MACRO 2000 Production Control Software
The Production Control Systems from Macro 2000s’ sophisticated ERP Manufacturing Management Software will allow manufactures to plan, execute and control production. Optimise your manufacturing business from order to shipping with Macro 2000’s Production Control systems including ERP and MRP.
Production Control Software
The Macro Production Planning and Production Control Systems follow very simple and well established principles.
To produce the Correct Product to meet demand at the required time
To do so at the lowest Practical Cost
To do so with the shortest practical lead times
To do so with the maximum degree of simplicity and flexibility
To make the available resources as efficient as possible
The system is designed to allow a wide range of facilities and options. These are not compulsory and the user need only use the facilities that he requires.
Please refer to separate overview for details of the Production Planning module.
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To assist in performing pre-production activities timeously
To ensure that planned production is started and complete so that products are completed within schedule and within cost.
To launch Production Jobs with required documentation (Job Cards, Material Requisition Forms, Bundle Tickets, etc.) These will detail to production personnel the jobs to be carried out, the materials required to be drawn for these jobs, and the activities to be performed in the production process.
To capture and monitor details of work in progress and production quantities.
To maintain a tracking history of job progress.
To report on exceptional conditions to ensure that jobs progress according to plan.
To capture and record the true cost of production and to record abnormal costs such as reprocessing costs, etc.
To report on the costs and efficiencies of completed jobs in the following categories:
Planned quantities versus quantities actually produced
Actual costs versus expected standard costs in various categories
Actual resource utilisation versus expected utilisation
Planned time scale versus actual time scale.
To record historical trends in production quantities and costs by product and historical production resource utilisation and efficiency trends
Macro 2000 Manufacturing and Production Control Software is an integrated production planning and control solution to improve production efficiency
The Production Control system provides a powerful set of planning facilities. These are used to assist in establishing a firm production plan. Details of the firm plan are input to the system and stored on the Production Master File as jobs
Each job is allocated a unique production job number which follows the job through all of its production steps. A “job” may be any activity that the user wishes to designate as such. Normally (but not essentially) the item being manufactured is defined as a product in the Bill of Materials system. Typical jobs could be production of a particular product, or part of a complete job such as the manufacture of a sub-assembly or component of the final product. Essentially each user will decide how “jobs” are structured.
Very little information is required to be entered for the Production Job Master Record. Compulsory Information includes:
Point of Manufacture (Factory)
Quantity to be produced
Planned Start Date
Planned Completion Date
Considerable other information may optionally be recorded in the Job Master Record. Optional Information includes:-
Product breakdown by size and/or colour
Production line or unit or group
Pre-production activity start date
Scheduled start date
Customer order number
Internal company order number
User defined information fields
Rough Cut MRP and CRP data
Additional information is obtained from Bill of Materials Structure File, the Production Routing File and the Factory Calendar.
The Bill of Materials is not compulsory. It is commonly used to determine :
Standard components of the particular job (materials, labour, machine requirements) and the component cost.
Standard activities in the production progress. Some components have implicit activities (e.g. machine utilisation), other activities have no direct component cost (e.g. draw raw materials).
Production Routing File
The Production Routing file is not compulsory. It is commonly used to determine the production activities and elapsed time. This file contains details of the production activities to be carried out for the particular job. Any activity may be defined as a production activity. An activity may optionally be assigned an elapsed time. The elapsed time can consist of set up and tear down time plus a unit production time, or may be based on user determined elapsed time.
Standard Routings. The system allows any number of standard routings to be recorded. A standard routing is a set of activities which are frequently used. Reference to the standard routing bypasses the need to load a specific activity routing for each individual job. Associated with each activity is the elapsed time from commencement to completion. The system is capable of calculations based on setup, queuing and unit process time. Standard Routings also record time requirement for use in elapsed time calculations.
Progress reporting points. Each activity may optionally be defined as a progress report point. i.e. the computer will be advised when the activity is complete. Each job must have at least two reporting points, commencement and completion. Any number of intermediate reporting points may also be used.
