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Factory Control System
BUSINESS LAYER
Production Organigram

                                           Production
                                           Manager



Manufacturing                              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
Production Processes
                 Production &            Make Products
                   Materials
                   Planning

Assemble /
 Package
 Products                                                Plant Inventory
                                                          Management


                           Prduction
Manufacturing              Processes
 Oversight                                                Manufacturing
                                                         Strategy Setting




   Make or Buy          Subcontracting           Manufacturing
    Planning                                       Materials
                                                 Procurement
Fabrication Flow

Raw Material    Components        Semi Finished       Finished
                                                      Products




Receive           Make           Make Sub-         Make Final    Deliver
Material       Components        Assemblies        Assemblies




                             Logistics Processes
Logistics Processes
    Store              Deliver       Store      Warehouses    Off-site
  Custumer           Production    Customer     Design and   Services
   Returns            Material      Returns       Layout     Execution




    Logistics                                                 Receive
Strategy Setting                                             Custumer
                                                              Returns
                                    Logistics
                                   Processes


    Maintain                                                 Warehouse
    Logistics                                                  Mgmt
  Information




Store Products       Assortment    Logistics    Inventory     Receive
                   and Space Mgt   Planning     Planning      Products
Product Aggregation
                                                         Manufacturing
                                                          Engineering




                                               creates                              creates


                 Routing                                         Routing Step                           Process Plan




                                                                           performs                                    performs
                        performs
Product                                    Assembly                                           Part                            Piece
                                                                                                                              Processing


                                                                                monitors

                makes              makes                                                             makes                    makes
monitors

      Factory              Job Shop                               W ork Center                               Machine
Shop Floor Control
Production                              Shop Floor
 Control




               Factory
    Product


                             Job Shop



                Part / Lot
                                                     Work
                                                     Center

                               Routing
                                Step
                                                                Machine

                                                      Machine
                                                       Step
Factory Process

                      P roductio
                       n Order




                                                  B atc h Lot
                       Make Factory
                        Dec is ions                                                           J ob S hops
  Fac tory                                                                                    Load Plan
Information                                                                                                                 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
Factory Material Flow
                                                                           Production
                                                                            Planning
                                                                                                                       Sales
                                      Purchasing



                                                        Material
                                                                                                Demand
                                                         Reqs

                                     Purchase
                                       Order                                Product
Supplier 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
Factory Locations Map
            Factory Locations
Suppliers                        Goods
                                Warehouse
                                  (Cold)




                Job Shop A      Job Shop B   Job Shop C




                                 Assembly
                                 Job Shop




                                 Products                 Customers
                                Warehouse
                                   (Cold)
Shop Floor
Production                            Shop Floor
 Control




              Factory
    Product


                           Job Shop



              Part / Lot
                                                   Work
                                                   Center

                             Routing
                              Step
                                                              Machine

                                                    Machine
                                                     Step
Job Shop Context
                      (Parts/Lots/Routing Step
                             Execution)               Routing Steps
                         Work Orders from
                              Factory
                                                                            Job Shop
                                                                             Services




Raw Material Detail                              Job Shop                                Completed
                                                                                          Detailed
                                                                                        Components
     (input)                                                                              (output)




                          Work Orders to                    Feedback from
                           Work Center                       Work Centers



                      (Parts/Lots/Routing Step
                             Execution)
Job Shop Locations Map
Job Shop Services

                                         Services
                                       Control Office


    ToolCrib        Maintenance      Transportation      Inspection             Stores
                    Department        Department         Department




Job Shop Work Centers

                                  Work Centers Control Office




           Work Center 1           Work Center 2                Work Center 3
Job Shop Process
                    Factory
                   WorkOrder
                                                                                                  Rescheduling
                                                 Batch Lot
 Factory
WorkOrder
                                                                           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
Job Shop Context
                      (Parts/Lots/Routing Step
                             Execution)               Routing Steps
                         Work Orders from
                              Factory
                                                                            Job Shop
                                                                             Services




