The user may create as many work centers as necessary to define the production activities that occur within the operation.

Within a work center, the user may establish additional definitions, called Activities. These activities may be set up separately from the work centers, and then used as needed within individual work centers. The activities may be assigned their own hourly charge rate.

And within an Activity, there is yet another classification called sub-activities, which have activity costs associated with them. These activity costs are established in the Activity Cost & Volume Type setup.

This section covers the production setup to be used in all production related modules. Please take time to think about how you want to use these tables for best production management.  Some sample data is provided with this setup as a guideline.  These tables are used in various modules throughout the system.

The production application module setup section allows you to prepare tables for specific production related modules your company has purchased.  Once setup in the system, you will be able to use these tables and/or perform certain functions automatically.  These tables are completed by preparing worksheet tables and/or setting certain switches.

Work Center Shift Setups may be established for use in capacity planning. Your work shift setup is a factor in your capacity. The more work hours you have the higher your capacity.  Each work shift has a starting and ending time (entered in 24-hour format). The user may enter as many shifts as may be needed to describe the availability of resources. Shifts may overlap, and be any duration. Provision for multiple breaks and lunches are made for long shifts. 

Enter System Setup/Production/Work Shift Setup

The following screen will appear:

The user may Add new or Edit and Delete existing shifts.

The user must either Save or Abaondon to close the screen.

Where Used:  In the job routing functions for a product.

«Mark as Completed in RoadMap in Section B Item 3-a»

This module is essential if you are using Activity Based Cost (ABC) methodology for managing the production floor.   The information entered here forwards to Production Work Center/Activity Setup.  Then both setups are used in the MANEX Capacity Planning module. 

Activity Costing and Activity Volume Type Description setup is a requirement only if your company is employing Activity Based Cost (ABC) methodology for managing the production floor. The Activity Costing and Activity Volume Type Descriptions are used in Production Work Center/Activity setup to assign Activity Costs and Activity Volume Types to a production Work Center/Activity.  The Activity Volume Type Description is a pre-requisite for Production Work Centers & Activities / Activity Setup & Run tab.

Your company should become knowledgeable about the principles of ABC prior to using Activity Costing and Activity Volume Type Descriptions.Activity Cost and Volume types allow the users to define the costs and capacity for individual activities within a work center.  It is used in the capacity planning module to determine available and required capacities.    It is also used to assign costs of operation.  For example, there may be several machines that can do the same job in a work center.  However, one may have a higher operating cost, but also greater capacity.  Both machines can be displayed as a resource.  The selection of the machine is performed in the routing and capacity modules.

Enter System Setup/Production/Activity Costing & Setup Type Setup

The following screen will appear:

To ADD new descriptions to these tables, click on the Edit button. The Reorder, Add, Delete buttons will become available under each column.  Depress the Add button, enter the description.  When complete depress the Save or Cancel button under the table. 

To DELETE existing descriptions to these tables, click on the Edit button.  The Reorder, Add, Delete buttons will become available uder each column.  Highlight the description you want to delete, depress the Delete button.  When complete depress the Save or Cancel button under the table. 

to REORDER descriptions to these tables, click ont he Edit button.  The Reorder, Add, Delete buttons will become available under each column.  Depress the REORDER button, then click and drag the activities to the desired order. When completed depress the Save or Cancel button uder the table.

Package configuration setup is provided so that the user may define a machine’s Units Per Hour.  This definition can then be accessed in the Production Work Centers & Activities setup/Activities Setup & Run tab.

Enter System Setup/Production/Package Configuration Module

The following screen will appear:

To ADD a record, depress the Add button, type in the Package Configuration and description.

To EDIT a record, depress the Edit button,  edit the Package Configuration and/or description.

To DELETE a record, highlight the Package Configuration and description you wish to delete, depress the Delete button.

Where Used:  In the Production Work Center/Activity Setup.

Assign work center to workstations (button)

Defect Code Entry In-Line Mode, the system will check to see if the serial number is currently in the Work Center which was set up here.  If not, a special supervisor’s password is required to transfer the serial number FROM a different Work Center.  After the supervisor password is entered, the system will use the new Work Center to be the default FROM Work Center until the user closes the screen.  The next time the user opens the screen, the default FROM Work Center will be changed back to the one defined in Systems Setup.