Each job may have a unique set of activities defined for it or it may use a standard routing. Any production job can be assigned to a standard routing number which is much easier than loading a complete routing for each job. Alternatively a standard routing can be loaded for a job and then modified to effectively provide a unique routing with a minimum of effort.
The time based aspects of the system use the factory calendar. This is a hierarchical calendar that provides a base calendar and an unlimited number of calendars for resources which do not follow the same calendar.
Planned Jobs are loaded into the system at any time before production commences. Several reports are available. The main one is:-
Production Schedule Report. This report schedules all planned production for the production period. It also produces a summary of components required to achieve the production by time period. All components, including materials, machine utilisation and labour utilisation are summarised. Machine and labour summaries are particularly important to ensure full utilisation of resource without over-commitment. When the job is to be started (a user decision) the status is set and the system will launch the job. As each job is launched shop floor documentation is produced. This can include:-
Work Orders or Job Cards
Raw Materials Requisition Forms
Production Routing Instructions
Documentation will be tailored to specific requirements.
The Production Tracking system provides optional Pre-production Tracking, Production Tracking and Post-Production Tracking. When each job is loaded a projected production schedule with expected completion dates is loaded into the Production Tracking File.
As each job commences the system is advised. All raw materials drawn for the job are logged against the particular job. Other than normal progress reports only exceptional conditions are then reported e.g. suspension of job, reprocessing activities, scrapped production, etc. Throughout the production process the quantities complete and completion dates are advised for each process. Tracking data can be captured via on-line screens, via scanning of bar-coded Job ticket labels, or automatically (e.g. ex Raw Material Issue data)
Much of the information used by the Production Tracking sub-system is obtained from the Production Routing Master File.
The number and description of production activities and progress reporting points (refer to earlier section on routing)
The normal duration between progress reporting points.
As the job progresses, “progress reporting points” are advised to the computer system. Each job must have at least two reporting points commencement and completion. Any number of intermediate reporting points may also be used. Progress may also be recorded at non-standard reporting points
Production Quantities are reported as follows:-
Final production quantity. The final quantity can be input direct to the Production System or may be automatically transferred from input to the Finished Goods Stock System. Input from the Finished Goods system is preferred because of the handover of completed product to the Finished Goods store is normally formal and documented.
Intermediate quantities may be reported at any reporting point. Use of this facility allows close control over the location of excessive reject product or product shrinkage.
There are a large number of Production Reports. Some of the reports are: –
Production Schedule Report. This report details all planned production for a specific production period.
Production Jobs Due for Commencement. This report lists all jobs due to be commenced in a specified period.
Production Launching Report. Production Launching is always under user control. A production job is never launched until the production supervisor tells the computer to do so. When launched the computer produces a detailed report which describes the job and production quantities. It lists all materials drawn for the job. It lists the production steps to be executed as shown in the Bill of Materials File. Production launching will automatically print job tickets, if required.
The system allows optional launching of more than one job as a group. This is useful for bulk material calculation and issue.
Work tickets. Work tickets are similar in concept to the Production Launching Report. The work ticket is a robust document intended to accompany the job around the factory. Work tickets are computer printed cardboard tickets listing details of the job (Product and Quantity) materials to be drawn, production activities as defined in Bill of Materials, and progress reporting points. It lists the activities from the bottom of the card up, each on a perforated tear off strip. If the tear off strip involves a progress report it is torn off and handed to the data capture operator for input to the computer system. Work tickets may be fully or partly bar-coded.
Material Requisition Forms.
Bundle Tickets. Bundle tickets are simply Work Tickets for sub-sections of a job. A job for say 1000 products may sub-divided into bundles of 50 products. The system will produce 20 bundle tickets for 50 products each. Bundle Tickets may bar-coded.