Raw Material Detail                              Job Shop                                Completed
                                                                                          Detailed
                                                                                        Components
     (input)                                                                              (output)




                          Work Orders to                    Feedback from
                           Work Center                       Work Centers



                      (Parts/Lots/Routing Step
                             Execution)
Job Shop Services
                        Job Shop
                         Services




Inspection    Stores    Maintenance    Tool Crib     Transport




 Inspection    Stores    Maintenance     Tool Crib     Transport
  Process     Process      Process       Process        Process
Inspection Process

                                                                                                               Inspection
                                                                                                               Exception




Inspections 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
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         Resources




Inspector Returns      Operator &         Liason Engineer
                        Foreman               Notified
                        Notified
Job Shop Services
                        Job Shop
                         Services




Inspection    Stores    Maintenance    Tool Crib     Transport




 Inspection    Stores    Maintenance     Tool Crib     Transport
  Process     Process      Process       Process        Process
Stores Process
 Shop Order   Shop Order     Floor                       Material                               Picking List
Replacement   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
Material Assignment
    Store Plan                                      Store Exception




Inventory Checking                                Issue Exception Report                 Wait for
                      Material and Alternate
                      Material not Available
                                                                                       Instructions




                                           Assign Material                 Material Assignment
Stores Process
 Shop Order   Shop Order     Floor                       Material                               Picking List
Replacement   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
Operator Material Picking
                                           Container Status




Picking Work List   Container Loading
                                           Loading Status




                              Upon Load
                              Completion




 Move Request            Request             Material Status
                      Transportation
Stores Process
 Shop Order   Shop Order     Floor                       Material                               Picking List
Replacement   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
Material Storage
        Incoming
                                                   Raise            Container
         Material
                                                  Exception          Waiting
      Classification


                        Space
                       Checking           No Space                  Store Plan
Material Type


                                            Storage
                                            Planning
                        Store Order
                                                                                                Stored Part
                                                                                                  Status
                                                              Container
                                                              Unloading

                                      Container
                                       Status                                    Material                     Part Inventory
                                                                                 Shelving



                                                                                            Inventory
                                                                                            Updating
Job Shop Services
                        Job Shop
                         Services




Inspection    Stores    Maintenance    Tool Crib     Transport




 Inspection    Stores    Maintenance     Tool Crib     Transport
  Process     Process      Process       Process        Process
Maintenance Process
                       Examine PM Plan             Defect                       Defect
PM 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
Maintenance Operations

Repair Order
                                         Repair Part                        Machine                         Transport        Machine Status   Maintenance
                                          Inventory                         Allocation                      Request             Update           Plan




Repair 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 ailability

Maintenance    Tools All ocation         Repair Parts
                                                                                          Work Center                        Transport
Informati on                              Purchase                                                                           Executed
                                                                                           Go-ahead
                                        Request Issuing




                          Repair Part                           Repair
                           Request                           Rescheduling
Maintenance Process
                       Examine PM Plan             Defect                       Defect
PM 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
Repairman Activities


Sign for m aterials     Turn in time tickets   Execute Repair    Mark last ticket
                                                                   'complete'




                                               Upon Exception



                         Maint Exception       Maint Exception      Wait for
                                                 Reporting        Instructions
Maintenance Process
                       Examine PM Plan             Defect                       Defect
PM 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
Master Mechanic Activities
                  Tools              Maintenance
                Availability            Plan




 Maintenance   Equipment &            Maint Plan
  Reporting    Repair Parts           Updating
                 Storage




  Machine      Equipment       Repair Part
   Status                       Inventory
Job Shop Services
                        Job Shop
                         Services




Inspection    Stores    Maintenance    Tool Crib     Transport




 Inspection    Stores    Maintenance     Tool Crib     Transport
  Process     Process      Process       Process        Process
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                         Location




Tool Inventory                 Tool Inventory                       Keep Tool History
                                 Updated
Tool Receiving
 Tool Crib        Space                       Container
Store Space      Checking       If No Space   Queued




