Optional Prerequisites for Shop Floor Tracking:

The Shop Floor Tracking Module is used to record detailed transactions of all of the user’s Work In Process (WIP) activity.  This screen is a critical piece in the communication process.  This allows production to update the system as products move through the shop floor.  Production can add notes and indicators to identify current issues and delays.  This information is readily available for program managers and others so they have important information when it is needed and without chasing it down in production.

From within this module, the following functions are available, depending on the user’s configuration:

For further detail of these functions see Article #3107 . 

Quality Inspection Entry Screen Field Definitions

Defect Information Screen Field Defintions

Enter the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select Production/Shop Floor Tracking by Work Order

 

The Main Screen will be displayed:

Depress the Find Button displays the following screen:   Select the desired Filter: by selecting the appropriate radio button - Open, Closed/Cancelled, or All. Select the desired Find: by selecting the appropriate radio button -  Work Order Number, Product Number, Customer, Sales Order Number, or All.  Enter the information into the red box, depress the Enter key and the information will populate the screen.    If you do not know the exact number, Customer, etc you may enter in a partial number, letter, etc, then once you depress the enter key the system will pull up the matching record onto the screen or a list of all Work Orders that contain the partial number, letter, etc. entered, to select from.

If user selects ANY of the Filters: and Find by All - a screen will appear listing all the Work Orders filtered by the selection,  in numerical order, along with the part number, and Customer name.    The user has the option to view the work order by either entering the work order number into the red box, or scrolling down the list, highlighting the desired record and double click on it.    And the information will populate the screen as displayed below:

The Shop Floor Tracking screen is then populated with the appropriate data.

Find the desired Work Order record within the system.

Highlight the current Work Center where quantity is displayed, as illustrated:

 

 

Depress the “Transfer” button. The system will prompt for a password. The following dialogue box will be displayed. The user may elect to transfer material within work centers (WC) or within activities (A) by pressing the appropriate radial button on the screen. ManEx will determine the next area to transfer product based on the product routing, and enter the location in the “To:” field. The user may elect to change this location by pressing the down-arrow button next to the field and selecting a different location.(NOTE: The user MUST have "Skip rights" or "Supervisor rights"  setup within the Security module in order to skip work center locations, or move product backwards) Exception to this rule is if user clicks on the Transfer to RWRK button. t will move all qty's in current selected WC to Rework WC without the need to have "Skip WC Rights"

Next, ManEx lists the number of products at the current location. The user may move all items, or select the quantity to be moved. This may be done by simply over-writing the quantity or by using the “arrows” to raise or lower the quantity shown. The user may also elect to print a traveler to accompany the parts at this time. Once the Print Traveler box is checked, a Footnote button appears, as shown.   Any Footnotes that a person enters within this screen is just temporary and is only printed on the Traveler report.    If the user elects to have the “Pop up printer Selection dialog” marked. The system will not print directly to the default printer. It will then bring up the Printer dialog box and allow the user to select which printer to send the traveler to.     In order to Print Traveler or Labels when completing work orders to Finished Goods, the system setup for SFT Defaults  must be set to have the printer ON for FGI Labels.

Depressing the Footnote button will bring up a note screen.

Depress the Edit button, Type in the footnote. Depress the Save button. Depress the Exit button.

Transferring Serialized product

If the work station being used to transfer serialized material is assigned to use a default work center in Production Work Center/Activity Setup module, when the user first opens the module, the module will use the default work center assigned for this workstation, if the transfer is "FROM" a different work center other than the default and user is NOT a supervisor or has the  option "Allow Changing Default Work Center for Serial Number Transfer" box checked within the Security module, they will receive the following message:

When user depresses "OK"  a supervisor approval is required to continue.  After supervisor’s password is entered, the default work center will be changed to the one that the supervisor entered password for.   For example:  the workstation is assigned to use “TU” as default work center, now if user chooses to use “AI” to transfer, the system will ask for supervisor’s password, if user cancels the password, the default work center will still be “TU”, but if the supervisor enters his/her password on this machine, the default work center will be changed to “AI”.  If now the user tried to transfer from “TU” again, the system will ask for supervisor’s password again.  If user exits the module and come back, the default work center will be “TU” again.

