Manufacturing & Service

Process
A process is a functionality intended to be used by manufacturing industries to produce finished products for sale. The production of products is typically in bulk quantities and is concerned with discrete units, bills of materials and the assembly of components.

Aqxolt ERP provides a complete solution and agility to succeed in managing entire business processes end-to-end. It lets you accommodate and manage a work center and plan workforce and machine required hours in a cost-effective manner depending on the complexity of the manufacturing process.

Creating Processes:

• Navigate to the Manufacturing app > Processes tab.
• Once in the Process section, you can track the processes already filled in and create
  new processes.
• To create a new process, click the “New” button.
• Select the “Manufacturing Process” record type and click the “Next” button.
• Enter the process name, organisation and contact details.
• Select the type of process, enter the barcode and select the product for which the
  manufacturing process is built.
• Select the workstation and work center; enter the required workforce and machine
  hours.
• Enter the cost details of the manufacturing process and enter the process description; then click the “Save” button to create a manufacturing process.

Process Cycle:
A process cycle is a sequence of steps required and a set of activities associated with the
manufacture of finished products. It essentially starts with the customer requirement and ends with delivery of the required product.

It is a framework that describes how and from where the process starts. It also describes when and how the interrelated operations depend on each other. It describes the progress of each process cycle, helping the user estimate the overall time required to produce a finished product.

Creating a Process Cycle:

• Navigate to the Manufacturing app > Processes tab.
• Once in the Process section, select the process record to create the process cycle.
• In the related tab, find the Process Cycle related list and click the “New” button.
• Enter the Process Cycle Name, the Progress of the process cycle and the Description.
• Select Previous and Next Process Cycle; then select the Workstation in which the
  process cycle will commence.
• Click the “Save” button to create a process cycle.

Routing Links are used to making an association between a routing and the BOM components that will be used in the process and the associated versions. 'Routing Link Code' links the Bill of Material to a Process Cycle and its Operation.

Routing

• Navigate to the app menu > Routing tab.
• Once in the Routing section, you can track the routing that is already created and also create a new routing.
• To create a new routing, click the “New” button.
• Select the Manufacturing Routing record type and click the “Next” button.
• Enter the Routing Code and select the Type and Status to be Certified.

• Select the Product, Channel, Raw Material and Finished Product sites.
• Enter the Maximum and Minimum lot size and click the “Save” button to create the Routing record.

To add the Routing Link Code:

• Navigate to the Process > Process Cycle (Related List)
• In the Related list, scroll down to the Routing Links tab.
• Create new routing link by adding the routing link code, process cycle, and
• This Routing link code will be assigned to the Bill of Materials and the Operations.

Operations

• Navigate to the operations tab in the related list to Routings.
• Once in the Operations section, you can track the operations that are already recorded and create a new Operations record.
• Click the “New” button to create operations.
• Enter the Operation Code, the Operation No., and the Next Operation No.
• Select the Work Center, Quantity, and Fixed Cost details.
• Click the “Save” button to create the Operations record.

A Bill of Material (BOM) is the functionality used to set up a production module in an ERP system. A BOM is essentially used to manage a list of components used to produce the end product. The manufacturing of the end product goes through numerous phases of production; a BOM records the details of components needed at various phases of production. Creating a BOM is essential because the correct component must be available during the manufacture of the finished products.

Every BOM record includes the product name, description, quantity, unit of measurement, procurement type, etc. and provides a centralised source of information to the person handling the BOM to manufacture a product.
Aqxolt ERP provides the flexibility to configure various types of Bills of Material depending on the business use for which they are intended.

