Standard Operations

The standard operation is a "template" operation used to create or modify the routing operations.

The definition of the fields of a standard operation is very similar to that of a routing operation.

Recover the standard operation data:

• if the operation unit is mentioned in the standard operation, it is used again, otherwise, the stock unit of the product in the routing is used.
  If not entered, the conversion coefficient is extracted from the coefficient table
• The times (rate, setting time and operating time) are converted if the time unit of the routing header is different from that of the standard operation.
  The standard operation is referenced in the operation that called it as a template.

 When modifying a standard operation, the modifications are not passed on to the associated operations.

It is mandatory to enter a site for a standard operation.

The production site associated with the user is proposed by default. It can be modified by another site authorized for the operator, depending on its authorizations.

The chosen site conditions the choice of the work centers on which this operation is defined. These work centers must exist at the site in question.

 It is possible to define the same standard operation code on two different sites.

The principal work center corresponds to the production resource on which the routing operation will be performed. It can be of machine, labor or sub-contracting type.

The scheduling of the operations looks at the availability of this work center. It is possible to specify a number of operators in the "Number of work centers" field. It is not possible to allocate to one operation more resources than there are at work center level.

If the work center has been selected with a "sub-contracting" type, the sub-contracting code for the second screen is set to "structural": in other words, the operation is systematically sub-contracted. The sub-contracting operations are managed with a lead-time described in the sub-contracting product record. The operation times are used to manage the equivalent of the load in hours, sent to the sub-contractor for information purposes.

To manage a temporary (or occasional) sub-contracting operation, it is necessary to enter the internal work center in the principal work center and enter the sub-contracting work center in the second screen with a "temporary" sub-contracting code. During the creation of a work order, scheduling is carried out in priority on the internal work center and it is possible to replace it with the sub-contracting work center if the scheduler finally wishes to sub-contract the operation.

The number of work centers makes it possible to manage the number of resources for identical resources in order to carry out an operation.

For instance, a labor work center may comprise 3 people. This is indicated by entering 3 in the number of resources.

A labor work center can be associated with the machine-type or labor-type main work center. The labor work center times are calculated using two coefficients:

• setting coefficient,
• operating coefficient applied to the setting time and operating time of the principal work center.

When creating a routing operation, the site attached to the work center must be the same as the site dedicated to the routing code, provided that the latter site is mentioned.

 This resource is considered as secondary and always available (or available at the same time as the main work center). Its load is managed for information purposes via coefficients applied to the main work center times.

If the main work center is of sub-contracting type, no secondary work center can be associated.

The number of work centers makes it possible to manage the number of resources for identical resources in order to carry out an operation.

For instance, a labor work center may comprise 3 people. This is indicated by entering 3 in the number of resources.

The time unit defines how time for the operations in this routing is expressed. The time unit can be 'hours' or 'minutes'.

It applies to the setup time, run time and the rate for all operations in the routing.

The operation time type conditions the production time entry.

The following values are possible:

• Proportional: the production time is proportional to the released quantity. It is expressed in hours and minutes (based on the time unit) for a given number of units (based on the management unit and basic quantity).
  With a proportional time type, the production time is entered in the operation time section and the rate section cannot be assigned.
• Rate: the production time is proportional to the released quantity. The rate is used to express the time in number of units per hour or minute, depending on the time unit.
  With a rate time type, the production time is entered in the rate section and the operating times, management unit and basic quantity cannot be entered.
• Fixed: the production time is independent of the released quantity. This time is expressed in hours or in minutes depending on the management unit.
  With a fixed time type, the production time is entered in the operating time section and the management unit, basic quantity and rate cannot be entered.

The setting time is a fixed amount of time necessary to prepare the work center. It is part of the work center load.

It is expressed in the time unit specified:

• either in the routing header (for a routing operation),
• or in the standard operation itself.
  

Depending on the resource being used, the number of decimals of the operation time can be insufficient to express the production time.

The management unit makes it possible to express the operation time for 1, 100, 1000 or a lot of units of parts to be produced.

If the management unit is chosen by lot, the size of the lot can be entered in the basic quantity.

The basis quantity entry depends on the management unit.

