9. 9. Factory Process P roductio n Order B atc h Lot Make Factory Dec is ions J ob S hops Fac tory Load PlanInformation W ork Orders Des ign Lots & Routings B ill of Material Update J ob Order Is s ue J ob S hops Load E xecution S hops Orders P lan Job Shops P roc ess Plan MPS Feedback Des ign & S imulate Routings Monitor J ob S hops Reques ts Job Shop Overload Fac tory Job Shop Monitor Orders Deliver E mpiric al Data Fac tory Routing Overload Upon Order J ob S hop Rate of Flow Completion P roducts Capac ity Reques t MP S Change Outs ourc ing Is s ue W ork Order P roduct S tatus P roduct A nalyze Update Order Outs ourc ing MPS Rate of Flow P erformanc e E mpiric al Data E xecuted Order Change Make or Buy J ob S hop Data Capac ity J ob S hop P erformanc e
  10. 10. Factory Material Flow Production Planning Sales Purchasing Material Demand Reqs Purchase Order ProductSupplier Activ ities Reqs Order Customer Activ ities Factory Product Invoice Product Inv oicing Supplier Delivered Return Goods In Process Material Parts Product Deliv ery Products Warehousing Cold Warehousing Hot Warehousing
  11. 11. Factory Locations Map Factory LocationsSuppliers Goods Warehouse (Cold) Job Shop A Job Shop B Job Shop C Assembly Job Shop Products Customers Warehouse (Cold)
  12. 12. Shop FloorProduction Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  13. 13. Job Shop Context (Parts/Lots/Routing Step Execution) Routing Steps Work Orders from Factory Job Shop ServicesRaw Material Detail Job Shop Completed Detailed Components (input) (output) Work Orders to Feedback from Work Center Work Centers (Parts/Lots/Routing Step Execution)
  14. 14. Job Shop Locations MapJob Shop Services Services Control Office ToolCrib Maintenance Transportation Inspection Stores Department Department DepartmentJob Shop Work Centers Work Centers Control Office Work Center 1 Work Center 2 Work Center 3
  15. 15. Job Shop Process Factory WorkOrder Rescheduling Batch Lot FactoryWorkOrder Notify Factory Job Shop Control Decisions Making Work Center Design & Overload Simulate WorkOrder Routings Completed Job Shop Update Work Work Center Information Centers Load Manpower Plan Work Center Capacity Part Order Work Center Material Work Center Part Routings Allocation Performance Performance Completion Work Center Manpower Notice Load Plan Allocation Tools Allocation Material Empirical Data Assignment Parts in Store Update Work Orders Analyze Equipment & Tools Allocation Performance Check Job Shop Allocations Parts Storage Empirical Data Upon Order Assign Monitor Work Completion Orders Orders Upon Parts Monitor Work Receipt Centers Requests Order Execution Feedback from Work Centers
  16. 16. Job Shop Context (Parts/Lots/Routing Step Execution) Routing Steps Work Orders from Factory Job Shop ServicesRaw Material Detail Job Shop Completed Detailed Components (input) (output) Work Orders to Feedback from Work Center Work Centers (Parts/Lots/Routing Step Execution)
  17. 17. Job Shop Services Job Shop ServicesInspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  18. 18. Inspection Process Inspection ExceptionInspections Plan Random Inspection Part Status Inspection Tasks Inspection Inspection Pattern Resource Exception Rescheduling Allocation Reporting Inspections Random Inspection Impact Analysis Allocatie Parts/Lot Inspection Planning Patterns Sequences Resources Receiving Execution Generation Planning In Process Inspection Inspector Lot Releasing Equipment Inspection Inspection Inspection Impact Engagement Releasing Results Completed Reporting Lot Statistics Equipment Status
  19. 19. In Process Inspection Inspection Parts Approved Parts Rejected Resource Status Plan In- Allocate Dispatch Inspect Parts Quality Control Process Inspection Inspector to Floor Statistics Updated Inspection ResourcesInspector Returns Operator & Liason Engineer Foreman Notified Notified
