What is Job Travelers

Job Travelers

The job traveler giving information to your shop floor with the manufacturing process require to perform the job, including job details, customer, order information, outputs, process, tasks, components, and images. It is printed at time of job release and "travels" with the job as it progresses through the shop floor.  

Vivienne @ www.mrp.com.my

What is minimum stock level ?

The minimum stock level is that level of stock below which stock should not be allowed to fall. In case of any item falling below this level, Production or Purchase needed to replenish the stock. 


Some system have the ability to assist user to generate a list of stock needed for their production planning or planned purchase order to take place from supplier. 


Do you have any system in place to assist you or you are still using excel for the control ? 


vivienne @ www.mrp.com.my

Jobs/Work Order/Production Order or Manufacturing Order workflow

Jobs/Work Order/Production Order or Manufacturing Order are used to make "outputs", which are finished items and subassemblies, using "inputs", which are the labor, materials, and subcontract services used to make the outputs.

What are the  Jobs/Work Order/Production Order or Manufacturing Order workflow ?

Step 1 – New Job/Work Creation

• Generate job/Work either directly from sales order line for custom to make items or
  
  
• Generate job/Work  in response to net demand (means when your Stock level is below safety level as set and production needed to replenish them) 

Step 2 – Job/Work Release

• Release job/Work when your work center is ready or available
  
• Print job Order with Process and component detail. 

Step 3 – Job/Work Processing

• Request and Issue components to jobs, there are 2 option here :
  
  
  • Option A – You can Print an issue list to store for picking stock that require by the job, then after that enter the entries in the system or 
  • Option B – Make issue entries directly, print issue list then get storekeeper to pick stock
    
    
• Sometime your Job/Work might have outsourcing to 3rd party, in this case, base on the Job creation, user can generate Purchase Order for 3rd party subcontract services also if applicable
  
• After job feed back from shop floor, user enter job routing sequence completions and/or labor hours
  
• Receive POs for subcontract services
  
• Enter manufactured job receipts from Shopfloor  

Step 4 – Close Job 

Vivienne @ www.mrp.com.my

Small Accounting software VS Manufacturing Software

Wondering why there are many companies using only small accounting software but not integrated manufacturing software ? 

Because they have not aware of the availability of manufacturing software in the market and what is the software can do. many small companies are fully aware of the limitations of general accounting software and excel spreadsheets, but are busy and never find the time to upgrade to a manufacturing software package. they are also fear and are worry of manufacturing software might be too costly to implement, too difficult to implement, and too hard to use.  Are you one of them ? 

Vivienne @ www.mrp.com.my

How are BOMs costed?

How are BOMs costed?

The Cost Rollup calculates a total estimated cost for the BOM parent. Each purchased component has an estimated cost from inventory. Each work center is given hourly rates for setup, labor, and manufacturing overhead which get applied to each routing sequence. Estimated costs for subcontract services are maintained in routing sequences. The Cost Rollup calculates all these costs up through all the subassemblies in the product structure to arrive at the total estimated cost for the BOM parent.


If the BOM includes secondary outputs, a portion of the parent item’s cost is allocated to each output on a percentage basis.

What is the BOM estimated cost used for?

BOM estimated costs are helpful for product pricing decisions. You also benefit by continuous monitoring of work center hourly rates, which keeps you in touch with your item labor and overhead costs.

Is the BOM estimated cost compared to actual job cost?

Not directly. When the job gets created from the parent item’s BOM, the program calculates an estimated job cost. If you modify the job’s BOM specifications, the estimated job cost gets changed accordingly. It is the estimated job cost that gets compared to actual job cost. 


Vivienne @ www.mrp.com.my

Job with BOM

So jobs also have BOMs?

Yes, each job has its own BOM. The parent item’s BOM is copied to the job and its component usage quantities are multiplied by the job quantity. Once the job’s BOM has been created, it can be modified for any special requirements.

Vivienne @ www.mrp.com.my

What are the BOM "components?"

What are the BOM "components?"

The BOM "components" are the subassemblies, purchased parts, and raw materials that comprise the physical product.

How are BOMs used?