Creating Bill of Materials for Manufacturing:

• Select the manufacturing process for which the BOM is required.
• In the related tab, find the Bill of Material (Manufacturing/Assembly Process) and click the “New” button.
• From the New Bill of Material Record Type pop-up, select “Manufacturing BOM” and click the “Next” button.
• Fill in the BOM name, the process cycle in which the BOM component is used.
• Select the phase (stage) of the BOM, then the unit of measurement of the BOM.
• Enter the BOM level, reference designators, part identification number, quantity, BOM (product), and BOM component.
• Select component type, procurement type, and type of BOM.
• Enter the cost details under the “Cost/Billing” section.
• Enter the description and BOM notes if applicable.
• Click the “Save” button to create the BOM record for the chosen manufacturing process.

Fields to note:

The BOM can be created for various component types, which can be understood as follows:

A work centre is a unit in an organisation where all activities associated with manufacturing processes are performed. Work centres are used to allocate resources and in work orders to complete the manufacturing process. Work centres are usually used to calculate the number of hours required to execute the process, the cost involved in project completion and the availability of the resources within a planned duration of the project end date.
Create Work Center
1. Navigate to the Manufacturing app > Work Center tab
2. Once in the Work Center tab, you can view the work centre information already filled in and create a new Work Center record.
3. To create a new work centre, click the “New” button.
4. Select the organisation details of the work centre.
5. Select the channel, site, site and shop floor warehouse for the work centre.
6. Click the “Save” button to create a work centre for the organisation.

Fields to note:

Work management involves creating, qualifying, dispatching, and executing requests for off-site work, called work orders. The steps and functions of the work order lifecycle work together to ensure that off-site issues are resolved in the most efficient manner possible. Users with the appropriate roles create the work orders and provide all the necessary information needed for the work order tasks. For the qualified, those work orders necessary tasks are created to complete the work order.

Creating a Work Order

In the work orders, one is able to view and edit the existing work orders, create new ones and also import a new document from the existing documentation. When creating a new work order, the following steps are followed:

A Work Order can be created in the following methods

• From Work Order Tab (Record level)
• From the Sales Order Tab (Converting sales order into work order)

1. Click on the Work Order tab as shown above. Once on the Work Order section, you are able to track the work orders already created and create new ones with the “New” button located on the top right corner of the work order page.

2. Register a new work order name, the supplier of the work order along with the organisation’s name and details. Also include the details of the project, the date of approval and the lead time

3. Other details of the budget are included covering the work order costs, along with the details of the related sales order and purchase orders.

4. Since the work orders are used in the manufacturing or processing environments, there is a section with the details including, costs, the process, types of the process and planned and completion dates.

5. The work order document also allows the description of the process that is being done.

For existing work orders, you have the ability to edit the details of the work order as the project goes on. The related tab that is next to the details of each work order allows that each record to be updated according to the progress of the project.

The work order page includes the related page that contains the related tab with links to all documents that relate to a particular work order. The work order lines are the specific process that needs to be completed, for instance, the details of each item to be manufactured or assembled.

The works order lines would help a business in dividing the duties so that the deadlines set for completion of the work orders are met. This can be through dividing the items to departments that manufacture or assemble specific items.

New work order line items can be added to the list by clicking on the “new” button that is on the right end of the page. There are other documents in the page, which are related to the work orders open. The work orders are identified by their unique names. The records are all that relate to the work orders open. This enables the business to manage their projects smoothly so that they are successfully executed and closed.

Fields to note:

1. Click on the Sales Order tab as shown below

2. Select the sales order that you would like to convert into work order and click on the down arrow in the top right-hand corner of the page and select ‘Create Work order’ as shown below.

3. Fill in the work order detail section and the work order line items section,  new work order line items can also be added along with the existing line items using ‘Add New’ button.

4. Click on ‘Save’ button which creates a new work order with a unique work order number.

The work order page offers an efficient method for the business to effectively manage the costs of a manufacturing process to ensure all orders are followed up to and addressed with simplicity. The work orders page also helps to make budgets of each project and the items required with minimum costs. For a supplier, receiving work orders also allows the organisation to understand the required items of each activity and how to deliver on each.

Capacity planning is the process of determining the production capacity needed in manufacturing a product. For an organization, capacity would be the ability of a given system to produce output within the specific period.

