HF-MES-manual/en/business/production.md

Production Management

1. Function Overview

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.

Core Functions:

Function	Description
Production Planning	Production plan formulation and breakdown
Work Order Management	Work order creation, approval, release, and change
Reporting Management	Production reporting and completion confirmation
Production Monitoring	Real-time production progress monitoring
Material Flow	Material release, picking, and semi-finished product flow
Production Reports	Production data statistics and analysis

2. Production Planning Management

2.1 Production Plan Types

Plan Type	Description	Time Range
Annual Plan	Annual production outline	1 year
Monthly Plan	Monthly production plan	1 month
Weekly Plan	Weekly production schedule	1 week
Daily Plan	Daily production dispatch	1 day
Emergency Plan	Rush order, change plan	Immediate

2.2 Production Plan Sources

Plan Generation Methods:

Source	Description	Automation Level
Sales Order	Generated from sales orders	Semi-automatic
Forecast Order	Generated from forecast data	Semi-automatic
Inventory Replenishment	Generated when inventory below safety level	Automatic
Manual Creation	Manually created plan	Manual

2.3 Plan Balance and Breakdown

Plan Balance Process:

┌─────────────┐    ┌─────────────┐    ┌─────────────┐    ┌─────────────┐
│Demand Plan  │───▶│Capacity Check│───▶│Plan Adjustment│───▶│Plan Confirmation│
└─────────────┘    └─────────────┘    └─────────────┘    └─────────────┘

Capacity Assessment Factors:

Assessment Item	Assessment Content
Equipment Capacity	Whether equipment capacity meets requirements
Material Capacity	Whether materials are available
Personnel Capacity	Whether personnel are sufficient
Tooling Capacity	Whether tooling fixtures are ready
Environmental Capacity	Whether production environment meets requirements

3. Work Order Management

3.1 Work Order Types

Work Order Type	Description	Trigger Method
Production Order	Normal production order	Plan triggered
Rework Order	Rework production order	Quality issue triggered
Material Supplement Order	Material supplement order	Scrap triggered
Trial Order	Trial production order	R&D triggered
Emergency Order	Emergency rush order	Ad-hoc triggered

3.2 Work Order Status Flow

Status Flow Diagram:

┌────────┐    ┌────────┐    ┌────────┐    ┌────────┐    ┌────────┐
│Pending │───▶│Created │───▶│Approved│───▶│Released│───▶│In      │
│Draft   │    │        │    │        │    │        │    │Production│
└────────┘    └────────┘    └────────┘    └────────┘    └────────┘
     │                                                          │
     │                                                          ▼
     │                                                    ┌────────┐
     │                                                    │Completed│
     └────────────────────────────────────────────────────▶│        │
                                                          └────────┘

Status Description:

Status	Description	Available Operations
Pending Draft	Plan being formulated	Edit, Delete
Created	Plan completed	Submit for approval, Edit
Approved	Approved	Release
Released	Released to production line	Start production
In Production	Production in progress	Reporting, Pause
Completed	Production completed	Receiving, Close
Closed	Work order closed	View
Cancelled	Work order cancelled	View

3.3 Work Order Creation

Creation Steps:

1. Go to [Production Management] → [Work Order Management]
2. Click [New Work Order]
3. Select product
4. Fill in work order information:
   • Production quantity
   • Planned start/end date
   • Planned production line
   • Priority
5. System automatically calculates material requirements
6. Save work order

[Note] Ensure product BOM and routing are maintained before creating work order.

3.4 Work Order Information

Work Order Basic Information:

Field	Description	Required
Work Order No.	Unique work order identifier	✓
Product Code	Product to produce	✓
Product Name	Product name	✓
Production Quantity	Planned production quantity	✓
Qualified Quantity	Qualified product quantity	-
Defective Quantity	Defective product quantity	-
Planned Start Date	Planned start date	✓
Planned End Date	Planned end date	✓
Actual Start Date	Actual start date	-
Actual End Date	Actual end date	-
Priority	Work order priority	✓
Work Order Status	Current status	System auto

Work Order Related Information:

Related Item	Description
Sales Order	Related sales order
Customer Info	Customer information
BOM Version	BOM version used
Process Version	Process version used

3.5 Work Order Approval

Approval Process:

1. Work order creator submits for approval
2. Approver receives approval task
3. Review work order information
4. Check material availability
5. Check capacity status
6. Approve or reject

[Tip] Work order quantity and planned dates can be adjusted during approval.