In effect, if the time is expressed for 1 unit, for 100 units or for 1,000 units, t he basis quantity is forced, respectively to 1, 100 or 1,000 units.

However, if the time is expressed for a lot, the basis quantity can be entered. If the processed routing code is dedicated to a site, it is initialized by the lot size of the pr oduct-routing for this site.

The basis quantity entry format depends on the operation unit.

The operation time is the time necessary to manufacture the product described in the routing.

The operating time unit can be:

• expressed in hours or minutes (see the time unit),
• assigned to 1, 100, 1000 or a lot of units of the operation based on the management unit,
• proportional or fixed based on the type of operation time
  Example: Time unit = Hours Time type = proportional Management unit = Time for 100 Operation time = 2 Operation unit = Kg Finished product unit = A REL-OPE conversion coefficient = 0.5
  The operation time is equal to 2 hours for 100 Kg. If the Work Order is launched for 1000 units of finished product, the time necessary to produce this operation is 10 hours to obtain 500 Kg.

The rate is a number of units produced by minute or by hour according to the time unit specified in the routing header (for an operation), or in the standard operation itself.

The number of units is expressed according to the time unit.

It can only be entered if the operation time type is the "rate".

Efficiency is a way to measure compliance to the preset standards. It can be calculated over a given period by work center: Standard hours calculated for a given production divided by the actual hours worked.

Efficiency makes it possible to correct the standard times of the routing (multiplying factor) according to the used resource.

Two efficiency rates are managed depending on the following:

• Work center: The rate is applied to all the routing operations that will take place at the work center.
• Routing operation: The rate only applies to the considered operation.

If both factors are entered, they add up.

The calculated operating time is corrected in the following way: work center efficiency * operation efficiency * time.

The WSTEFFINH - Work center efficiency history parameter (GPA chapter, MIS group) is used to specify whether the efficiency defined at work center level should be used on the routing operation.

• If WSTEFFINH is set to Yes, the efficiency entered in the work center is suggested by default when creating the routing operation with this work center. The calculated runtime = runtime entered * 1 / operation efficiency.
• If WSTEFFINH is set to No, the efficiency entered in the work center is combined with that entered in the routing operation. The calculated runtime = runtime entered * 1 / work center efficiency * 1 / operation efficiency.

This percentage is used to balance the quantities on the production operations based on the released quantity.

It is possible to introduce a shrinkage percentage on the work center, which is used to weight the planned runtimes for an operation using this work center by a loss or gain on the quantity produced for the work center.

This is the planned setting time to obtain the setting time allocated to the labor work center linked to the main work center.

This coefficient applied to the planned setting time to obtain the setting time allocated to the labor work center linked to the main work center.

This field is only available for entry if the labor work center is entered.

This is the coefficient applied to the planned operation time. It is used to obtain the operation time for the labor work center linked to the principal work center. This field is only available for entry if the labor work center is defined.

Operation times are subdivided as follows:

Proportional times are expressed for the production of an operation unit (and not in the stock unit of the finished product using the routing).

Preparation time is 'waiting time' set at the start of an operation.

 Preparation time is always expressed in hours. It does not use the time unit defined in the routing header (field Time unit). Preparation time is not applied to the work center load.

Although preparation time is waiting time it can be used for the time it takes to prepare for an operation on a work center. This might be time for settling liquids or cleaning a machine. For this type of scenario, that is when preparation time is used for setting time at the start of an operation, the resource must be available.

When scheduling preparation time the calendar for the defined resource is applied. This means that if, for example, a work center (machine or labor) runs from 08:00-12:00 and 13:00-17:00 with a break for one hour between 12:00-13:00, preparation time will be interrupted by the one hour break.

If the operation requires an 'emergency release', a reduction coefficient can be assigned that makes it possible to completely remove any preparation time.

Waiting time is 'delay time' that occurs after an operation. It is non-productive time such as drying time or cooling time that occurs after a process has been completed on a machine and until the machine can next be used.

 Waiting time is always expressed in hours. It does not use the time unit defined in the routing header (field Time unit). Waiting time is not applied to the work center load.

