Add Operations to a Production Order

Note! This manual is developed for the MKG004 software. If you use MKG5 or MKG3, the description of the operation may differ from your environment. We aim to create a product-specific description for this topic in the future.

To add an operation to a production order, the line 'No operations' must be selected. Then you can choose the New... button on the tab Management Mat/Op.

MKG recognizes three types of production order operations: Manned Operation, Unmanned Operation, and Outsourcing.

Manned Operation

Manned operations are operations that are carried out internally. For this, both an employee and a machine must be available. The screen will look as follows:

• Operation. Selection field to select the operation. This field is mandatory.
• Order. A number that determines the order of the operations. The step size can be set in the administration settings.
• Production Phase. To be able to subdivide the production process into phases, operations can be assigned to a Production Phase. The MKG production planning can plan on these phases (only use if Planning is actively used).
• Description. Description of the operation.
• Certificate. Certificate associated with the operation.
• Week Start. The expected start week (date) of the operation.
• Outsource. Checkbox for the user to select whether or not the operation is outsourced.
• One-time. Checkbox to indicate that the operation should only be performed once regardless of the production order quantity.
• Quantity. The number of times the selected operation must be performed per product. Default value is 1.
• Setup Time. Entry of the setup time in hours, minutes, and/or seconds. The setup time is one-time and is not multiplied by the quantity. The man/machine ratio is handled as one-to-one within the software. Time input can be done by, for example:
• 122m = 122 minutes and is displayed as 2:02:00
• 0.5h = 30 minutes (half an hour) and is displayed as 0:30:00
• 8h = 8 hours and is displayed as 8:00:00
• 3600s = 1 hour (3600 seconds) and is displayed as 1:00:00
• 2h12m50s = 2 hours, 12 minutes, and 50 seconds and is displayed as 2:12:50
• Operation Time. Entry of the operation time in hours, minutes, and/or seconds for the operation of one product. This is multiplied by the above quantity and then by the production quantity of the line. Behind the operation time field, it states for how many units this time applies. For example: 'per 1', 'per 10', or 'per 100' units.
• Quantity/Hour. If there is more feeling for a quantity per hour, this field should be filled in. If a quantity per hour is entered, the operation time will be calculated. If the operation time is entered, the quantity per hour is calculated.
• Man/Machine. Here the ratio of Man per Machine is indicated. The software calculates this by splitting the hourly rate into a man and machine part. This determines whether more or less man part is calculated.
• Alt. Resource. This is used in the production planning. For each operation, a resource is defined. Through this field, it can be determined whether an alternative resource should be resorted to.
• Unmanned. Checkbox to indicate that the operation can produce unmanned.
• Start Condition. To enable registration of hours through the Hours PC or Shop Floor, the start condition must be met. We recognize the following variants:
• None. Registration is always possible (provided the status and action schema allows it).
• Previous operation has started. Only when the previous operation has started, this operation becomes visible in the hours registration.
• Previous operation has a number ready. Only when the previous operation has the number ready that was previously determined, this operation becomes visible in the hours registration. It is advised to follow this setting by the below setting 'Spec. required'. With this option, there is an input option where a ready number can be specified if necessary.
• Previous operation is complete. Only when the previous operation is reported complete, it becomes visible in the hours registration.
The above start conditions are intended to prevent erroneous hours registrations and to create a clearer overview (only the operations that can actually be performed are visible).
• Spec. Required. If this choice is made, the current status of the operation must be specified for each operation that is stopped in the hours registration (fully, a number, or percentage ready).
• Operation Entry. The advisory price for the operation can be adjusted here.
• Setup Entry. The advisory price for the setup can be adjusted here.
• Operation Specification. Selection field to select a specification under which the costs of this operation fall.
• Setup Specification. Selection field to select a specification under which the costs of this setup operation fall.
• Operation Memo. Memo field for the operation. Here, for example, a work instruction regarding the operation can be specified.
• Setup Memo. Memo field for the setup operation. Here, for example, a work instruction regarding the setup can be specified.

With operation times, per unit and per order quantity, a total sum of the operation times is shown. In addition, information is available about registered times (NC) processed and not yet processed (not processed).

Unmanned Operation

An operation with the property 'Unmanned' means that times can continue during breaks and after working hours. No employee is needed for the production. However, these operations must also be started, and occasionally an eye must be kept on them. Even if it is just to arrange the material supply and the removal of products. These manned actions for an unmanned operation are called bypass and this bypass can be set up or specified using the following options:

• Unmanned. No employee is directly needed for the operation.
• No bypass. In the production planning, the operation can just keep running (it is always started in a presence time slot).
• Bypass by number. Depending on the entered number (VC), the bypass is planned. Specify the number after which bypass is necessary: the required bypass time, the bypass buffer, and whether the bypass is critical. Critical means that the production planning searches for the first available presence time slot for the bypass.
• Bypass by time. Depending on the elapsed time duration, the bypass is planned. Specify the time after which bypass is necessary: the required bypass time, the bypass buffer, and whether the bypass is 'critical'. This means that the production planning searches for the first available presence time slot for the bypass.