 

The information set up in this screen will be used in Capacity Planning & Dynamic Scheduling modules.

Setup Type List

The Setup Type description is input into a previous screen “Activity Costing & Setup Type Setup/Activity Setup Type Description”.  

Component Package Configuration List

The Component Package Configuration is set up in a prior screen. See Setup Package Configuration.

Use of Run and Setup Times in the Production Schedule Setup module is optional unless either Job Costing or Capacity Planning Modules are in use.

 

The following screen will appear:   For the highlighted Work Center, enter in the Hourly Charge Rate.

To add a Work Shift, highlight the Work Center, then depress the "Add Work Shift"   button.    The following popup screen will appear to select from.  The work shifts listed on the popup screen have been setup in the Work Shift Setup module.   Highlight the work shift(s) and depress the "OK" button.

To Assign Work Center to Workstations In this screen, highlight the name of the Work Center. Depress the button at the bottom of the screen "Assign work center to workstations",  the following assignment screen appears: 

 

To enter a new assignment, depress the Add button.  When setting up a workstation user must enter the Full computer name in the Workstation Name field and the Computer description in the Workstation Description field.  See Example below.

 

Depress the Activity tab.   The user may add Work Center Activities by selecting the Add button from the main tool bar.

To add an activity ID and related description, choose the applicable work center from the drop down menu:
Enter the Act ID, Activity Description.    Note:  The system does NOT allow you to generate the same Activity ID in different Work Centers.   Click on the Cap Totaling box to elect calculating capacity. Save changes or Abandon Changes.

To attach a Cost Rate to an activity, click on the Edit button, then on the Add button (bottom of screen) in the Activity Costing Section.

To attach a Cost Rate to an activity, click on the Edit button, then on the Add button (bottom of screen) in the Activity Costing Section.

Select the activity from the pull down:  (The activity costing descriptions are defaulted in from the Activity Costing & Setup Type Setup module)  Highlight the activity to which the Cost Rate will be attached. Enter in the Cost/hr rate. Save changes or Abandon Changes.

 

Once the Activity ID and Description, Cap Totaling election and hourly charge rate have been entered, depress the Activity Setup & Run tab.

 

Depress the Edit button.  For the Setup Type Description section.  Depress the  Add button (on screen).

Select the Setup Type Description from the pull down:  (These are defaulted in from the Activity Costing & Setup Type Setup module). Enter the time in hours and minutes. Depress the Save button (on screen).

 

	This button allows the user to enter instructions for setting up the Setup Type.
	This button allows the user to load a photo for an instruction. The photo file should be in the ManEx directory, and should be BMP or TIF format.

For Component Package Configuration, depress the Add button (on screen)

Select the Component Package Configuration from the pull down menu: (The Component Package Configuration(s) are defaulted in from the Package Configuration module). Enter in the Volume per hour, and then the yield factor %. Volume is the number of units per hour. This may be boards per hour, units per hour, connections per hour, etc. The Yield factor affects the volume such that lower yield means it will take longer to make the same number of good parts.For example, if the standard volume is 100 parts per hour, and the total yield is 80%, then the effective yield would be 80 parts per hour. Depress the Save button (on screen).

Once all changes are complete depress Save or Abandon changes.

Where Used:  In all Shop Floor related Activities.

«Mark as Completed in RoadMap in Section B Item 3-d»

These types are established to be available during time and attendance tracking in production. Please refer to the Time & Attendance Management module.  If the user chooses to track an employee’s time, the time may be associated with attendance or a specific job (Work Order). Attendance is in for the day and out at the end of the day, like a time clock. Job (Work Order) logging is when an employee begins work on a work order (product) or finishes working on a work order. When the employee visits the screen for job (Work Order) logging, they are prompted to define whether they are logging in for attendance, defined as “Time Clock” or job defined as “Job (Work Order) In Or Out”.

Enter System Setup/Prduction/Time & Attendance Types Module This section is provided to add additional ways for logging and keeping track of time spent by employees on each work order. Enter various different time tracking modes in this section.

The following screen will appear:

The ADD, EDIT, and DELETE buttons are available.

The user adds a type by clicking on the ADD button and entering the type in the entry field box. Time and Attendance Types indicate how the hours are to be collected. (In the future, General Ledger Numbers will be associated with each type listed.)  Therefore, each type of job (Work Order) logging will collect charges accordingly.