                  Creating                    Storage Order
               Storage Order




Storage Plan      Storage
                  Planning




                 Container      In Case of    Tool Receiving
                 Unloading      Exception       Exception




                 Incoming
               Tools Analysis
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                         Location




Tool Inventory                 Tool Inventory                       Keep Tool History
                                 Updated
Tool Allocation Planning
                                         Stock Checking                    Tool Inventory




                                                 If Tool and Alternate
                           If Tool Available        Tool Unaivalable




                  Reordering Planning                     Issue Purchase            Notify Shop Floor
Tool Assignment                                              Request




Tool Allocation      Allocate Tools
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                         Location




Tool Inventory                 Tool Inventory                       Keep Tool History
                                 Updated
Tool issuing

Tool Crib Work     Container Loading     Loading Rate of
     List                                    Flow




                            Upon Load
                            Completion




Tools Transport    Request Transport
   Request
Job Shop Services
                        Job Shop
                         Services




Inspection    Stores    Maintenance    Tool Crib     Transport




 Inspection    Stores    Maintenance     Tool Crib     Transport
  Process     Process      Process       Process        Process
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 Mat'l Handler                                       Order
 Receiv ed                                                              Mat'l H andler                                                               Executed




  Direct Control of                   Transport
Automated Transport                   Resorces                                                                                                                   Ev aluate Transport
                                                                                                                                      Update Empirical
      Dev ices                        Allocated                                                                                                                     Perf orm ance
                                                                                                                                          Data




                                                                                                                                      Transport Em pirical        Transport Trend D ata
                                                                                                                                            Data
Allocate Resources
Transport Request                        Transport Plan




 Move Request                         Transport Sequencing   Assign Transport
   Analysis                                                    Resources




                    Transport Order                             Transport
                                                               Assignments
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 Mat'l Handler                                       Order
 Receiv ed                                                              Mat'l H andler                                                               Executed




  Direct Control of                   Transport
Automated Transport                   Resorces                                                                                                                   Ev aluate Transport
                                                                                                                                      Update Empirical
      Dev ices                        Allocated                                                                                                                     Perf orm ance
                                                                                                                                          Data




                                                                                                                                      Transport Em pirical        Transport Trend D ata
                                                                                                                                            Data
Move Executing

 Transport Plan    Materials & Tools    Container Status                  Transport
                        Status                                            Resources




                  Receive Items to be    Start Moving                   Transp Resources
Transport Plan                                             Upon Move        Releasing
   Analysis             Moved                              Completion




                                         On Exception


                                        Transp Exception
                                           Reporting
Shop Floor
Production                            Shop Floor
 Control




              Factory
    Product


                           Job Shop



              Part / Lot
                                                   Work
                                                   Center

                             Routing
                              Step
                                                              Machine

                                                    Machine
                                                     Step
Work Center Context
            (Parts/Lots/Routing Step Execution)
                   Work Orders from               Processing Steps
                      Job Shop




Last Work                        Work Center                         Next Work
 Center                                                               Center




                      Work Orders to                Feedback from
                        Machine                        Machine




              (Job/Process Step Execution)
Work Center Locations Map
  Work Center Locations

                          Work Center
                            Buffer




                           Conveyor




        Machine 1          Machine 3    Machine 2
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                            Analysis


Job Rate of Flow         Job Monitoring    Upon Parts       Parts Storage
                                            Receipt




                                                                                     Upon Lot Completion
Work Center Decisions Making

                    Work Center Decisions
                          Making




     Update Queue                           Schedule Job
Schedule Job
   Machines
                      Machines
  As signments
                     As signments
                      Checking


   Machine
   Requests
                   Machine Allocation   Machine     Raise Rerouting                 No Action
                   Requests Analysis    Overload       Request
 Machine Load
     Plan




Job 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
                      Scheduling
Buffer Load Plan
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                            Analysis


Job Rate of Flow         Job Monitoring    Upon Parts       Parts Storage
                                            Receipt




                                                                                     Upon Lot Completion
Monitor Buffer Operations

                      Monitor Buffer
                       Operations




   Buffer Receiving                    Buffer Picking
Buffer Receiving
                            Exception                       Wait for
                            Reporting                     Instructions