3.6 Work Order Release

Release Conditions:

Condition	Check Item	Description
Complete Information	All required fields filled	✓
Approved	Work order status is approved	✓
Valid BOM	BOM is approved and effective	✓
Valid Process	Routing is approved and effective	✓
Materials Available	Required materials in stock	✓
Line Available	Production line is available	✓

Release Steps:

1. Select approved work order
2. Click [Release] button
3. System performs availability check
4. Availability check passed
5. Confirm release information
6. Work order status changes to "Released"

[Note] If availability check fails, materials need to be replenished or work order adjusted first.

3.7 Work Order Change

Change Types:

Change Type	Description	Impact
Quantity Adjustment	Increase/decrease production quantity	Affects material requirements
Plan Adjustment	Adjust planned dates	Affects scheduling
Line Change	Change production line	Affects scheduling
Process Adjustment	Adjust process sequence	Affects routing
Emergency Rush	Adjust work order priority	Affects scheduling

Change Process:

Change Request → Change Approval → Change Execution → Change Confirmation

[Tip] Work order changes during production need to be handled carefully as they may affect ongoing production operations.

4. Reporting Management

4.1 Reporting Types

Reporting Type	Description	Timing
Start Reporting	Process starts operation	At process start
Completion Reporting	Process completes operation	At process completion
Exception Reporting	Process abnormally paused	When exception occurs
Shift Reporting	Shift handover record	At shift handover

4.2 Reporting Process

Process Reporting Flow:

Start Reporting → Process Operation → Completion Reporting → Next Process

Detailed Flow:

┌──────────┐    ┌──────────┐    ┌──────────┐    ┌──────────┐
│Start     │───▶│Operation │───▶│Completion│───▶│Quality   │
│Reporting │    │In Progress│    │Reporting │    │Inspection│
└──────────┘    └──────────┘    └──────────┘    └──────────┘
                                                            │
                    ┌──────────────────────────────────────┘
                    │
                    ▼
              ┌──────────┐
              │Process   │
              │Transfer  │
              └──────────┘

4.3 Start Reporting

Operation Steps:

1. Go to [Production Management] → [Reporting Management]
2. Select work order ready to start
3. Select process
4. Fill in start information:
   • Start time
   • Operator
   • Equipment selection
5. Submit start report
6. System records start time

[Tip] After start reporting, the system locks the process to prevent duplicate starts.

4.4 Completion Reporting

Operation Steps:

1. Select started work order
2. Select process
3. Fill in completion information:
   • Completed quantity
   • Qualified quantity
   • Defective quantity
   • Defect reason (if any)
   • Operation time
   • Material consumption (if needed)
4. Submit completion report
5. System automatically triggers quality inspection (if inspection point configured)

Completion Reporting Information:

Field	Description	Required
Completed Quantity	Quantity completed this time	✓
Qualified Quantity	Qualified product quantity	✓
Defective Quantity	Defective product quantity	-
Defect Reason	Description of defect reason	-
Operation Time	Actual operation time	✓
Material Consumption	Quantity of materials consumed	-

4.5 Reporting Data

Reporting Record Information:

Data Item	Description
Reporting Time	Reporting operation time
Reporting Type	Start/Completion/Exception
Work Order No.	Related work order
Process No.	Related process
Operator	Person performing operation
Equipment No.	Equipment used
Reporting Quantity	Reported quantity
Qualification Rate	Qualified quantity/Reported quantity
Operation Time	Actual operation time

5. Production Monitoring

5.1 Monitoring Content

Real-time Monitoring Data:

Monitoring Item	Description	Update Frequency
Work Order Progress	Completion status of each work order	Real-time
Process Progress	Completion status of each process	Real-time
Production Statistics	Daily/Shift production volume	Real-time
Defective Rate	Defective product ratio	Real-time
Equipment Status	Equipment running status	Real-time
Personnel Status	Operator status	Real-time

5.2 Monitoring Dashboard

Production Dashboard Display:

┌─────────────────────────────────────────────────────────────┐
│                    Production Monitoring Dashboard          │
├─────────────────────────────────────────────────────────────┤
│                                                             │
│  Today's Production Overview:                               │
│  ┌──────────────┐ ┌──────────────┐ ┌──────────────┐         │
│  │  Plan Output │ │ Actual Output│ │  Achievement │         │
│  │   10000     │ │   9520      │ │   95.2%    │         │
│  └──────────────┘ └──────────────┘ └──────────────┘         │
│                                                             │
│  Production Line Status:                                    │
│  ┌─────────────────────────────────────────────────────┐   │
│  │ SMT-A Line ████████████░░░░  80%    Running         │   │
│  │ SMT-B Line ██████████████░░  85%    Running         │   │
│  │ Assembly-A ██████████░░░░░░  60%    Running         │   │
│  └─────────────────────────────────────────────────────┘   │
│                                                             │
└─────────────────────────────────────────────────────────────┘

5.3 Process Flow Control

Flow Rules:

Flow Type	Description	Configuration Requirement
Sequential Flow	Operations in defined sequence	Routing definition
Parallel Flow	Multiple processes simultaneously	Routing definition
Conditional Flow	Process selection based on conditions	Flow condition configuration

Process Start Conditions:

Condition Item	Check Content
Previous Process Complete	Whether previous process completed
Materials Available	Whether materials ready
Equipment Ready	Whether equipment idle
Personnel Ready	Whether operators ready

6. Material Flow

6.1 Material Release Management

Release Process:

Material Request → Warehouse Preparation → Scan Release → System Confirmation

Release Methods:

Method	Description	Application Scenario
By Work Order	Release based on work order BOM	Batch production
By Process	Release based on process requirements	Multi-process production
By Line	Batch release to production line	Continuous production
Auto Release	System automatically controls release	Automated production line

6.2 Material Consumption Record

Consumption Data:

Data Item	Description
Material Code	Material consumed
Material Batch	Material batch number
Consumption Quantity	Quantity consumed this time
Consumption Time	Consumption time
Related Work Order	Related work order
Related Process	Related process
Consumption Type	Actual consumption/Scrap

6.3 Work In Process (WIP) Management

WIP Monitoring:

Monitoring Item	Description
WIP Work Order Count	Number of work orders in production
WIP Process Count	Number of processes in progress
WIP Quantity	Quantity in progress at each process
Flow Time	Flow time at each process
Accumulation Status	Accumulation status at each process

7. Production Statistics and Analysis

7.1 Production Reports

Report Type	Description	Target User
Daily Production Report	Daily production statistics	Workshop Supervisor
Monthly Production Report	Monthly production statistics	Production Manager
Work Order Statistics	Work order execution statistics	Planner
Output Statistics	Output completion statistics	Production Supervisor
Quality Statistics	Production quality statistics	Quality Supervisor

7.2 Production Indicators

Core KPI Indicators:

Indicator	Calculation Formula	Description
Output Achievement Rate	Actual Output/Plan Output × 100%	Target: ≥100%
Production Qualification Rate	Qualified Quantity/Total Quantity × 100%	Target: ≥98%
Labor Utilization Rate	Actual Working Hours/Available Hours × 100%	Target: ≥85%
Process Flow Time	Average flow time at each process	Shorter is better
WIP Turnover	WIP Quantity/Daily Output	Target: 3-5 days

7.3 Production Analysis

Analysis Dimensions:

Analysis Dimension	Analysis Content
Capacity Analysis	Capacity utilization, bottleneck analysis
Efficiency Analysis	OEE analysis, efficiency improvement potential
Quality Analysis	Defective product analysis, quality trend
Material Analysis	Material consumption analysis, over-consumption analysis
Labor Analysis	Working hours utilization analysis, overtime analysis

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End of Production Management