  20. 20. Job Shop Services Job Shop ServicesInspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  21. 21. Stores Process Shop Order Shop Order Floor Material Picking ListReplacement In Process Stocked Availability Material Material Material Requested Requested Requested Material Material Material Operator Material Request Request Assignment Picking Fulfilled Allocation Material Status Operator Check Space Material Storage Carries Availability Material No Space Raise Exception Wait for Instructions
  22. 22. Material Assignment Store Plan Store ExceptionInventory Checking Issue Exception Report Wait for Material and Alternate Material not Available Instructions Assign Material Material Assignment
  23. 23. Stores Process Shop Order Shop Order Floor Material Picking ListReplacement In Process Stocked Availability Material Material Material Requested Requested Requested Material Material Material Operator Material Request Request Assignment Picking Fulfilled Allocation Material Status Operator Check Space Material Storage Carries Availability Material No Space Raise Exception Wait for Instructions
  24. 24. Operator Material Picking Container StatusPicking Work List Container Loading Loading Status Upon Load Completion Move Request Request Material Status Transportation
  25. 25. Stores Process Shop Order Shop Order Floor Material Picking ListReplacement In Process Stocked Availability Material Material Material Requested Requested Requested Material Material Material Operator Material Request Request Assignment Picking Fulfilled Allocation Material Status Operator Check Space Material Storage Carries Availability Material No Space Raise Exception Wait for Instructions
  26. 26. Material Storage Incoming Raise Container Material Exception Waiting Classification Space Checking No Space Store PlanMaterial Type Storage Planning Store Order Stored Part Status Container Unloading Container Status Material Part Inventory Shelving Inventory Updating
  27. 27. Job Shop Services Job Shop ServicesInspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  28. 28. Maintenance Process Examine PM Plan Defect DefectPM Plan Reported by Reported by Machine Operator Monitor PM Plan Request for Execution Attention Major Engineering Secure Repair Activity Approval Maint Ins pector Dis covers Defect Examine Repair Type Minor Repair Order Repair Iss uing Defect Adjusted on Defect Reported to Spot Master Mechanic Maintenance Operations Time Repairman Master Cost Reporting Activities Mechanic Department Activities Activities
  29. 29. Maintenance OperationsRepair Order Repair Part Machine Transport Machine Status Maintenance Inventory Allocation Request Update PlanRepair Order Tools All ocation Repair Parts Machine Request Machine Maintenance Repairman Analysis Availabil ity Allocation Equipment & Stoppi ng Starting Chargi ng Checki ng Requesting Material Transfer No Av ailabilityMaintenance Tools All ocation Repair Parts Work Center TransportInformati on Purchase Executed Go-ahead Request Issuing Repair Part Repair Request Rescheduling
  30. 30. Maintenance Process Examine PM Plan Defect DefectPM Plan Reported by Reported by Machine Operator Monitor PM Plan Request for Execution Attention Major Engineering Secure Repair Activity Approval Maint Ins pector Dis covers Defect Examine Repair Type Minor Repair Order Repair Iss uing Defect Adjusted on Defect Reported to Spot Master Mechanic Maintenance Operations Time Repairman Master Cost Reporting Activities Mechanic Department Activities Activities
  31. 31. Repairman ActivitiesSign for m aterials Turn in time tickets Execute Repair Mark last ticket complete Upon Exception Maint Exception Maint Exception Wait for Reporting Instructions
  32. 32. Maintenance Process Examine PM Plan Defect DefectPM Plan Reported by Reported by Machine Operator Monitor PM Plan Request for Execution Attention Major Engineering Secure Repair Activity Approval Maint Ins pector Dis covers Defect Examine Repair Type Minor Repair Order Repair Iss uing Defect Adjusted on Defect Reported to Spot Master Mechanic Maintenance Operations Time Repairman Master Cost Reporting Activities Mechanic Department Activities Activities