Production Activity Report. This is a report advising completion of a certain activity and an instruction to a specific person to commence the next activity. This is normally used for pre-production tracking
Production Progress Balance and Tracking Report. This report lists all jobs currently in progress, the progress to date with completed quantities and dates, etc., also lists production quantity balances in various locations.
Production Flow Exception Report. This report advises all jobs which are overdue at a progress reporting point.
Production Analysis Report. This report summarises reported production and compares it with planned production. It also summarises actual versus planned machine and labour utilisation by period.
Overdue Progress Report. This report lists all jobs which are currently in progress and are overdue for reporting at a particular progress report point.
Work in Progress Value Report. The report lists production jobs currently in progress and the current value of each particular job.
Production Completion Report. This report summarises actual production for completed job and compares it to planned production. It also summarises actual versus planned utilisation of materials and resources to produce job cost variance reporting.
Production Job Actual Cost versus Standard Cost Report. This report is available in two versions, a summary report which shows totals and variances by major group and a detail report which lists every standard and actual cost for a job. The latter report allows detailed investigation as to why the actual costs of a particular job vary significantly from the standard costs.
Daily Production Summary. This report details production quantities by product for each day with totals.
Monthly Production Summary. This report summarises production for the month in quantities produced by product. It shows actual cost summaries (both for complete job and unit cost
Monthly Resource Capacity Utilisation Summary. This report summarises by resource actual utilisation versus available capacity to show percentage utilisation of resources.
Monthly Resource Efficiency Utilisation Report. This report summarises by resource actual utilisation versus expected standard utilisation to produce a summary of efficiency of resource utilisation.
Production Cost Control
Production costing is based on information derived from various sub-systems and from the Production Job Master File.
Bill of Materials Standard Costing. This system advises the quantity and the cost of each of the components used in the job (material, labour, machine). The various costs determine the standard cost of manufacture.
Raw Materials Stock System. Where raw materials are issued the cost is allocated to the particular job. The actual cost over-rides the theoretical cost obtained from the Bill of Materials. Note that the Raw Material Stock System allows for the product of one job to be re-entered into the Raw Materials sub-system, ie. components, sub assemblies etc.
Other costs can be allocated to the job as required. Examples of additional costs allocated could be:-
Costs may be directly allocated via data capture (e.g. Raw Materials), or set to standard costs (e.g. overhead recovery). Cost allocation need not be in the same categories as standard cost allocation. The system has full support for contribution cost reporting on user determined principles.
The main production cost reports are:-
Production Completion Report. This report is produced at the end of each job. It details planned and actual quantities produced and standard and actual costs with variances.
Cost of Production Report. This report details for the period production and costs of production by category (material, labour, trimming, packing, machine cost, etc.) Summary totals are job category, by department and overall. The report also summarises reprocessing costs and the cost of scrapped production.
Production Cost Exception Report. The system knows from the Bill of Materials Master File the units of raw material, labour, machine time, etc., theoretically needed to produce a given quantity of output. If the actual component quantities used exceed the theoretical quantities by more than a specified percentage details are reported. This report also details all reprocessing costs and scrapped jobs.
Production Cost Contribution Report
The system maintains a file of Production Statistics History. This file retains a record of:-
Each product manufactured. For each product the file records by day, week or month for as long as needed.
Number of Units produced
Reject and sub-standard production
Standard Unit Cost and Total Cost
Actual Unit Cost and Total Cost
Standard Production Time
Actual Production Time
For each resource the following data can be recorded, also by day, week or month for a two year period.
Resource Availability (in minutes or hours)
Resource Utilised for period (standard time)
Resource Utilised for period (actual time).
Reject and sub-standard production
A resource could be a machine, an employee, or a cost centre. Data can be recorded for multiple categories of resource.
Materials Backflush where needed the system has facilities to automatically backflush materials backwards through the system.
Material backflush is used for two purposes:
To calculate the standard material required for a job or a series of jobs. This is mainly used for comparison to the actual quantity.
To automatically calculate and create transactions for material actually used in production jobs. This facility is used where the actual material issue is not recorded.