442 lines
18 KiB
Markdown
442 lines
18 KiB
Markdown
# Production Management
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## 1. Function Overview
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The Production Management module is the core module of the MES system, covering the entire process from production planning to production execution. It achieves digitalization, transparency, and intelligence of the production process.
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**Core Functions:**
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| Function | Description |
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|----------|-------------|
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| Production Planning | Production plan formulation and breakdown |
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| Work Order Management | Work order creation, approval, release, and change |
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| Reporting Management | Production reporting and completion confirmation |
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| Production Monitoring | Real-time production progress monitoring |
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| Material Flow | Material release, picking, and semi-finished product flow |
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| Production Reports | Production data statistics and analysis |
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## 2. Production Planning Management
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### 2.1 Production Plan Types
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| Plan Type | Description | Time Range |
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|-----------|-------------|------------|
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| Annual Plan | Annual production outline | 1 year |
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| Monthly Plan | Monthly production plan | 1 month |
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| Weekly Plan | Weekly production schedule | 1 week |
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| Daily Plan | Daily production dispatch | 1 day |
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| Emergency Plan | Rush order, change plan | Immediate |
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### 2.2 Production Plan Sources
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**Plan Generation Methods:**
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| Source | Description | Automation Level |
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|--------|-------------|------------------|
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| Sales Order | Generated from sales orders | Semi-automatic |
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| Forecast Order | Generated from forecast data | Semi-automatic |
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| Inventory Replenishment | Generated when inventory below safety level | Automatic |
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| Manual Creation | Manually created plan | Manual |
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### 2.3 Plan Balance and Breakdown
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**Plan Balance Process:**
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```
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┌─────────────┐ ┌─────────────┐ ┌─────────────┐ ┌─────────────┐
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│Demand Plan │───▶│Capacity Check│───▶│Plan Adjustment│───▶│Plan Confirmation│
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└─────────────┘ └─────────────┘ └─────────────┘ └─────────────┘
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```
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**Capacity Assessment Factors:**
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| Assessment Item | Assessment Content |
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|-----------------|-------------------|
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| Equipment Capacity | Whether equipment capacity meets requirements |
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| Material Capacity | Whether materials are available |
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| Personnel Capacity | Whether personnel are sufficient |
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| Tooling Capacity | Whether tooling fixtures are ready |
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| Environmental Capacity | Whether production environment meets requirements |
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## 3. Work Order Management
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### 3.1 Work Order Types
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| Work Order Type | Description | Trigger Method |
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|-----------------|-------------|----------------|
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| Production Order | Normal production order | Plan triggered |
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| Rework Order | Rework production order | Quality issue triggered |
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| Material Supplement Order | Material supplement order | Scrap triggered |
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| Trial Order | Trial production order | R&D triggered |
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| Emergency Order | Emergency rush order | Ad-hoc triggered |
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### 3.2 Work Order Status Flow
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**Status Flow Diagram:**
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```
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┌────────┐ ┌────────┐ ┌────────┐ ┌────────┐ ┌────────┐
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│Pending │───▶│Created │───▶│Approved│───▶│Released│───▶│In │
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│Draft │ │ │ │ │ │ │ │Production│
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└────────┘ └────────┘ └────────┘ └────────┘ └────────┘
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│ │
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│ ▼
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│ ┌────────┐
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│ │Completed│
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└────────────────────────────────────────────────────▶│ │
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└────────┘
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```
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**Status Description:**
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| Status | Description | Available Operations |
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|--------|-------------|---------------------|
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| Pending Draft | Plan being formulated | Edit, Delete |
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| Created | Plan completed | Submit for approval, Edit |
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| Approved | Approved | Release |
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| Released | Released to production line | Start production |
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| In Production | Production in progress | Reporting, Pause |
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| Completed | Production completed | Receiving, Close |
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| Closed | Work order closed | View |
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| Cancelled | Work order cancelled | View |
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### 3.3 Work Order Creation
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**Creation Steps:**
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1. Go to [Production Management] → [Work Order Management]
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2. Click [New Work Order]
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3. Select product
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4. Fill in work order information:
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- Production quantity
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- Planned start/end date
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- Planned production line
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- Priority
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5. System automatically calculates material requirements
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6. Save work order
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**[Note]** Ensure product BOM and routing are maintained before creating work order.
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### 3.4 Work Order Information
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**Work Order Basic Information:**
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| Field | Description | Required |
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|-------|-------------|----------|
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| Work Order No. | Unique work order identifier | ✓ |
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| Product Code | Product to produce | ✓ |
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| Product Name | Product name | ✓ |
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| Production Quantity | Planned production quantity | ✓ |
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| Qualified Quantity | Qualified product quantity | - |
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| Defective Quantity | Defective product quantity | - |
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| Planned Start Date | Planned start date | ✓ |
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| Planned End Date | Planned end date | ✓ |
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| Actual Start Date | Actual start date | - |
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| Actual End Date | Actual end date | - |
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| Priority | Work order priority | ✓ |
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| Work Order Status | Current status | System auto |
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**Work Order Related Information:**
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| Related Item | Description |
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|--------------|-------------|
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| Sales Order | Related sales order |
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| Customer Info | Customer information |
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| BOM Version | BOM version used |
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| Process Version | Process version used |
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### 3.5 Work Order Approval
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**Approval Process:**
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1. Work order creator submits for approval
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2. Approver receives approval task
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3. Review work order information
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4. Check material availability
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5. Check capacity status
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6. Approve or reject
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**[Tip]** Work order quantity and planned dates can be adjusted during approval.