  33. 33. Master Mechanic Activities Tools Maintenance Availability Plan Maintenance Equipment & Maint Plan Reporting Repair Parts Updating Storage Machine Equipment Repair Part Status Inventory
  34. 34. Job Shop Services Job Shop ServicesInspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  35. 35. Tool Crib Process Tool Tool from Fabricated / Shop Floor Shop Floor Purchased Tool Request Received Tools Arrival Tool Allocation Tool Receiving Planning If New Tool If Bad Tool If Dam aged Tools Scrapping Tools Set out Tool History Tool Status / Tool issuing for Maintenance LocationTool Inventory Tool Inventory Keep Tool History Updated
  36. 36. Tool Receiving Tool Crib Space ContainerStore Space Checking If No Space Queued Creating Storage Order Storage OrderStorage Plan Storage Planning Container In Case of Tool Receiving Unloading Exception Exception Incoming Tools Analysis
  37. 37. Tool Crib Process Tool Tool from Fabricated / Shop Floor Shop Floor Purchased Tool Request Received Tools Arrival Tool Allocation Tool Receiving Planning If New Tool If Bad Tool If Dam aged Tools Scrapping Tools Set out Tool History Tool Status / Tool issuing for Maintenance LocationTool Inventory Tool Inventory Keep Tool History Updated
  38. 38. Tool Allocation Planning Stock Checking Tool Inventory If Tool and Alternate If Tool Available Tool Unaivalable Reordering Planning Issue Purchase Notify Shop FloorTool Assignment RequestTool Allocation Allocate Tools
  39. 39. Tool Crib Process Tool Tool from Fabricated / Shop Floor Shop Floor Purchased Tool Request Received Tools Arrival Tool Allocation Tool Receiving Planning If New Tool If Bad Tool If Dam aged Tools Scrapping Tools Set out Tool History Tool Status / Tool issuing for Maintenance LocationTool Inventory Tool Inventory Keep Tool History Updated
  40. 40. Tool issuingTool Crib Work Container Loading Loading Rate of List Flow Upon Load CompletionTools Transport Request Transport Request
  41. 41. Job Shop Services Job Shop ServicesInspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  42. 42. Transport Process Transport Resources Status Update Transport Allocatie R esources Set Mov e Standards Mov e Order Assignment Accepted Mov e Executing Transport Request Dispatched to by Matl Handler Order Receiv ed Matl H andler Executed Direct Control of TransportAutomated Transport Resorces Ev aluate Transport Update Empirical Dev ices Allocated Perf orm ance Data Transport Em pirical Transport Trend D ata Data
  43. 43. Allocate ResourcesTransport Request Transport Plan Move Request Transport Sequencing Assign Transport Analysis Resources Transport Order Transport Assignments
  44. 44. Transport Process Transport Resources Status Update Transport Allocatie R esources Set Mov e Standards Mov e Order Assignment Accepted Mov e Executing Transport Request Dispatched to by Matl Handler Order Receiv ed Matl H andler Executed Direct Control of TransportAutomated Transport Resorces Ev aluate Transport Update Empirical Dev ices Allocated Perf orm ance Data Transport Em pirical Transport Trend D ata Data
  45. 45. Move Executing Transport Plan Materials & Tools Container Status Transport Status Resources Receive Items to be Start Moving Transp ResourcesTransport Plan Upon Move Releasing Analysis Moved Completion On Exception Transp Exception Reporting
  46. 46. Shop FloorProduction Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  47. 47. Work Center Context (Parts/Lots/Routing Step Execution) Work Orders from Processing Steps Job ShopLast Work Work Center Next Work Center Center Work Orders to Feedback from Machine Machine (Job/Process Step Execution)
  48. 48. Work Center Locations Map Work Center Locations Work Center Buffer Conveyor Machine 1 Machine 3 Machine 2
