Mascidon, LLC


SAP Business  One Add-on Products



Production Entry for Repetitive Manufacturers

Quick, efficient input of production is a cornerstone of repetitive manufacturing.  SAP Business One has a traditional production reporting system - create a production order - issue the production order to the floor - get back a filled in production traveler - update the production using the production order.  Production reporting in a repetitive environment needs to be much simpler - part produced and how many is typically the extent of reporting. 


In a repetitive manufacturing environment, the Mascidon Scheduling Module is used to schedule the work to be done on the shop floor.  This creates a schedule file which can be reported against.  Part of the scheduling function is to assign part  production to operators.  When it comes time to enter production:
  • Operator enters or scans their badge
    • All work assigned to this operator is shown on the screen
  • Key in quantity produced next to item
  • Hit the Save button
    • System creates production order for this item, releases it, back flushes the components, receives the item produced, closes it.

If the main component item is batch controlled:
  • Operator enters or scans their badge
    • All work assigned to this operator is shown on the screen
  • Key in quantity produced next to item
  • Select the batch of the key component (i.e. Coil heat number)
  • Hit the Save button
    • System creates production order for this item, releases it, issues the batch controlled item and back flushes other components, receives the item produced, closes it.

If reporting scrap at the same time as production:
  • Operator enters or scans their badge
    • All work assigned to this operator is shown on the screen
  • Key in quantity produced next to item
  • Key in scrap quantity
  • Hit the Save button
    • System creates production order for this item, releases it, back flushes the components, receives the item produced, closes it.
    • An inventory issues transaction is created for the scrapped quantity


There is also the option to use an alternative component.  For instance, if a stamping company normally uses coil steel to produce 1,000 pieces of a product, the production of 10 pieces could be done using a laser cut of sheet steel - and this functionality is part of the production entry.

 

And when an operator makes a mistake in data entry - they simply click the 'Reverse' button. The 'Reverse Button' creates a 'disassembly' production order.  

 

This lean manufacturing approach using SAP Business  One reduces data entry significantly - while maintaining data integrity. This process preserves SAP functionality but is a whole lot simpler!

 

The production entered is also stored in user tables.  These tables are used to produce production reports by date range for items or employee or shift.  Using SAP Business One's integrated Crystal Report writer tool, production reports can be printed in any format, dependent only on the data actually collected.

 

Note: if using SAP Business One version 9 and using bin control on the floor:

  • Components are flushed from the 'Production' bin (actual name is under user control)
    • Implies that transfers from warehouse bins to 'production' bin is required prior to commencing and reporting production
      • Bin on hand is not allowed to go negative
  • Produced items are received into the 'Production' bin