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### 3.6 Work Order Release
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**Release Conditions:**
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| Condition | Check Item | Description |
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|-----------|------------|-------------|
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| Complete Information | All required fields filled | ✓ |
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| Approved | Work order status is approved | ✓ |
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| Valid BOM | BOM is approved and effective | ✓ |
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| Valid Process | Routing is approved and effective | ✓ |
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| Materials Available | Required materials in stock | ✓ |
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| Line Available | Production line is available | ✓ |
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**Release Steps:**
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1. Select approved work order
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2. Click [Release] button
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3. System performs availability check
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4. Availability check passed
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5. Confirm release information
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6. Work order status changes to "Released"
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**[Note]** If availability check fails, materials need to be replenished or work order adjusted first.
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### 3.7 Work Order Change
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**Change Types:**
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| Change Type | Description | Impact |
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|-------------|-------------|--------|
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| Quantity Adjustment | Increase/decrease production quantity | Affects material requirements |
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| Plan Adjustment | Adjust planned dates | Affects scheduling |
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| Line Change | Change production line | Affects scheduling |
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| Process Adjustment | Adjust process sequence | Affects routing |
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| Emergency Rush | Adjust work order priority | Affects scheduling |
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**Change Process:**
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```
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Change Request → Change Approval → Change Execution → Change Confirmation
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```
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**[Tip]** Work order changes during production need to be handled carefully as they may affect ongoing production operations.
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## 4. Reporting Management
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### 4.1 Reporting Types
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| Reporting Type | Description | Timing |
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|----------------|-------------|--------|
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| Start Reporting | Process starts operation | At process start |
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| Completion Reporting | Process completes operation | At process completion |
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| Exception Reporting | Process abnormally paused | When exception occurs |
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| Shift Reporting | Shift handover record | At shift handover |
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### 4.2 Reporting Process
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**Process Reporting Flow:**
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```
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Start Reporting → Process Operation → Completion Reporting → Next Process
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```
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**Detailed Flow:**
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```
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┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
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│Start │───▶│Operation │───▶│Completion│───▶│Quality │
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│Reporting │ │In Progress│ │Reporting │ │Inspection│
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└──────────┘ └──────────┘ └──────────┘ └──────────┘
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│
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┌──────────────────────────────────────┘
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│
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▼
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┌──────────┐
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│Process │
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│Transfer │
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└──────────┘
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```
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### 4.3 Start Reporting
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**Operation Steps:**
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1. Go to [Production Management] → [Reporting Management]
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2. Select work order ready to start
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3. Select process
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4. Fill in start information:
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- Start time
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- Operator
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- Equipment selection
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5. Submit start report
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6. System records start time
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**[Tip]** After start reporting, the system locks the process to prevent duplicate starts.
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### 4.4 Completion Reporting
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**Operation Steps:**
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1. Select started work order
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2. Select process
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3. Fill in completion information:
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- Completed quantity
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- Qualified quantity
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- Defective quantity
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- Defect reason (if any)
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- Operation time
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- Material consumption (if needed)
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4. Submit completion report
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5. System automatically triggers quality inspection (if inspection point configured)
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**Completion Reporting Information:**
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| Field | Description | Required |
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|-------|-------------|----------|
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| Completed Quantity | Quantity completed this time | ✓ |
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| Qualified Quantity | Qualified product quantity | ✓ |
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| Defective Quantity | Defective product quantity | - |
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| Defect Reason | Description of defect reason | - |
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| Operation Time | Actual operation time | ✓ |
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| Material Consumption | Quantity of materials consumed | - |
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### 4.5 Reporting Data
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**Reporting Record Information:**
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| Data Item | Description |
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|-----------|-------------|
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| Reporting Time | Reporting operation time |
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| Reporting Type | Start/Completion/Exception |
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| Work Order No. | Related work order |
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| Process No. | Related process |
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| Operator | Person performing operation |
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| Equipment No. | Equipment used |
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| Reporting Quantity | Reported quantity |
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| Qualification Rate | Qualified quantity/Reported quantity |
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| Operation Time | Actual operation time |
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## 5. Production Monitoring
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### 5.1 Monitoring Content
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**Real-time Monitoring Data:**
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| Monitoring Item | Description | Update Frequency |
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|-----------------|-------------|------------------|