                                    Space not
                                    Available

                           Operator Carries                 In-area Storage    Operator
Operator
                               Material                                         Leaves
 enters
                                                                              Buffer Area
 Buffer
  Area



            Finished       Scrap Storing        Returned Tools
           Lots/Parts                               Storing
             Storing




           Lots / Parts       Scrap Status          Tool Status
             Status
Monitor Buffer Operations

                      Monitor Buffer
                       Operations




   Buffer Receiving                    Buffer Picking
Buffer Picking
                                                              Buffer Pickup
                  Operator                                     Instructions
                   enters
                 Buffer Area
                                                                                            Invalid Items
                                           Operator
                                           Analyzes
                                         Instructions


                     Special Equipment
                     Required
                                                            Load          In Case of        Exception         Wait for
Equipment   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
Shop Floor
Production                            Shop Floor
 Control




              Factory
    Product


                           Job Shop



              Part / Lot
                                                   Work
                                                   Center

                             Routing
                              Step
                                                              Machine

                                                    Machine
                                                     Step
Machine Context


                         Work Orders             Processing
                            from                 Instructions
                         Work Center




Buffer Picking                         Machine                                       Buffer
                                                                                    Receiving
                 Semi-Finished                           Semi-Finished / Finished
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 Inspection
Notif y Tool Control   Tool Remov al         Request
                                          Transportation




                                                                                                             Upon Job Completion
Machine Setup
Previous 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
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 Inspection
Notif y Tool Control   Tool Remov al         Request
                                          Transportation




                                                                                                             Upon Job Completion
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
Machining Process
Part 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)
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 Inspection
Notif y Tool Control   Tool Remov al         Request
                                          Transportation




                                                                                                             Upon Job Completion
Operator Inspection

                                              Lot not Completed


                                                                    Scrap



Part Inspection    Part not        Bad Part                        Rework        Part Counting               Lot Statistics
                                                                                                   Lot
                  Compliant        Handling                                                      Completed


                                                                  Conditioning

     Part            Part Status                                                                             Lot Statistics
APPLICATION LAYER
Batch Manufacturing
                   Batch
                Manufacturing




Manufacturing      Shop Floor         Mfg
 Automation         Control        Engineering




Manufacturing      Shop Floor
   Tools          Control System
Manufacturing Engineering

                                   Mfg
                                Engineering




Process      Robotics       NC                  Group      Routing   Plant Layout
Planning                Programming           Technology
Batch Manufacturing
                   Batch
                Manufacturing




Manufacturing      Shop Floor         Mfg
 Automation         Control        Engineering




Manufacturing      Shop Floor
   Tools          Control System
Shop Floor Control
                                                         Shop Floor
                                                          Control


                                                                                                                             Work
                                                                                                                             Center

Production    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
Production Control
Production 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
Production Order Control
 Purchase Order




     fulfills
                     Production Control
Purchasing
                                            Production Order




    Supplier

                            Production      Production
                           Order Control   Order Closing
                                                                 Hours
    Material                                                   Accounting


                                            Hours Spent
                                                                             Integration
                                                                            Transaction
Inventory
 Control                                                        Finance
Inventory Control
                                            Inventory Control


Purchasing                Purchase Order           Statistical
               fulfills                            Inventory
                                                    Control
                                                      (SIC)




 Factory                     Material             Material Issue
 Control       issues                              Registration




                                           Stock Flow
Production Control
Production 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
Factory to Production Flow
                      Material Usage                Accounting Data



Facility Usage                                                            MPS/MRP Change
                                                                             Request




                                       Factory to
                                       Production
                                                                              Inventory Cost
 Production
 Completions




                  Capacity                Factory RoF            Manpower
                 Constraints                                    Performance
Production Control
Production 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
Work Order Flow
Production                 Factory Control                          Job Shop                 Work Center
 Control                                                             Control                  Control




issues to factory with    translates product reqm't             splits factory WO into       translates jobshop WO
    product reqm't           into part reqm't and                workcenter WO for          into jobs to be assigned
                           issues WO to job shop                 specific part reqm't          to specific machines