If you check the Pay box, that means the company will pay for that type.  For example, an unexcused absence would NOT be checked, but Jury Duty might be checked if it is the company policy to pay for jury duty.

Overtime hours are established for determining overtime pay if the timeclock function is used without shift data per person.  Hours entered in excess of X hours per day or week would be counted as overtime.

User Work Shift - user will check this radial if they want this as a work shift.

Shift Tolerance allows users to consider a line at the timeclock  .If an employee logs in a few minutes early, or late, the system will log them in at the beginning of their shift.

Where Used:  In all job logging functions for a product’s work orders.

«Mark as Completed in RoadMap in Section B Item 3-e»

There are a number of functions within MANEX that the user may establish as default conditions during operations. Each function relating to this setup screen is described in the Fields & Definitions article.

Interval for Refreshing Shop Floor

When the user is in the Shop Floor module, and has information displayed on the screen (for example, the wip status of a work order). The user then leaves the screen up and alone to do another task (say breaks for lunch). Then the data represented by the screen may actually undergo changes by other employees. If the user does not use the screen in the meantime, when they return from their alternate task, the information on the screen would be incorrect (because someone else moved material). ManEx performs a periodic update (refresh) to Shop Floor screens when the user has information displayed on the screen, but has not performed any functions in the meantime. The period of the refresh rate is initially set to every two and a half minutes by ManEx. So, if the user has a work order tracking screen displayed with a work order showing wip, and does not perform any transaction for 2-1/2 minutes, ManEx will automatically update the information on the screen. This timing is initially set at 2-1/2 minutes, but the user may change this period in this setup. However, the trade-off for shorter periods is increased network traffic, and setting too many workstations to be refreshed every few seconds will seriously impact the server’s ability to deliver data.

Whenever a product is moved from one work center to another, the user has the option to print a move ticket (like a traveler) for each transaction. This move ticket may be printed and accompany the material to the next work center, identifying the work order, product date, work center, etc. The user may choose to turn this feature off by selecting the “Printer OFF” button in the setup. If the printer is turned on (“Printer ON”), then a sheet with the details will be printed for every product movement.

FGI Label Printing Defaults

Whenever a product is moved from one work center to the Work Center called FGI (Finished Goods Inventory), the user has the option to print a move ticket (like a traveler) for each transaction. This move ticket may be printed and accompany the material to finished goods, identifying the work order, product date, work center, etc. The user may choose to turn this feature off by selecting the “Printer OFF” button in the setup. If the printer is turned on (“Printer ON”), then a sheet with the details will be printed for every product movement.

Print Work Instructions on Move Tickets

If the user chooses to print move tickets, then they may also choose whether or not work instructions and work order notes are included in the printing.

If the user wishes to move material by the panel, sheet or roll, they may select “Default to PANEL” as the method of tracking quantities. This requires the user to define in the product definition the number of products contained in a panel/sheet/roll. Then, if this method is chosen, the user moves panels and ManEx keeps track of the number of units. If the user chooses to identify material movement by quantity of product, then the “Default to Quantity” button should be selected.

Bar Code Tracking

If the user is tracking serial numbers through the production process, and is using the ManEx bar code tracking module, then they have the option of defining a default method for picking up the bar-coded serial numbers. One option is to scan one serial number at a time, and collect those serial numbers for processing a transaction. Another option is to enter the beginning and ending serial number of a series of serial numbers and allow ManEx to fill in all of the serial numbers in between for processing a transaction. The third option is for the user to manually enter the quantity of boards to be moved. If the boards are serialized, then a list of serial numbers is presented to the user from which to select the serial numbers being moved with the quantity of parts.  The user has the option to change any of these defaults at the time of entry.  Please refer to the Shop Floor Tracking Management manual.  The ManEx Manufacturing System Software has bar code scan and print capability which is designed primarily for transfer of products in Shop Floor Tracking and input of inspection data by serial number and defect code.

Installation:  Bar Code Shop Floor Tracking is an OPTIONAL module; it is NOT a part of the Core ManEx MES modules.

·         Upon purchase of this module, ManEx will send a soft-key to activate the module

·         If Bar Coding of Serial Numbers is desired, the Serial Number tracking must be setup in Shop Floor Tracking Defaults . 