If the user is using tracking by serial numbers, and if the user is transferring a lesser quantity than displayed, ManEx will display a screen from which to select the serial number(s) to be moved in the transaction.  The user may select one or more serial numbers to match the quantity being transferred, and then press the OK button.

The user must select the proper number of serial numbers or the transaction will be cancelled. 

Depress the OK button. The material will transfer and the Traveler will go directly to the default printer. (This report requires that the user have the bar code font available).

 

Since less is being transferred, the following message will appear Yes – will bring up the Transfer Material screen again. No – will bring you back to the regular Shop Floor Tracking module.
If there are kit shortages remaining on kit, the following message will be displayed when transferring product into FGI.  User can select to continue moving the product into FGI or select "No' to cancel  the transfer.

 

If the product is included in an active Cycle count, or Physical Inventory count, the following message will appear after depressing the OK button on the transfer screen anud user  will not be allowed to transfer product until the count has been completed and posted.

 

Discussion on the Accounting Entries

If the user also has accounting installed, then the appropriate journal entries will forward to the Accounting “Release to General Ledger” screen. Briefly, assuming that the user has the material cost set up in the Inventory Control Item master, then when the product reaches the Work Center “Finished Goods Inventory”, the entry will be to debit Finished Goods Inventory (or the warehouse home general ledger number of the product) and to credit WIP .If the product ended up in the Work Station “Scrap”, then the debit would be to the default scrap general ledger account, as set up in the Accounting Set Up.

Configuration Variance

If the Material Cost per the product was not equal to the sum of the standard costs per the BOM components, then a configuration variance will be created.

Please refer to the “Wip Value" Article #913 for further explanation.

Entering a Defect Code Entry to a Work Order

For closed Work Orders:  In the Security module, there is an option which must be checked per user for the “Defect Code Entry”. Once the Security right has been entered, the user may edit a “closed” Work Order.

 

 

Enter the SQLMANEX.EXE (within the ManEx root directory)  This action will then prompt the user for a password
The following screen will be displayed, select Production/Shop Floor Tracking by Work Order Module Find a Work Order in SFT by WO Module

When a valid location is entered, then system searches the Bill of Material to find manufacturers approved for the product, and displays a list of the approved manufacturers for the user to identify which manufacturer was associated with the defect observed. The user double-clicks on the manufacturer's name for the defective part, and the manufacturers name is placed in the defect information screen.   (Note:  the location field MUST be populated if using the Test and repair module)

The user then must select an Employee from the pull down.  The employee's being displayed in the pull down are only the employee's that are assigned to work centers (in the Security module) that are the same work centers listed in the Shop Floor Tracking by Work Order module and is sorted by the Employee User ID Number. 

 

 

The user may also enter a brief comment about the defect, for future reference.

The completed screen should appear as follows:

Depress the Save record action button to save changes or the Abandon changes action button to abandon changes.

If you depress the Save record action button, the following message will be displayed:

If you want to add another defect record for the same user "ONE" then depress YES, if you want to add a defect record for a different user (Example user "TWO"), then you must depress NO.  Depress the Add record action button and enter user "TWO"s password and continue to enter the defect information.

When the user has completed the defect information, they may click on the Test & Repair tab, to enter more information about the part.

NOTE:  The Test & Repair is actually a separate OPTIONAL module, but has been included into the Defect Entry screen for ease of use for the operators.  For further detail about this module see Article #4211..

Adding Work Order Defect Information With Serial Number Tracking 

 Enter the Defect Entry screen. Depress the Add Record action button.  Un-check the "Skip Serial No Field" 

If the user is tracking serial numbers, then the first field to be entered (or bar-code scanned) is the serial number of the product being inspected. (Not the Work Order number).

Enter in a serial number. When the serial number has been entered, ManEx will complete the work order and product information. ManEx will also enter the current work center location of the serial number supplied.