                                                 Work Order




          Master            Requirements              Statistical              Assembly
      Production and          Planning                Inventory                Scheduling
        Inventory                                       Control
         Planning
Work Order Data Structure
Production Work    Factory Work Order         Job Shop Work Order    Work Center Work
    Order                                                                 Order




                                 Work Order                         Part In-process




                  Work Order Timing              Work Order RoF
Shop Floor Control
                                                         Shop Floor
                                                          Control


                                                                                                                             Work
                                                                                                                             Center

Production    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
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
                         crud
Dynamic Factory
Data                                  reads              creates            creates


                                                                                          Routing
                        Job Shop to                        Factory to Job
                        Factory                                Shop
Factory Data Structure
                                                                              Factory Empirical Data
                                  Material             Product
 Make or Buy Data



                                                                                                            Factory Service Order


                                                                               Factory Trend Data
Manufacturing Costs

                                             Factory



                                                                                                               Factory Service
   Factory Plans




                      Production Plan                  Job Shop Performance
                                                                                                       Raw Material              Product Inventory
                                                                                                        Inventory
Manufacturing Costs
                                    Manufacturing Costs




Material 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)
Factory Control Sub-functions
                     Receive Product    Product Manufacturing   Parts Completion Date   Explosion of Product
Report 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 rements
Parts & 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
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
                         crud
Dynamic Factory
Data                                  reads              creates            creates


                                                                                          Routing
                        Job Shop to                        Factory to Job
                        Factory                                Shop
Production to Factory Flow

Manpower Budget




                  Production to   Equipment & Facility
                    Factory            Budget



Product Reqm't
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
                         crud
Dynamic Factory
Data                                  reads              creates            creates


                                                                                          Routing
                        Job Shop to                        Factory to Job
                        Factory                                Shop
Factory to Job Shop Flow
                                                          Raw Material Availability



Part Reqm't                Factory to Job Shop




                                                          Job Shop Capacity Plan




              Equipment & Facility      Manpower Budget
                   Budget
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
                         crud
Dynamic Factory
Data                                  reads              creates            creates


                                                                                          Routing
                        Job Shop to                        Factory to Job
                        Factory                                Shop
Job Shop to Factory Flow
                    Material Usage                 Manpower
                                                  Performance
  Capacity
 Constraints
                                                                Inventory Cost



Accounting Data
                                    Job Shop to
                                      Factory

                                                                Facility Usage


 Job Shop RoF



                  Part Completion                  Assembly
                                                  Completion
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
                         crud
Dynamic Factory
Data                                  reads              creates            creates


                                                                                          Routing
                        Job Shop to                        Factory to Job
                        Factory                                Shop
Dynamic Factory Data
        Factory Empirical                          Make or Buy Data
              Data




Factory Trend                   Dynamic Factory
    Data                             Data




                Part Location                     Product Location
Factory Control
    Product                     Factory to                Production to               Work Order
                                Production                   Factory




                                                                          updates        Facility
                      updates          creates         reads

       Lot                                                                updates

                  creates                    Factory
                                             Control
                                                                           creates   Job Shop Load
                                                                                          Plan
                       crud
Dynamic Factory
Data                                reads              creates            creates


                                                                                        Routing
                      Job Shop to                        Factory to Job
                      Factory                                Shop
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Fcs - Encyclopedia