In Capacity Planning, we can get the daily overview of the work assigned to work centers or Resource Groups.

To Create Capacity Planning

• Navigate to the app menu > Capacity Planner.
• Create a new Capacity Planning record by clicking “New.”
• Add capacity planner name, Start Date, and End Date.
• Make sure “Demand Aggregation” is Monthly.
• Click Save.
• In the Related list, we have Resource Groups, Resource Allocation, Capacities, and Demand.

The resource is used for the manufacturing process. Manufacturing resource groups can be electromechanical assemblies, cable assemblies, machinery, and human resource as well as Job floor assistants, assembly workers, and others. The human resource comes under workforce in manufacturing.

A Resource Group can have a team of the professional workforce or a resource group having a set of machinery used for a particular process.

• Add the resource group on capacity planner's related list by clicking the “New” button.
• A resource group can be of Record type “Workforce” or “Machine.”
• Select Workforce if you want to create Workforce resource group or Machine if you need to create Machine resource group.
• Add the Skill Group Name, Runtime Cost Price (Hour) and Billing Price.
• Add Process, Process Cycle, and Capacity Planner.

Another way of adding resource groups is from “Manufacturing Schedule.”

• Navigate to App menu > Manufacturing Schedule
• You will land on the PLANNER tab showing Capacity Planning which has subtabs
• Navigate to Resource Groups in the sub tabs and click “New” button to add new resource group.

Resource Allocation

Resource needs to be allocated to a resource group in the capacity planner. Allocating employee to a workforce Resource Group or allocating machines to a Machine Resource Group; like allocating Floor Assistants to the Job Floor Assistant Resource group.

• In the related section of Capacity Planner click “New Resource Allocation”
• Fill in the Resource Name, Start Date, and End Date; make it active.
• If creating workforce resource; select Employee, if creating Machine resource; select Machine.
• Select Resource Group, Work Center and Capacity Planner.

Resource Requirement

Resource Requirement is done to connect the Resource Group with the work planner wherein the Runtime and Runtime costs can be specified based on the work planner requirements.

• In the related section of the Resource Group, add the resource requirement.
• Create New, add the Resource Requirement Name.
• Add Runtime, Runtime Cost, Setup time and Setup cost.
• Assign Resource Group and Work Planner.
• Click Save.

We can view/create this on the Manufacturing Schedule page as well.

• Navigate to App menu > Manufacturing Schedule
• You will land on the PLANNER tab showing Capacity Planning which has subtabs
• Navigate to Resource Requirements in the sub tabs and click “New” button to add new resource requirement.

Work Planning is done to have a detailed outlook on how the workforce is utilized to accomplish a task and how work centers are linked to process. Work planning also gives an overview of the Project related tasks. We can add a work planner record and assign it to Process, Process Cycle and Work Center.

• Navigate to the App Menu > Work Center
• Go to Work planner in the related section of a work center
• Create New
• Add work planner name, Work Center, Process and Process Cycle.

We can view/create this on the Manufacturing Schedule page as well.

• Navigate to App menu > Manufacturing Schedule
• You will land on the PLANNER tab showing Capacity Planning which has subtabs
• Navigate to Work Planner in the sub tabs and click “New” button to add new Work Planner record.

View and modify the process schedule

• On the scheduler subtab of the Manufacturing schedule, view the Gantt chart of work orders associated with each operation of the manufacturing order.
• To view the Gantt chart in various views like Time, Day, Week, Month and Year view, select the view options from the section above the Gantt chart.

• To reschedule the work order associated to the individual operation, simply drag and drop it the available new date/time. The changes are reflected in the work order record.
• To mark the percentage of progress of each work order, select the slider icon and drag it to display the progress.
• To make further changes to the work orders, expand the manufacturing order by clicking the folder icon in front of it. All the work order related to the manufacturing order will be displayed under it.
• Click the work order, on the Job Execution, make the necessary changes and click the “Save” button.