The user now has the option of continuing to scan (or type) serial numbers, and log the defect information for each one later, or enter a serial number then the defects for that serial number, enter the next serial number, then the defects for the second serial number, etc. When multiple serial numbers have been entered, the data will refer to the serial number that is highlighted in the Serial Number list.

ManEx will enter in the lot size according to the quantity of serial numbers showing in the serial number list.

Go to the Defects Information Tab to enter in the Defect info for each SN entered:

The next field, “NPF” is provided for the user to record when observing the product and finding that there is “No Problem Found”. If 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 no 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 exceeds that established in the system setup/Quality Defect Codes the user will receive the displayed warning message and will allow you to proceed on with the Inspection.  This is just a notification that the board has passed the maximum NPF cycle. 

Entering Defect Information

This screen operates as described under Entering Defect Information without serial numbers, except that the user must enter data for each serial number recorded. The serial number may be chosen by highlighting the serial number in the serial number box on the first screen, or in the defects information screen, by pressing the down arrow button next to the serial number field and selecting a serial number.

Defect information is entered in the same fashion as described above, except that the user should remember that the data being entered is for one part at a time, by serial number of the part.

The other difference in using serial number defect tracking is that on the Test & Repair screen, the user may view the Serial Number History tab. This view will display both the transfer history of the serial number through the work centers, and the history of defects associated with the serial number of the product.

(Note: if you are entering Defect information and not using the Serial No, then this screen will remain blank)

The user completes the defect entry for the first defect code (The location, quantity of defects observed, etc.). The process is repeated for each defect observed, storing the location and serial number to be analyzed at a later time.

At the conclusion of defect entries for the lot, the Save action button is pressed to retain the data.  If the user elects to ignore all data entered in this session, the Abandon  changes action button may be clicked to void any entries. Notice that ManEx computes the total number of defects observed for the defect code and displays the number next to the defect code. 

Entering Defect Information Without Serial Number Validation

The “Enter Serial Number without Vailidation” option will only be enabled if the user skips the regular Serial number entry, and if the Work Order Product has not been serialized within the ManEx system.   

This feature has been added to allow the users the ability to inspect Serial Numbers that do not actually exist within the ManEx system. (for example serial number created outside of ManEx, by customer or other software, etc. . .)  If the user checks the “Enter serial number without validation” then ManEx does not validate when the users enters the Serial Number.  The system just records the entry for later SQC analysis purpose.  

Enter the Defect Entry screen. Depress the Add Record action button.  Select “Enter Serial Number without Validation. ”

 

 

The remaining process will then be the same as listed above.

In order to have the "DPMO by Employee" report create valid data, the user must be sure to enter the opportunities for defects (PPM) in the Work Order Traveler Setup and the employee must inspect the board and be assigned to the defects.  The "DPMO by Employee" report only gathers data if BOTH "Inspected By" and "Emp" are the same user, and the PPM is setup.   See Article #3156  for further detail on DPMO.   The following steps need to be followed to collect and track defects per employee. 

All data must be Entered in the Quality Inspection Entry and Defect Information screens, with in the Shop Floor Tracking Module.

Entering a Defect Code Entry to a Work Order for the "DPMO by Employee" report

Enter the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select Production/Shop Floor Tracking by Work Order

Depress the "Inspection" button located at the top of the screen.

The following screen will appear:

Entering Quality Inspection Data

The first information tab records information about the work order. This includes lot size, failures, inspection quality, date, etc. 

Depress the Add action button.  Enter the password of the Employee that has inspected the product and will be assigned to the defects.  Example:  If user "ONE" is going to be assigned to the defect(s) then you must enter user "ONE"'s password. 

Check the Skip Serial No. Field (if not applicable).

Enter the Work Order number, choose the Inspection Work Center from the pulldown, enter Lot Size inspected, Inspected Qty, and Failed Qty.

The Date, Time, Pass Qty, and Yeild % will default in.

Depress the Defects Information tab and the following screen will appear:

The user may then enter a defect code by manually typing in the code, or by scanning a bar-code menu, or by double clicking on the field to review a list of defect codes.