  • 3. Production Organigram Production Manager Manufacturing 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. Production Processes Production & Make Products Materials Planning Assemble / Package Products Plant Inventory Management Prduction Manufacturing Processes Oversight Manufacturing Strategy Setting Make or Buy Subcontracting Manufacturing Planning Materials Procurement
  • 5. Fabrication Flow Raw Material Components Semi Finished Finished Products Receive Make Make Sub- Make Final Deliver Material Components Assemblies Assemblies Logistics Processes
  • 6. Logistics Processes Store Deliver Store Warehouses Off-site Custumer Production Customer Design and Services Returns Material Returns Layout Execution Logistics Receive Strategy Setting Custumer Returns Logistics Processes Maintain Warehouse Logistics Mgmt Information Store Products Assortment Logistics Inventory Receive and Space Mgt Planning Planning Products
  • 7. Product Aggregation Manufacturing Engineering creates creates Routing Routing Step Process Plan performs performs performs Product Assembly Part Piece Processing monitors makes makes makes makes monitors Factory Job Shop W ork Center Machine
  • 8. Shop Floor Control Production Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  • 9. Factory Process P roductio n Order B atc h Lot Make Factory Dec is ions J ob S hops Fac tory Load Plan Information 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. Factory Material Flow Production Planning Sales Purchasing Material Demand Reqs Purchase Order Product Supplier 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. Factory Locations Map Factory Locations Suppliers Goods Warehouse (Cold) Job Shop A Job Shop B Job Shop C Assembly Job Shop Products Customers Warehouse (Cold)
  • 12. Shop Floor Production Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  • 13. Job Shop Context (Parts/Lots/Routing Step Execution) Routing Steps Work Orders from Factory Job Shop Services Raw Material Detail Job Shop Completed Detailed Components (input) (output) Work Orders to Feedback from Work Center Work Centers (Parts/Lots/Routing Step Execution)
  • 14. Job Shop Locations Map Job Shop Services Services Control Office ToolCrib Maintenance Transportation Inspection Stores Department Department Department Job Shop Work Centers Work Centers Control Office Work Center 1 Work Center 2 Work Center 3
  • 15. Job Shop Process Factory WorkOrder Rescheduling Batch Lot Factory WorkOrder 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. Job Shop Context (Parts/Lots/Routing Step Execution) Routing Steps Work Orders from Factory Job Shop Services Raw Material Detail Job Shop Completed Detailed Components (input) (output) Work Orders to Feedback from Work Center Work Centers (Parts/Lots/Routing Step Execution)
  • 17. Job Shop Services Job Shop Services Inspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  • 18. Inspection Process Inspection Exception Inspections 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. 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 Resources Inspector Returns Operator & Liason Engineer Foreman Notified Notified
  • 20. Job Shop Services Job Shop Services Inspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  • 21. Stores Process Shop Order Shop Order Floor Material Picking List Replacement 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. Material Assignment Store Plan Store Exception Inventory Checking Issue Exception Report Wait for Material and Alternate Material not Available Instructions Assign Material Material Assignment
  • 23. Stores Process Shop Order Shop Order Floor Material Picking List Replacement 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. Operator Material Picking Container Status Picking Work List Container Loading Loading Status Upon Load Completion Move Request Request Material Status Transportation
  • 25. Stores Process Shop Order Shop Order Floor Material Picking List Replacement 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. Material Storage Incoming Raise Container Material Exception Waiting Classification Space Checking No Space Store Plan Material Type Storage Planning Store Order Stored Part Status Container Unloading Container Status Material Part Inventory Shelving Inventory Updating
  • 27. Job Shop Services Job Shop Services Inspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  • 28. Maintenance Process Examine PM Plan Defect Defect PM 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. Maintenance Operations Repair Order Repair Part Machine Transport Machine Status Maintenance Inventory Allocation Request Update Plan Repair 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 ailability Maintenance Tools All ocation Repair Parts Work Center Transport Informati on Purchase Executed Go-ahead Request Issuing Repair Part Repair Request Rescheduling