  49. 49. Work Center Process WorkOrder Waiting for WorkOrder from Job Instructions Completed Shop Work Center Work Center Cannot Notify Problem to Empirical Data Work Center Decisions Making Proceed Job Shop Order Completion Notice Work Center Capacity WorkCenter Assign Jobs to Job Assignments Machines Empirical Data Update Lot Transport Request from Request Machine Work Center Capacity Update MU Requests Service Order Monitoring Mfg. Unit Performance Require Lot Transport Job Performance Monitor Buffer Operations MU Performance Upon Job Completion AnalysisJob Rate of Flow Job Monitoring Upon Parts Parts Storage Receipt Upon Lot Completion
  50. 50. Work Center Decisions Making Work Center Decisions Making Update Queue Schedule Job
  51. 51. Schedule Job Machines Machines As signments As signments Checking Machine Requests Machine Allocation Machine Raise Rerouting No Action Requests Analysis Overload Request Machine Load PlanJob As signment Job Queue Update Machine Capacity Proces s Plan Job Sequencing Job Steps Evaluate Alternate Raise Exception Stop Scheduling Machine Capacity Machine Overload Machine and / or Check No Availability Proces s Plan Job & Buffer SchedulingBuffer Load Plan
  52. 52. Work Center Process WorkOrder Waiting for WorkOrder from Job Instructions Completed Shop Work Center Work Center Cannot Notify Problem to Empirical Data Work Center Decisions Making Proceed Job Shop Order Completion Notice Work Center Capacity WorkCenter Assign Jobs to Job Assignments Machines Empirical Data Update Lot Transport Request from Request Machine Work Center Capacity Update MU Requests Service Order Monitoring Mfg. Unit Performance Require Lot Transport Job Performance Monitor Buffer Operations MU Performance Upon Job Completion AnalysisJob Rate of Flow Job Monitoring Upon Parts Parts Storage Receipt Upon Lot Completion
  53. 53. Monitor Buffer Operations Monitor Buffer Operations Buffer Receiving Buffer Picking
  54. 54. Buffer Receiving Exception Wait for Reporting Instructions Space not Available Operator Carries In-area Storage OperatorOperator Material Leaves enters Buffer Area Buffer Area Finished Scrap Storing Returned Tools Lots/Parts Storing Storing Lots / Parts Scrap Status Tool Status Status
  55. 55. Monitor Buffer Operations Monitor Buffer Operations Buffer Receiving Buffer Picking
  56. 56. Buffer Picking Buffer Pickup Operator Instructions enters Buffer Area Invalid Items Operator Analyzes Instructions Special Equipment Required Load In Case of Exception Wait forEquipment Request Special Instructions Accumulation Invalid Items Reporting Request Equipment from Job Shop Material/Tools Operator Special Status Updating Leaves Equipment Buffer Area Receiving In Case of Delay Material / Tools Delay Reporting Status Update
  57. 57. Shop FloorProduction Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  58. 58. Machine Context Work Orders Processing from Instructions Work CenterBuffer Picking Machine Buffer Receiving Semi-Finished Semi-Finished / Finished
  59. 59. Machine Process Notif y Foreman Wait f or Instructions In Case of Exception Job Arriv es Operator Report Start-up Acquire Tools Setup Machine Load / Run / Av ailable Remov e Work Piece Update Machine Update Operator Status Status Report Job Completion Update Job Status Operator InspectionNotif y Tool Control Tool Remov al Request Transportation Upon Job Completion
  60. 60. Machine SetupPrevious Setup Teardown Store Old Tools in Buffer Setup Tuning Pickup new Tools Tools Setup from Buffer Pickup Test Negative Parts from Inspection Machine Status Buffer First-Piece Machining Buffer Content First-Piece Notify to Inspecting Forem an Machine Ready
  61. 61. Machine Process Notif y Foreman Wait f or Instructions In Case of Exception Job Arriv es Operator Report Start-up Acquire Tools Setup Machine Load / Run / Av ailable Remov e Work Piece Update Machine Update Operator Status Status Report Job Completion Update Job Status Operator InspectionNotif y Tool Control Tool Remov al Request Transportation Upon Job Completion