If machine time is required for an operation during the allowed waiting time you should add a new operation to this routing. A machine might be required for example, for drying or cooling components at a work center. The additional operation must be for the appropriate resource type, such as 'cooler'.

When scheduling time for these resources if, for example, a work center (machine or labor) runs from 08:00-12:00 and 13:00-17:00 with a break for one hour between 12:00-13:00:

• When scheduling waiting time the calendar for the defined resource is applied. Waiting time will be interrupted by the one hour break.
• When scheduling time for the additional resource the calendar for the defined resource is applied. Time will be interrupted by the one hour break.

Post operation, or post run time is a 'deadline' that occurs after waiting time. It is non-productive time, typically 'transfer time', or a transition period from one work center to the next work center that occurs after a process has been completed on a machine and until the machine can next be used.

 Waiting time is always expressed in hours. It does not use the time unit defined in the routing header (field Time unit). Waiting time is not applied to the work center load.

If operator time is required for an operation during the allowed post run time you should add a new operation to this routing. An operator might be required for example, for the transportation or carriage, or the transition between two work centers. The additional operation must be for the appropriate resource type, such as 'carrier'.

When scheduling time for these resources if, for example, a work center (machine or labor) runs from 08:00-12:00 and 13:00-17:00 with a break for one hour between 12:00-13:00:

• When scheduling post run time a neutral 24 hour calendar for the defined resource is applied. Post run time is not, therefore, interrupted by the one hour break.
• When scheduling time for the additional resource the calendar for the defined resource is applied. Time will be interrupted by the one hour break.

If the operation requires an 'emergency release', a reduction coefficient can be assigned that makes it possible to completely remove any post run time.

 When scheduling time for these resources, if both waiting time and post run (post operation) time has been declared for the operation only the largest of the two values is used.

Work order operation quantities are expressed in the operation unit. Use this operation unit to express operating time in a different unit to that of the product being produced by the routing.

For example, a product managed by unit is subject to three different operations, none of which produce intermediate stock:

• Mixing time (operation 1) is expressed for a lot with Kilogram as the unit;
• Extrusion time (operation 2) is a rate in meters per hour;
• Cutting time (operation 3) is expressed in hours per unit.

There is no need to create semi-finished products for each production phase.

The operation unit is associated with a conversion coefficient for the stock unit of the product being produced by the routing and the operation unit.

The technical sheet is used to record two types of information.

• the text describing the control process or the operati ng mode.
• a set of questions/answers in order to introduce a parameter entry during quality control or production tracking.
  The answers provided can be controlled via preset values and give rise to statistics.

This field is not associated with any application processing: it can be entered as information.

The tool is represented by a product reference whose category is of tool type.

This field is not associated with any application processing: it can be entered as information.

The sub-contracting code is used to determine whether the operation is carried out internally or if it is sent outside to a sub-contracting supplier.

It can take the following values:

• No: the operation is never sub-contracted. The sub-contracting product and the sub-contracting work center cannot be assigned,
• Structural: the operation is systematically sub-contracted. The factory does not have the required skills or toolings. The sub-contracting product is mandatory and the sub-contracting work center cannot be assigned. it is loaded with the principal work center, which, in this case, must be of the sub-contracting type.
• Temporary (conjuncture related): the operation is carried out internally in priority, but in case of overload or temporary problem, it can be sub-contracted. The sub-contracting product and the sub-contracting work center can be assigned and are mandatory.

This is the code for a product with the category type ‘service’.

The service can be performed by an external subcontractor.

A subcontract work center can be used for the following: 

• Managing load issued to a subcontractor;
• Tracking subcontracted hours (if used for 'generic' subcontracted work);
• To represent a specific subcontractor.

A subcontract work center has the work center type set to 'Subcontracting'.

Routing operations are validated to ensure the work center site of a 'subcontract' work center matches the site for the routing code, if defined.

In the case of the definition of a generic sub-contracting service, a reference price can be entered in the operation.

This unit price (by operation unit) is used to value the service upstream of the order entry.

Operation grouping code.

Formula used to intervene in the formatting of the grouping code during release.

This menu is used to associate a text with the standard operation.