  • 30. Maintenance Process Examine PM Plan Defect Defect PM 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. Repairman Activities Sign for m aterials Turn in time tickets Execute Repair Mark last ticket 'complete' Upon Exception Maint Exception Maint Exception Wait for Reporting Instructions
  • 32. Maintenance Process Examine PM Plan Defect Defect PM 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. Master Mechanic Activities Tools Maintenance Availability Plan Maintenance Equipment & Maint Plan Reporting Repair Parts Updating Storage Machine Equipment Repair Part Status Inventory
  • 34. Job Shop Services Job Shop Services Inspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  • 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 Location Tool Inventory Tool Inventory Keep Tool History Updated
  • 36. Tool Receiving Tool Crib Space Container Store Space Checking If No Space Queued Creating Storage Order Storage Order Storage Plan Storage Planning Container In Case of Tool Receiving Unloading Exception Exception Incoming Tools Analysis
  • 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 Location Tool Inventory Tool Inventory Keep Tool History Updated
  • 38. Tool Allocation Planning Stock Checking Tool Inventory If Tool and Alternate If Tool Available Tool Unaivalable Reordering Planning Issue Purchase Notify Shop Floor Tool Assignment Request Tool Allocation Allocate Tools
  • 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 Location Tool Inventory Tool Inventory Keep Tool History Updated
  • 40. Tool issuing Tool Crib Work Container Loading Loading Rate of List Flow Upon Load Completion Tools Transport Request Transport Request
  • 41. Job Shop Services Job Shop Services Inspection Stores Maintenance Tool Crib Transport Inspection Stores Maintenance Tool Crib Transport Process Process Process Process Process
  • 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 Mat'l Handler Order Receiv ed Mat'l H andler Executed Direct Control of Transport Automated Transport Resorces Ev aluate Transport Update Empirical Dev ices Allocated Perf orm ance Data Transport Em pirical Transport Trend D ata Data
  • 43. Allocate Resources Transport Request Transport Plan Move Request Transport Sequencing Assign Transport Analysis Resources Transport Order Transport Assignments
  • 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 Mat'l Handler Order Receiv ed Mat'l H andler Executed Direct Control of Transport Automated Transport Resorces Ev aluate Transport Update Empirical Dev ices Allocated Perf orm ance Data Transport Em pirical Transport Trend D ata Data
  • 45. Move Executing Transport Plan Materials & Tools Container Status Transport Status Resources Receive Items to be Start Moving Transp Resources Transport Plan Upon Move Releasing Analysis Moved Completion On Exception Transp Exception Reporting
  • 46. Shop Floor Production Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  • 47. Work Center Context (Parts/Lots/Routing Step Execution) Work Orders from Processing Steps Job Shop Last Work Work Center Next Work Center Center Work Orders to Feedback from Machine Machine (Job/Process Step Execution)
  • 48. Work Center Locations Map Work Center Locations Work Center Buffer Conveyor Machine 1 Machine 3 Machine 2
  • 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 Analysis Job Rate of Flow Job Monitoring Upon Parts Parts Storage Receipt Upon Lot Completion
  • 50. Work Center Decisions Making Work Center Decisions Making Update Queue Schedule Job
  • 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 Plan Job 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 Scheduling Buffer Load Plan
  • 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 Analysis Job Rate of Flow Job Monitoring Upon Parts Parts Storage Receipt Upon Lot Completion
  • 53. Monitor Buffer Operations Monitor Buffer Operations Buffer Receiving Buffer Picking
  • 54. Buffer Receiving Exception Wait for Reporting Instructions Space not Available Operator Carries In-area Storage Operator Operator Material Leaves enters Buffer Area Buffer Area Finished Scrap Storing Returned Tools Lots/Parts Storing Storing Lots / Parts Scrap Status Tool Status Status
  • 55. Monitor Buffer Operations Monitor Buffer Operations Buffer Receiving Buffer Picking
  • 56. Buffer Picking Buffer Pickup Operator Instructions enters Buffer Area Invalid Items Operator Analyzes Instructions Special Equipment Required Load In Case of Exception Wait for Equipment 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. Shop Floor Production Shop Floor Control Factory Product Job Shop Part / Lot Work Center Routing Step Machine Machine Step
  • 58. Machine Context Work Orders Processing from Instructions Work Center Buffer Picking Machine Buffer Receiving Semi-Finished Semi-Finished / Finished
  • 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 Inspection Notif y Tool Control Tool Remov al Request Transportation Upon Job Completion
  • 60. Machine Setup Previous 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. 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 Inspection Notif y Tool Control Tool Remov al Request Transportation Upon Job Completion