Specification:

·         ManEx uses the Microsoft Truetype BC C39 Narrow Font.  See Article #1225  for the installation procedure.

·         Use of a Y-Type keyboard-emulation scanner is supported by ManEx.  The scanner output goes into ManEx via the keyboard-input cable.  Bar code fields may be scanned or manually entered with the scanner installed.

·         Most scanners require ¼” of white space surrounding the bar code.  Laser and inkjet printed labels must have adequate resolution, contrast and clarity to print barcodes that are readable.

·         ManEx recognizes a bar code by an asterisk (*) at the beginning and end of the bar coded field.

Serial Number Tracking Method

Enter System Setup/Production/Shop Floor Tracking Defaults Module

The following screen will appear:

When the user has completed the changes they must press the Save or Abandon button, before exiting.

Where Used:  In all shop floor functions for a product’s work orders.

Mark as Completed in RoadMap Section B Item 3

In this setup, the user defines the method to be used by ManEx to determine the capacities and scheduling in the Capacity Planning module.

The default, “Run & Setup Time” will calculate the resources and costs associated with those entered in the work center setups and activities for the product. The costs will be based on the work center rates, and the capacity on the product routing information.

The Activities Drivers option may be used in conjunction with the Job Planning module, and will calculate the costs and durations based on parameters entered by the users in the planning module.Normally, the Run & Setup time option is used.However, once the system has an active capacity planning module in place, the user may use Activities Drivers to schedule priorities in the Dynamic Scheduling Module.

No change is required in this setup unless the user is going to make extensive use of the job planning module.

Note:  In order to add Times in Routing, the Run and Setup Time MUST be selected in this module. 

Enter System Setup/Production/Production Scheduling Method Module

The following screen will appear:

The user may click on the Edit button to change the defaults.

The user must Save or Abandon changes after entering the Edit Mode.

Where Used: In all shop floor functions defining labor costs, and for Capacity Planning Modules.

«Mark as Completed in RoadMap in Section B Item 3-g»

In Shop Floor Tracking, the ability to record the results of quality inspections is available to the user. These records usually contain information about the lot or work order being inspected, the quantity of parts viewed, the quantity of parts rejected and the number and types of defects observed in the process. In the ManEx Quality Defect Setup, the user has the opportunity to define these defects, and to shape the manner in which they are used.

Entry Mode:  The results of inspection may be entered in ManEx in two basic ways:  1, in Batch Mode; and 2, using In-Line processing.  Batch mode allows the user to perform the inspection on a batch or lot of materials, and enter the observations at a later time. In this mode, the user does not automatically forward the product to the next workstation, but merely inspects it and allows production personnel to move the material.   Using the In-Line mode is like inserting an inspection step at the end of a work center, viewing the parts one at a time, and passing or failing the part. If the part passes, it is moved by ManEx to the next work center, and the user has only to physically move the parts to the next workstation. The ManEx WIP tracking automatically moves the part to the next work center. Parts which fail the inspection may stay in their current work center, be moved to another (rework) work center, or passed on to the following work center, at the option and discretion of the operator.

Rework Cost By:  The Cost of Quality may be determined in one of two possible ways: 1, by defining a specific cost to each defect code; and 2, by manual entry of the actual rework time as determined by the inspector during inspection. In this setup area, the user selects whether to track the costs by Defect Cost (assigned to each defect code), or Manually (by entering the rework time as defects are determined).

Work Center Inspection:  The user has the option of viewing defects based on the product routing (Product Routing), or to view all defects (Maximum Routing).   The Maximum Routing will show ALL defect codes in inspection, the Product Routing will only display those that have been related to a work center in which the inspection is taking place.  However, the user can still opt to see the max (ALL) defects within the Defect Entry screen.    

The Maximum NPF No box, no problems found, is provided for the user to record when observing the product.   If, in the Defect Entry  screen, the serial number had previously been rejected, and analysis of the product yield no further problem, either with cosmetics or function, then the user may change this number to 1, meaning the first time it was inspected or tested, no problem was found. If the product serial number is subsequently rejected again, and a second inspection finds a problem, the number may be incremented to a “2”. This will alert users to repeated rejections of a product serial number, one or more times with no discernable defects. If the number of times that a part has experienced an NPF (no problems found) exceeds that established here in the system setup, the user will not be allowed to go further.