  62. 62. Load / Run / Remove Work Piece Process Plan Job Step Analysis Process Plan Machining House Keeping Analysis Job Steps Invalid Replace Process Process Plan Process Plan Plan Deviations No Replacement Raise Exception Wait for Instructions
  63. 63. Machining ProcessPart Setup Chip Making Tool Change Part Positioning Inspection by Operator Parts Removal from the Machine Feed Rate Job Rate of Override Flow (For NC machines only)
  64. 64. Machine Process Notif y Foreman Wait f or Instructions In Case of Exception Job Arriv es Operator Report Start-up Acquire Tools Setup Machine Load / Run / Av ailable Remov e Work Piece Update Machine Update Operator Status Status Report Job Completion Update Job Status Operator InspectionNotif y Tool Control Tool Remov al Request Transportation Upon Job Completion
  65. 65. Operator Inspection Lot not Completed ScrapPart Inspection Part not Bad Part Rework Part Counting Lot Statistics Lot Compliant Handling Completed Conditioning Part Part Status Lot Statistics
  66. 66. APPLICATION LAYER
  67. 67. Batch Manufacturing Batch ManufacturingManufacturing Shop Floor Mfg Automation Control EngineeringManufacturing Shop Floor Tools Control System
  68. 68. Manufacturing Engineering Mfg EngineeringProcess Robotics NC Group Routing Plant LayoutPlanning Programming Technology
  69. 69. Batch Manufacturing Batch ManufacturingManufacturing Shop Floor Mfg Automation Control EngineeringManufacturing Shop Floor Tools Control System
  70. 70. Shop Floor Control Shop Floor Control Work CenterProduction Factory Job Control Control Shop Control Factory Job Shop Job Shop Work Buffer Machine Job Control Control Services Center Control Control Control Application Application Control Work Buf fer Machine Job Control Center Control Control Component Control Component Component Component Tool Stores Maintenance Trans port Ins pection Crib Control Control Control Control Control Tool Crib Maintenance Transport Inspection Stores Control Control Control Control Control Component Component Component Component Component
  71. 71. Production ControlProduction Costs Product Production Plan Facility creates Engineering Data updates crud crud uses Production Production Manpower Shared Data crud Control crud cu creates creates reads Factory Work Order Performance Production to Factory to Factory Production
  72. 72. Production Order Control Purchase Order fulfills Production ControlPurchasing Production Order Supplier Production Production Order Control Order Closing Hours Material Accounting Hours Spent Integration TransactionInventory Control Finance
  73. 73. Inventory Control Inventory ControlPurchasing Purchase Order Statistical fulfills Inventory Control (SIC) Factory Material Material Issue Control issues Registration Stock Flow
  74. 74. Production ControlProduction Costs Product Production Plan Facility creates Engineering Data updates crud crud uses Production Production Manpower Shared Data crud Control crud cu creates creates reads Factory Work Order Performance Production to Factory to Factory Production
  75. 75. Factory to Production Flow Material Usage Accounting DataFacility Usage MPS/MRP Change Request Factory to Production Inventory Cost Production Completions Capacity Factory RoF Manpower Constraints Performance
  76. 76. Production ControlProduction Costs Product Production Plan Facility creates Engineering Data updates crud crud uses Production Production Manpower Shared Data crud Control crud cu creates creates reads Factory Work Order Performance Production to Factory to Factory Production
  77. 77. Work Order FlowProduction Factory Control Job Shop Work Center Control Control Controlissues to factory with translates product reqmt splits factory WO into translates jobshop WO product reqmt into part reqmt and workcenter WO for into jobs to be assigned issues WO to job shop specific part reqmt to specific machines Work Order Master Requirements Statistical Assembly Production and Planning Inventory Scheduling Inventory Control Planning
