Re: Shop Floor Control in BPCS

Al Mac ,
  Thank u for the details.I could not find any detail
archieve on this topic.The ver of BPCS is 6.1 and its
an engineering industry which requires the accuracy at
the inventory levels, forecasting and customer order
handling.But the users can not enter the details at
sho floor level so planning to skip it with some trade
off in the accuracy.

 Mand.

 --- Al Mac <macwheel99@xxxxxxxxxxx> wrote: > 
> >what are the affects on  the other modules in terms
> >of data accuracy and functionality if I am not
> using
> >the Shop floor control in BPCS.
> 
> Mand
> 
> A related discussion thread might be in what ways
> SFC JIT etc. do not do an 
> adequate job of data accuracy, data mining, granular
> detail, data 
> intelligibility, for which enhancements /
> modifications / add-ons are 
> essential.
> 
> What version of BPCS are you on, and what kind of a
> company?
> We are a manufacturer and engineer to customer order
> using 405 CD.
> We use a mixture of JIT and SFC ... we use CST900 to
> purge our completed 
> shop orders.
> We run MPS MRP full regeneration every nite, CAP
> regen twice a week, DRP 
> never regen.
> We have several modifications throughout the
> process.
> 
> I think that for our volume, either or both of SFC
> and JIT are essential, 
> along with accuracy in posting/reporting on shop
> orders progress, and also INV,
> for inventory accuracy (components consumed, WIP);
> for knowing what our production is costing the
> company; and
> for tracking our ability to meet customer schedules.
> 
> We also use our labor reporting tickets outside of
> BPCS to help track 
> repair of WIP ... where quality rejects some work,
> but it is not so far 
> gone that it has to be scrapped.
> 
> One of our modifications has been to use labor
> reporting to track tooling 
> usage, which ties into our preventative maintenance.
> 
> There is some granularity that affects our costs,
> that we are not tracking, 
> such as setup time.
> Recently we have been accepting smaller orders, in
> which setup is much more 
> critical to the costs, and I wonder if there is a
> way to have the system 
> budget a fixed setup cost on all parts, like is
> possible to budget with 
> scrap factors and yield.  We do track precise scrap
> consumption.
> 
> For us, setup time cost is irrespective of volume to
> be made.  Some of our 
> operations are extremely fast, so that if we are
> making thousands quantity, 
> setup impact on unit cost is insignificant.  The
> acceptance of tiny orders 
> is a trade-off between the cost of materials tied up
> in making quantities 
> that won't be needed right away, but setup not
> significant cost, vs. making 
> in small quantities to keep a customer happy.  I do
> not believe we are 
> getting the granularity of detail from BPCS right
> now to help make that 
> kind of decision properly.
> 
> There are some one time customer ordered parts, that
> the powers that be 
> decided to manufacture without running through all
> the BPCS.  For those 
> items we do not have accurate costing, and I have my
> doubts that we have 
> accurate inventory on their components.  We also
> have some items for which 
> manufacturing gets started before engineering gets
> completed.
> 
> I think it would be possible for a similar company
> to use SFC+INV without 
> JIT and get all the benefits of JIT ... what JIT
> does for us is to simplify 
> the human work load of data management and entry.
> 
> I think it would be possible for a similar company
> to use JIT+INV without 
> SFC and get all the benefits of SFC ... what SFC
> does for us is to simplify 
> the making of corrections, adjustments, and dealing
> with very hot customer 
> requests.
> 
> For some customer parts that can in fact be made in
> a very few days, when 
> we have the raw materials in house, we can accept a
> customer order, and 
> immediately start production on it (using SFC)
> without waiting on MRP or 
> JIT mass planning.  I do not believe that agility
> would be practical 
> without SFC.  But if your company does not need
> agility, then perhaps you 
> can do without SFC.
> 
> Of if you do not need the same granularity of
> costing and inventory 
> accuracy that we want, then perhaps you can manage
> without SFC or JIT, or 
> whatever is the equivalent in the later versions of
> BPCS.
> 
> -
> Al Macintyre
> BPCS/400 Computer Janitor at
> http://www.globalwiretechnologies.com/
> See Al at http://www.ryze.com/go/Al9Mac
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