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| Work Order Progress | Completion status of each work order | Real-time |
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| Process Progress | Completion status of each process | Real-time |
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| Production Statistics | Daily/Shift production volume | Real-time |
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| Defective Rate | Defective product ratio | Real-time |
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| Equipment Status | Equipment running status | Real-time |
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| Personnel Status | Operator status | Real-time |
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### 5.2 Monitoring Dashboard
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**Production Dashboard Display:**
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```
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┌─────────────────────────────────────────────────────────────┐
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│ Production Monitoring Dashboard │
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├─────────────────────────────────────────────────────────────┤
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│ │
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│ Today's Production Overview: │
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│ ┌──────────────┐ ┌──────────────┐ ┌──────────────┐ │
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│ │ Plan Output │ │ Actual Output│ │ Achievement │ │
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│ │ 10000 │ │ 9520 │ │ 95.2% │ │
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│ └──────────────┘ └──────────────┘ └──────────────┘ │
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│ │
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│ Production Line Status: │
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│ ┌─────────────────────────────────────────────────────┐ │
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│ │ SMT-A Line ████████████░░░░ 80% Running │ │
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│ │ SMT-B Line ██████████████░░ 85% Running │ │
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│ │ Assembly-A ██████████░░░░░░ 60% Running │ │
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│ └─────────────────────────────────────────────────────┘ │
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│ │
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└─────────────────────────────────────────────────────────────┘
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```
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### 5.3 Process Flow Control
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**Flow Rules:**
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| Flow Type | Description | Configuration Requirement |
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|-----------|-------------|--------------------------|
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| Sequential Flow | Operations in defined sequence | Routing definition |
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| Parallel Flow | Multiple processes simultaneously | Routing definition |
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| Conditional Flow | Process selection based on conditions | Flow condition configuration |
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**Process Start Conditions:**
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| Condition Item | Check Content |
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|----------------|---------------|
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| Previous Process Complete | Whether previous process completed |
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| Materials Available | Whether materials ready |
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| Equipment Ready | Whether equipment idle |
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| Personnel Ready | Whether operators ready |
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## 6. Material Flow
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### 6.1 Material Release Management
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**Release Process:**
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```
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Material Request → Warehouse Preparation → Scan Release → System Confirmation
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```
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**Release Methods:**
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| Method | Description | Application Scenario |
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|--------|-------------|---------------------|
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| By Work Order | Release based on work order BOM | Batch production |
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| By Process | Release based on process requirements | Multi-process production |
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| By Line | Batch release to production line | Continuous production |
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| Auto Release | System automatically controls release | Automated production line |
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### 6.2 Material Consumption Record
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**Consumption Data:**
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| Data Item | Description |
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|-----------|-------------|
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| Material Code | Material consumed |
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| Material Batch | Material batch number |
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| Consumption Quantity | Quantity consumed this time |
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| Consumption Time | Consumption time |
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| Related Work Order | Related work order |
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| Related Process | Related process |
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| Consumption Type | Actual consumption/Scrap |
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### 6.3 Work In Process (WIP) Management
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**WIP Monitoring:**
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| Monitoring Item | Description |
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|-----------------|-------------|
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| WIP Work Order Count | Number of work orders in production |
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| WIP Process Count | Number of processes in progress |
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| WIP Quantity | Quantity in progress at each process |
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| Flow Time | Flow time at each process |
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| Accumulation Status | Accumulation status at each process |
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## 7. Production Statistics and Analysis
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### 7.1 Production Reports
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| Report Type | Description | Target User |
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|-------------|-------------|-------------|
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| Daily Production Report | Daily production statistics | Workshop Supervisor |
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| Monthly Production Report | Monthly production statistics | Production Manager |
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| Work Order Statistics | Work order execution statistics | Planner |
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| Output Statistics | Output completion statistics | Production Supervisor |
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| Quality Statistics | Production quality statistics | Quality Supervisor |
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### 7.2 Production Indicators
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**Core KPI Indicators:**
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| Indicator | Calculation Formula | Description |
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| Output Achievement Rate | Actual Output/Plan Output × 100% | Target: ≥100% |
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| Production Qualification Rate | Qualified Quantity/Total Quantity × 100% | Target: ≥98% |
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| Labor Utilization Rate | Actual Working Hours/Available Hours × 100% | Target: ≥85% |
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| Process Flow Time | Average flow time at each process | Shorter is better |
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| WIP Turnover | WIP Quantity/Daily Output | Target: 3-5 days |
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### 7.3 Production Analysis
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**Analysis Dimensions:**
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| Analysis Dimension | Analysis Content |
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| Capacity Analysis | Capacity utilization, bottleneck analysis |
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| Efficiency Analysis | OEE analysis, efficiency improvement potential |
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| Quality Analysis | Defective product analysis, quality trend |
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| Material Analysis | Material consumption analysis, over-consumption analysis |
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| Labor Analysis | Working hours utilization analysis, overtime analysis |
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---
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**End of Production Management** |