The list displayed will depend on which view is selected. If Work Center Defects is chosen, only those defects associated with the work center (as established in the Quality Defect Codes setup) will be displayed. If All Defects is chosen, then every defect entered in the Quality Defect Codes  setup will be displayed.

The user may select one or more defects from the list by holding down the Control Key while clicking on the defects to be selected.

After completing the selection of the defects involved with the current inspection, clicking on the OK button loads the selected defects into the defect information screen.

Although Manex will enter a Charge To Work Center code based on the work center entered or the location of the part, the user may modify the originating work center by clicking on the field and selecting another work center from the list.

The user may (optionally) then enter in the location (reference designator) where the defect was observed.

The user then must choose the Emp from the pull down, which would be "ONE", because it needs to be the same user that has been entered in the "Inspected By".  The user is allowed to enter other user's name on Defect detail page in the "Emp" column.  But when the "DPMO by Employee" report is run, it will not display the records assigned to the different users.  

The system will check the BOM to be sure that the location entered here matches locations entered on the Bill of Materials. 

When a valid location is entered, then system searches the Bill of Material to find manufacturers approved for the product, and displays a list of the approved manufacturers for the user to identify which manufacturer was associated with the defect observed. The user double-clicks on the manufacturer's name for the defective part, and the manufacturers name is placed in the defect information screen.

Manex defaults the number of defects to one item, but the user may overwrite the quantity with an observed quantity greater than one.

The user may also enter a brief comment about the defect, for future reference.

The completed screen should appear as follows:

Depress the Save record action button to save changes or the Abandon changes action button to abandon changes.

If you depress the Save record action button, the following message will appear:

If you want to add another defect record for the same user "ONE" then depress YES, if you want to add a defect record for a different user (Example user "TWO"), then you must depress NO.  Depress the Add record action button and enter user "TWO"s password and continue to enter the defect information.

When the user has completed the defect information, he/she may review the "DPMO by Employee" report Article #815, or may click on the Test & Repair page, to enter more information about the part.

The Test & Repair is actually a separate OPTIONAL module, but has been included into the Defect Entry screen for ease of use for the operators.  Please see the Test & Repair Management (T&R) article for more information.

To obtain reports, depress the Report button. 




The following screen will be displayed:

JOB TRAVELER REPORT

Highlight the “Job Traveler” report. Make the desired selections in the Detail Report Section.   Note: The Work Instruction may not appear in the Traveler if the user prints it to an Excel Worksheet file. Some of the reports are quite complex, with multiple relationships and filters. In this instance, the Work Instructions are in a different data base than the routing and therefore will not be available.   Depress the OK button

The following screen will appear: Enter a Work Order Number.    Select to Display Time in Decimal Format or not.   The default is "YES"     Depress the OK button

The following report will be displayed:

 

Enter the Desired Work Order Number. Enter a Work Center ID between Single Quotes.  If ALL Work Centers are desired leave '*' Defaulted. Note:  The leading zero's for SN will be removed from Report.   Depress the "OK" button

The following report is available:

WORK ORDER LIST CONNECTED TO THE SERIAL NUMBER REPORT

Enter a desired Serial Number:   Depress the OK button

 

The following Report will be displayed:

 

 

Highlight the “Transfer History” report.

Depress the OK tab. The following screen will appear:

 

Enter a Work Center ID in between the Single Quotes:  If ALL Work Centers are desired leave '*' defaulted Enter a Starting Date Range and Ending Date Range" Leading zero's for SN will be removed from report

The following Report will be displayed.

WORK ORDER WORK CENTER NOTES REPORT

Highlight the “Work Order Work Center Notes” report.

Depress the OK button.  The following screen will appear:

 

Enter a desired Work Order Number. Depress the OK button.

The following report will be displayed:

SERIAL NUMBER TRACKING HISTORY REPORT

Highlight the “Serial Number Tracking History” report. 

Depress the OK button.  The following screen will appear:

 

Enter Beginning Serial Number within the single quotes. Enter Ending Serial Number within the single quotes.   Leading zero's for SN will be removed from report.