Standard operations

The standard operation.

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

Recover the standard operation data:

• If the operation unit is referenced in the standard operation, it’s reused, otherwise, the stock unit for 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.

The production site.

The production site defined on the user record is displayed by default but can be edited.

Identifies the type of operation that's performed on the work center. This might be a machine, a labor, or a subcontracted operation.

Subcontracting type work centers are managed externally by subcontract suppliers.

Identifies the production resource to use for the operation. This work center is the main or principal work center for the operation.

The resource can be a machine, a labor, or a subcontract work center. Operation scheduling considers the availability of the work center.

Subcontracting type work centers are managed using the lead time defined in the subcontract product record. Subcontract operation times are not used by the scheduling.

The labor work center.

When creating a routing operation, the work center site needs to match the site for the routing code, if defined.

Scheduling is not carried out for labor work centers. They’re considered secondary and always available, or available at the same time as the main work center. Their load is managed for information purposes only using the coefficients defined for the main work center.

Defines how time for the operation is expressed. The time unit can be hours or minutes.

The time applies to the setup time, run time, and the rate.

The operation time type applied to the production time entry.

• Proportional: The production time is proportional to the released quantity. It’s expressed in hours and minutes, as based on the time unit for a given number of units, which is based on the management unit and base quantity.
  With a proportional time type, the production time is entered in the operation time section. 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. 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. The management unit, basic quantity, and rate cannot be entered.

Specifies a fixed amount of time needed to prepare a work center.

It’s part of the work center load. It’s expressed in either the time unit specified in the routing header or in the standard operation itself. The time can be zero.

Depending on the resource being used, the number of decimals for 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, 1,000, or a lot of units of parts to be produced.

If the management unit is by lot, the lot size can be entered as the base quantity.

The base quantity depends on the management unit.

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

However, if the time is expressed for a lot, the base quantity can be entered. If the processed routing code is assigned to a site, it's initialized for the lot size of the product-routing for the site.

The time needed to manufacture the product described in the routing.

The operating time:

• Is defined in hours or minutes (Time unit field)
• Is expressed for 1, 100, 1,000, or a lot of units of the operation based on the management unit

• Can be proportional or fixed based on the operating time type

  Example

  Time unit = Hours
  Time type = proportional
  Management unit = Time for 100
  Operating time = 2
  Operating unit = kg
  Finished product unit = un
  REL-OPE conversion coefficient = 0.5
  The operation time is equal to 2 hours for 100 kg. If a work order is created for 1,000 units of the finished product, the time needed for the 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 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.

2 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 the work center. The calculated run time = run time 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 run time = run time 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’s possible to introduce a shrinkage percentage on the work center, which is used to weight the planned run times for an operation using the work center by a loss or gain on the quantity produced for the work center.

The coefficient applied to the planned operation time 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. They're 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 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. When preparation time is used for setting time at the start of an operation, the resource needs to be available.

When scheduling preparation time, the calendar for the defined resource is applied. This means that if, for example, a machine or labor work center runs from 08:00 to 12:00 and from 13:00 to 17:00 with a 1 hour break from 12:00 to 13:00, preparation time will be interrupted by the 1 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’s non-productive time.

Waiting time is not applied to the work center load. It's for periods such as drying time or cooling time that occurs after a process was completed on a machine and until the machine can next be used.

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

When scheduling time for these resources if, for example, a machine or labor work center runs from 08:00 to 12:00 and from 13:00 to 17:00 with a 1 hour break from 12:00 to 13:00:

• When scheduling waiting time: If the resource needs to be available, the calendar for the resource also applies to the waiting time. For this example, time will be interrupted by the 1 hour break.
• When scheduling time for the additional resource: The calendar for the defined resource also applies to the waiting time. The additional resource time will be interrupted by the 1 hour break.

Post operation, or post run time is a "deadline" that occurs after waiting time. It's non-productive time.

Post run time is not applied to the work center load. It's typically "transfer time", or a transition period from one work center to the next work center that occurs after a process was completed on a machine and until the machine can next be used.

If operator time is needed for an operation during the post run time, you should add a new operation to the routing. An operator might be needed, for example, for the transportation or carriage, or the transition between 2 work centers. The additional operation needs to be for the appropriate resource type, such as "carrier".

When scheduling time for these resources if, for example, a machine or labor work center runs from 08:00 to 12:00 and from 13:00 to 17:00 with a 1 hour break from 12:00 to 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 1 hour break.
• When scheduling time for the additional resource, the calendar for the defined resource is applied. Time will be interrupted by the 1 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.

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

The technical sheet. It records 2 types of information:

• The text describing the control process or the operating 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 using preset values and to provide statistics.

Indicates if the operation is subcontracted to an outside company. Subcontract is the term used to describe the purchase of a service for carrying out an operation for a work order.

• No: The operation is never subcontracted. You cannot assign a subcontract product or a subcontract work center to the operation.
• Normal: The operation is always subcontracted. The factory does not have the required skills or toolings. The subcontract product is mandatory. The main (principal) subcontract work center is assigned as the subcontract work center.
• By exception: The operation is carried out internally. It can be subcontracted in exceptional circumstances such as when instances of overload or temporary issues occur. The subcontract product and the subcontract work center are mandatory.

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 that the work center site of a subcontract work center matches the site for the routing code, if defined.