“Maximum number of inspections/WC” Box:  This field is for serial number use only.  The user may define how many times a given serial number can pass through a given Work Center.  If the user selects the “Skip Serial Number” field, this max number will be come invisible.  In the Defect Entry screen, once the pass number of a serial number exceeds the max number as set up here, a supervisor or special rights password is needed to continue.  Please refer to the Implementation – Security

Enter System Setup/Production/Quality Defect Codes Module

The following screen will appear:

The user initiates a new defect code by clicking on the Add button.   Note:  When creating a new Defect Code you will want the Defect Code descriptive as possible because this is what appears in the Pareto Chart in the SQC module information.      NOTE:  The  "Defect Code" field is NOT editable once it has been saved.

To associate a Work Center with a defect code, depress the Edit button and place the cursor in the ID Work Center window, as illustrated   Select the Work Center.

 

Depress the Edit button and work centers assigned to or deleted from the defect code.  All fields are editable except for the "Defect Code" field. 

 

When all changes have been completed, the user must Save or Abandon changes. 

User may ONLY delete a Defect Code if it has not been used in the SQC module. This info needs to be retained for history/reporting purposes. If the defect code has been used in the SQC module user will receive the following warning when trying to delete the defect code. 

 

Where Used:  In all Statistical Quality Control tracking operations and reporting.

«Mark as Completed in RoadMap in Section B Item 3-h»

If the user is utilizing the CAR (Corrective Action Reporting) module, then the types of corrective actions may be grouped into specific categories in relation to the nature of the problems. For example, one problem type might be Customer Originated corrective actions. Another might be actions required of a Supplier. Another might be directed toward Engineering or Quality departments, or any company function. Another consideration may be to organize the problem types by the target of the action, like a work order or process.

If the user is utilizing the CAR (Corrective Action Reporting) module, then the types of corrective actions may be grouped into specific categories in relation to the nature of the problems. For example, one problem type might be Customer Originated corrective actions. Another might be actions required of a Supplier. Another might be directed toward Engineering or Quality departments, or any company function. Another consideration may be to organize the problem types by the target of the action, like a work order or process.

Once these problem types are defined, they may be placed in order by clicking on and dragging the box to the left of the type to the (vertical) position desired.

Enter System Setup/Production/CAR Problem Types Module

The following screen will appear:

To Add CAR Problem types, depress the Add button, and enter the type in the text box at the bottom of the list.

«Mark as Completed in RoadMap in Section B Item 3-i»

This Corrective Action Reporting number type refers to the number of the document that resulted in the corrective action. While the Corrective Action Reporting itself has a number assigned to it, there is usually another document that originates the corrective action. This document may be an RMA (Returned Material Authorization) report from the customer (e.g.  RMA # 0112), and the Corrective Action Reporting Number type would be “RMA Number”. The source document may be a DMR (Discrepant Material Return) originated by production inspection or incoming inspection. The Corrective Action Reporting number type would be “DMR Number” to describe the number identified in the Corrective Action Reporting report. The number type is used solely to identify the source of the numbered document referred to in the Corrective Action Reporting.

Enter System Setup/Production/CAR Number Types Module

The following screen will appear:

To add CAR Number types, depress the Add button, and enter the type in the text box at the bottom of the list.

Where Used:  In all Corrective Action activities.

«Mark as Completed in RoadMap in Section B Item 3-j»

Enter System Setup/Production/Tools Setup Module

The following screen will appear:

This screen is used to create a button which will appear in the Shop Floor Tracking module.  The button will direct the program to a user written program which is used to print labels for serialization.

The system automatically enters the screen name as Shop Floor Tracking.  Then the user types in the Button Caption and the name and path of the executable file.

Enter System Setup/Production/Outside Program Calls Setup Module

The following screen will appear:

 

The user must Save or Abandon changes after entering the Edit mode.

 

 

If the user Saves the changes.  A button will be created in Shop Floor Tracking with the Button Caption name entered in the Setup screen:

 

When user depresses this button, the following screen will appear and they will need to enter a serial number, the program will then gather all the part number, work order information into a text file, and the user defined program will use the text file to print the label.

 

 

Where Used:   Shop Floor Tracking module.