Starting a manufacturing order

• To carry out the manufacturing order click on the Builder subtab of the manufacturing schedule tab.
• Click the “Start” button to carry out the manufacturing order.
• Click the work order under each process cycle to carry out the job execution of each Action/Task associated with the work order.
• Once in the Worksheet tab of Job Execution, you can track the Actions/Tasks that are already filled in and create a new Action/Task.
• To carry out the Action/Task, select the action/task and click the “Start” button. Once the action/task has been started you can pause, finish and stop the Action/Task.

• To create an action/task for a specific work order, click the “New” button.
• To make further changes to the Action/Task select the down arrow on the right-hand side and click the “Edit” button.
• Click the “Save” button after making necessary changes.
• Click the “Previous” and “Next” button to view or start the Action/Tasks.
• To view the drawings of the action/task click the Drawings tab.
• The Time Tracking tab lets you track the time and duration of each Action/Task.
• Click the Resources tab to allocate the resource for the selected Action/Task. You will be presented with a screen below.

• Select the Resource group under the work planner
• Select the checkbox under the Action section to associate the resource with the selected resource group and click the “Save” button to create the resource allocation record.
• The Current Production tab gives the details of finished and scrapped products.

Create the Serial Numbers/Batches.

Once all the operations have been completed, create the Serial Numbers/Batches to the finished product.

• On the Manufacturing Order tab click the Serial Number/Batches sub tab.
• Click the “New” button to create a Serial Number or a Batch, you will be presented with a popup screen below.

• Enter the Serial Number or Batch Number and enter the Manufacturing, Availability and Expiration Dates
• Enter the Cost Price and click the “Save” button.

Work Orders for Service/Installations

You can also create work orders for products that require service/installations manually by following these steps:

• Navigate to the Maintenance app > Maintenance Schedule
• Once in the Planner sub tab of Maintenance Schedule, you can track the capacity planning overview of the selected work center, a resource group or a resource.
• To create a new work order, click the “+Work Order” button located on the top right corner.
• Enter the Name of the work order and the Start and Expected Dates.
• If the work order being created is associated with a sales order, select “Sales Order.”
• Select the Product of type SST to maintain and select the type of work order
• Enter the Quantity, the Production Version and the Routing.
• Click the “Schedule Work Order” button to create the work order.

View and modify the process schedule

• On the scheduler subtab of the Maintenance schedule, view the Gantt chart of work orders, work centers, and resources upon selecting the view.

• To view the Gantt chart in various views like Time, Day, Week, Month and Year view, select the view options from the section above the Gantt chart.
• To reschedule the work order associated to the individual operation, simply drag and drop it the available new date/time. The changes are reflected in the work order record.
• To mark the percentage of progress of each work order, select the slider icon and drag it to display the progress.
• To make further changes to the work orders, double-click the work order you will be presented with a job execution page
• Click the work order, on the Job Execution, make the necessary changes and click the “Save” button.

Starting a work order

• To carry out the work order click on the Builder subtab of the maintenance schedule tab.
• Click the “Start” button to carry out the maintenance order.
• Click the work order under each process cycle to carry out the job execution of each Action/Task associated with the work order.
• Once in the Worksheet tab of Job Execution, you can track the Actions/Tasks that are already filled in and create a new Action/Task.
• To carry out the Action/Task, select the action/task and click the “Start” button. Once the action/task has been started you can pause, finish and stop the Action/Task.

• To create an action/task for a specific work order, click the “New” button.
• To make further changes to the Action/Task select the down arrow on the right-hand side and click the “Edit” button.
• Click the “Save” button after making necessary changes.
• Click the “Previous” and “Next” button to view or start the Action/Tasks.
• To view the drawings of the action/task click the Drawings tab.
• The Time Tracking tab lets you track the time and duration of each Action/Task.
• Click the Resources tab to allocate the resource for the selected Action/Task.