BOMs are used by the MRP screen to generate Custom to make jobs for manufactured items in response to customer orders and your desired stocking levels. MRP uses each item’s BOM specifications to create the job’s routing and BOM. 


Vivienne @ www,mrp.com.my

What is the BOM Routing ?

What is the BOM "routing?"

The BOM "routing" can be thought of as a "bill of labor." In the routing you define the setup, labor, and subcontract service sequences that comprise the manufacturing process.


Vivienne @ www.mrp.com.my

What are BOM revisions ?

What are BOM "revisions?"

Each BOM is assigned to a current "revision", which represents the latest engineering specifications for the BOM parent. Past revisions are stored to provide a history of engineering changes.

Vivienne @ www.mrp.com.my

What is an BOM output

What is an BOM "output?"

An BOM "output" refers to a finished item produced from a BOM. Most BOMs are defined with one output, which is the BOM "parent" item, but you can also define "secondary" outputs for by-products and co-products. Secondary outputs are commonly used by batch process manufacturers, remanufacturers, and disassemblers.


Vivienne @ www.mrp.com.my

What Are Bill of material (BOM) ?

BOM 

What are bills of material?

"Bills of material" (BOMs) are used to define the manufacturing specifications for your products or those you make on behalf of others. Manufacturing specifications include "outputs", "revisions", a "routing", and "components."

Vivienne @ www.mrp.com.my

ERP Software package.

Very disapointed with your ERP software package ? take a fresh look at your manufacturing process workflow. Identify your processes in every department, Implement all the system’s core processes, such as routings and work centers, so that the software is used to its full potential and can deliver the results you want it to be. or get the solution consultant to discuss your problem and propose a solution to address your manufacturing issues. 

Vivienne @ www.mrp.com.my

Basic module that you must have in your manufacturing package? Routing Setup

What are the basic module that you must have in your manufacturing package ?  


1. Routings Setup which allow you to setup your processes used to manufacture your parent products and to specify the work centers where the item are performed. Routings provide workers with manufacturing specifications and enable you to schedule jobs, track WIP and calculate the labour cost, subcontract service  and factory overhead. 


Any software package that dont have routings setup is not a serious manufacturing solution. Do you have this in your software package already ?  


vivienne @ www.mrp.com.my

Do you have a software to address your manufacturing problem ?

Do you have a software to address your manufacturing problem ? 

ERP software packages address all kinds of functions, including accounting, inventory, purchasing, sales, CRM, service, project management, financial applications, human resources and etc

These functions are important to every company, but if you are running a manufacturing company and you do not have the right software to address the basic requirement of your manufacturing, you will never reach your efficiency potential.


What are the basic features that are essential to any manufacturing industries ?  Here is my list.

1. Routings 
2. Bills of Material 
3. Costing
4. MRP
5. Job Release
6. Job Traveler 
7. Work Center Scheduling
8. Job Tracking 

Manufacturing BOM

Manufacturing BOM 
in our BOM menu you will find all screen related to the entry and maintenance of your bills of material and process routings.

BOM Setup
BOM Master 
Machines
Process Categories
Task Templates
Revision Names


Main Menu
Work Centers
Subcontractors
Bills of Material
Component Replace
Process Replace
Shop Rates
Estimated Purchase Costs
Cost Rollup
BOM Explorer
Where Used


Reports
Multi-Level BOM
Costed BOM  

Vivienne from www.mrp.com.my

Manufacturing Processes Sample

In this sample, product A, product B, product C, and product D are packed using packing machines.

- There is a machine called Mixer 1 for the materials mixing process.
- There are 3 packing machines, Packer 1, Packer 2, and Packer 3 for the packing process.
- There is an inspector called Inspector1 for the inspection process.
- Materials of product A, product B, product C, and product D are set as Product A-Material, Product B-Material, Product C-Material, and Product D-Material.
- ProductA-Material, ProductB-Material, ProductC-Material, and ProductD-Material pass the mixing process.
- Intermediate items produced in the mixing process pass the packing process next.
- Then, items produced in the packing process pass the inspection process and finally ProductA, ProductB, ProductC and ProductD will be produced.