  78. 78. Work Order Data StructureProduction Work Factory Work Order Job Shop Work Order Work Center Work Order Order Work Order Part In-process Work Order Timing Work Order RoF
  79. 79. Shop Floor Control Shop Floor Control Work CenterProduction Factory Job Control Control Shop Control Factory Job Shop Job Shop Work Buffer Machine Job Control Control Services Center Control Control Control Application Application Control Work Buf fer Machine Job Control Center Control Control Component Control Component Component Component Tool Stores Maintenance Trans port Ins pection Crib Control Control Control Control Control Tool Crib Maintenance Transport Inspection Stores Control Control Control Control Control Component Component Component Component Component
  80. 80. Factory Control Context Product Factory to Production to Work Order Production Factory updates Facility updates creates reads Lot updates creates Factory Control creates Job Shop Load Plan crudDynamic FactoryData reads creates creates Routing Job Shop to Factory to Job Factory Shop
  81. 81. Factory Data Structure Factory Empirical Data Material Product Make or Buy Data Factory Service Order Factory Trend DataManufacturing Costs Factory Factory Service Factory Plans Production Plan Job Shop Performance Raw Material Product Inventory Inventory
  82. 82. Manufacturing Costs Manufacturing CostsMaterial Cost Material Resource Cost Resource Outside Overhead Cost Overhead Cost Processing Cost (lot)Plastics Cost Receipt Cost Direct Labor Cost Benefit Cost (Activity) (Item) (Item) (Item) Metals Cost Issue Cost Maintenance Cost Quality Cost (Item) (Item) (Resource Units) (Lot)All Other Costs Move Cost Equip. Depreciation Cost (Item) (Lot) (Resource Value)
  83. 83. Factory Control Sub-functions Receive Product Product Manufacturing Parts Completion Date Explosion of ProductReport Product Finished Parts M ake/Buy Analysis Completion Simulation Scheduling Req mts into Parts JobShop Status Req uirements Inventory Planning Control Decisi on Model s Groupi ng of Parts i nto Lots JobShop Actual Capacity Analysi s Factory Control Fi nished Parts Shipping JobShop Reqmts Capacity Planning Planning Status Reporti ng of T ransmi t Purchased Requi rementsParts & Material s Recei ve JobShop Factory Product Product Products JobShop Status Performance JobShop Completion Performance Reporti ng of Manpower Deci si on Data Completion Feedback All ocati on Updating Noti fi cati on Analysi s Status Reporting Analysi s Speci al T ool s & Fi xtures Support Recei pts
  84. 84. Factory Control Context Product Factory to Production to Work Order Production Factory updates Facility updates creates reads Lot updates creates Factory Control creates Job Shop Load Plan crudDynamic FactoryData reads creates creates Routing Job Shop to Factory to Job Factory Shop
  85. 85. Production to Factory FlowManpower Budget Production to Equipment & Facility Factory BudgetProduct Reqmt
  86. 86. Factory Control Context Product Factory to Production to Work Order Production Factory updates Facility updates creates reads Lot updates creates Factory Control creates Job Shop Load Plan crudDynamic FactoryData reads creates creates Routing Job Shop to Factory to Job Factory Shop
  87. 87. Factory to Job Shop Flow Raw Material AvailabilityPart Reqmt Factory to Job Shop Job Shop Capacity Plan Equipment & Facility Manpower Budget Budget
  88. 88. Factory Control Context Product Factory to Production to Work Order Production Factory updates Facility updates creates reads Lot updates creates Factory Control creates Job Shop Load Plan crudDynamic FactoryData reads creates creates Routing Job Shop to Factory to Job Factory Shop
  89. 89. Job Shop to Factory Flow Material Usage Manpower Performance Capacity Constraints Inventory CostAccounting Data Job Shop to Factory Facility Usage Job Shop RoF Part Completion Assembly Completion

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