  • 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. Machining Process Part 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. 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 Inspection Notif y Tool Control Tool Remov al Request Transportation Upon Job Completion
  • 65. Operator Inspection Lot not Completed Scrap Part Inspection Part not Bad Part Rework Part Counting Lot Statistics Lot Compliant Handling Completed Conditioning Part Part Status Lot Statistics
  • 67. Batch Manufacturing Batch Manufacturing Manufacturing Shop Floor Mfg Automation Control Engineering Manufacturing Shop Floor Tools Control System
  • 68. Manufacturing Engineering Mfg Engineering Process Robotics NC Group Routing Plant Layout Planning Programming Technology
  • 69. Batch Manufacturing Batch Manufacturing Manufacturing Shop Floor Mfg Automation Control Engineering Manufacturing Shop Floor Tools Control System
  • 70. Shop Floor Control Shop Floor Control Work Center Production 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. Production Control Production 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. Production Order Control Purchase Order fulfills Production Control Purchasing Production Order Supplier Production Production Order Control Order Closing Hours Material Accounting Hours Spent Integration Transaction Inventory Control Finance
  • 73. Inventory Control Inventory Control Purchasing Purchase Order Statistical fulfills Inventory Control (SIC) Factory Material Material Issue Control issues Registration Stock Flow
  • 74. Production Control Production 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. Factory to Production Flow Material Usage Accounting Data Facility Usage MPS/MRP Change Request Factory to Production Inventory Cost Production Completions Capacity Factory RoF Manpower Constraints Performance
  • 76. Production Control Production 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. Work Order Flow Production Factory Control Job Shop Work Center Control Control Control issues to factory with translates product reqm't splits factory WO into translates jobshop WO product reqm't into part reqm't and workcenter WO for into jobs to be assigned issues WO to job shop specific part reqm't to specific machines Work Order Master Requirements Statistical Assembly Production and Planning Inventory Scheduling Inventory Control Planning
  • 78. Work Order Data Structure Production 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. Shop Floor Control Shop Floor Control Work Center Production 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. 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 crud Dynamic Factory Data reads creates creates Routing Job Shop to Factory to Job Factory Shop
  • 81. Factory Data Structure Factory Empirical Data Material Product Make or Buy Data Factory Service Order Factory Trend Data Manufacturing Costs Factory Factory Service Factory Plans Production Plan Job Shop Performance Raw Material Product Inventory Inventory
  • 82. Manufacturing Costs Manufacturing Costs Material 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. Factory Control Sub-functions Receive Product Product Manufacturing Parts Completion Date Explosion of Product Report 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 rements Parts & 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. 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 crud Dynamic Factory Data reads creates creates Routing Job Shop to Factory to Job Factory Shop
  • 85. Production to Factory Flow Manpower Budget Production to Equipment & Facility Factory Budget Product Reqm't
  • 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 crud Dynamic Factory Data reads creates creates Routing Job Shop to Factory to Job Factory Shop
  • 87. Factory to Job Shop Flow Raw Material Availability Part Reqm't Factory to Job Shop Job Shop Capacity Plan Equipment & Facility Manpower Budget Budget
  • 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 crud Dynamic Factory Data reads creates creates Routing Job Shop to Factory to Job Factory Shop
  • 89. Job Shop to Factory Flow Material Usage Manpower Performance Capacity Constraints Inventory Cost Accounting Data Job Shop to Factory Facility Usage Job Shop RoF Part Completion Assembly Completion
  • 90. 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 crud Dynamic Factory Data reads creates creates Routing Job Shop to Factory to Job Factory Shop
  • 91. Dynamic Factory Data Factory Empirical Make or Buy Data Data Factory Trend Dynamic Factory Data Data Part Location Product Location
  • 92. Factory Control Product Factory to Production to Work Order Production Factory updates Facility updates creates reads Lot updates creates Factory Control creates Job Shop Load Plan crud Dynamic Factory Data reads creates creates Routing Job Shop to Factory to Job Factory Shop