Outsourcing

An operation can by default be given the property 'Outsourcing'. It is also possible to determine this manually when entering the pre-calculation. If the checkbox for 'Outsource' is checked, the operation screen will be adjusted and look as follows:

To mark an operation as outsourcing, the checkbox at the field Outsource must be active. The screen presents the associated fields. The following data can then be filled in alongside those of the regular operation:

• Available. Week (date) in which the outsourcing must be executed. This is usually determined by the planning.
• Purchase. Week (date) in which the outsourcing must be purchased to get it back on time.
• Creditor. Selection field to select the creditor/supplier.
• Number of days. This allows indicating the expected lead time in calendar days (days between purchased and received). Depending on an administration setting, these days may or may not take weekends and/or holidays into account. The number of days is transferred to the planning.
• Specification. Selection field to select a specification under which the costs of this outsourcing fall.
• Internal/External Memo. Memo fields for outsourcing. Information related to the outsourcing can be placed here.
• Quantity. The quantity expressed in pcs.
• Weight. The quantity expressed in kg.
• Length. The quantity expressed in m.
• Surface Area. The quantity expressed in m².
• Volume. The quantity expressed in m³.
• Net Price. The net price and the corresponding unit of the outsourcing.
• Cost Price. Presentation of the cost price of the line.
• Advisory Price. The advisory price as used in the pre-calculation.
• Entry Price. User-adjustable advisory price.
• Fixed Costs. Here, the one-time fixed costs for an outsourcing can be entered (not charged to the production order).
• Other Costs. Here, the one-time other costs of the outsourcing can be entered (not charged to the production order).
• Total Price. The Entry Price multiplied by the Quantity.

Transfer Material Data for Outsourcing

For outsourcing, material data can be easily used. Two starting points are possible:

1. Transfer data from the production order line (semi-finished product).
2. Transfer data from the linked materials.

To make a choice, click the Advice… button.

The column 'Semi-finished product' presents the data of the production order line. The data of the linked materials are in the column 'Linked materials'. By clicking one of the Transfer… buttons, a choice can be made. This action automatically fills in the data. These can be manually changed afterward.

Operations Maintenance Toolbar

Within the 'Operations Maintenance' screen, in addition to the standard buttons New, Edit, Delete, Copy, Save, and Cancel line, there are a number of other buttons available: Link with Material (Ctrl+E), Purchase Quote (Ctrl+I) and Questions (Ctrl+Q).

Link Operation/Outsourcing to Materials/Semi-finished Products

This button is available for making a link. Sometimes it is useful to make a link between material and an operation or between an operation and different materials. Presentation on workplace documents and instruction can thus be more specific. For outsourcing, it can be specified which materials are involved. The screen below becomes visible:

Within this screen, a choice can be made between the available materials in the production order. A subordinate production order line can also be linked to an operation at a higher level. Open the 'Semi-finished products' tab for this. In the same way as under materials, a selection can be made from the available production order lines. The use of the buttons Mark all and Clear marking speak for themselves.

The button Surface Area… is intended to specifically determine the surface area to be calculated for VRM material lines. Based on the made choice, the surface area is calculated and passed on to the operation (outsourcing).

The button Maintenance… starts the material maintenance screen, so previously entered material lines can be consulted or adjusted.

Operation (Outsourcing) to the Purchase Quote Request List

This icon is only available for outsourcing. Here, a purchase quote can be requested.

Production Order Questions

To force notifications from the shop floor or to start a dialogue with a production employee, questions can be linked to an operation. The intention is that these questions are answered by the production employees. This not only results in a post-calculation consisting of registered time and material but also allows the employees' comments to be neatly recorded.

Questions can be centrally formulated under 'Standard questions', found under the menu item: MKG Time Registration Process Tables Standard Questions. These standard questions can be looked up in the field 'Question no.' in the screen below. If the questions are specific to the operation or this product is unique, a question can also be manually entered, exclusively for this VC operation line (see example below):

A production order question is entered as follows:

• Question no.. A generally formulated question can be chosen from the 'Standard questions' table. This minimizes input. All other fields are thus automatically determined.
• Question Description. Here the question is formulated.
• Answer Type. The chosen type determines the format of the answer. Smart choice in this promotes user convenience and is handy for use in reporting.
• Text. Allows typing an answer.
• Choice. The best can be chosen from a predefined list of answers.
• Date. The answer can only consist of a specified date.
• Number. It is enforced that nothing other than a number can be entered.
• Yes/No. The answer will be either a confirmation or a denial.
• Choice List. If the option 'Choice' is selected at the Answer Type, there is the possibility to specify a Choice List. This is a "," separated list (for example 'Choice 1, Choice 2, No choice' is a choice list consisting of three options).
• Order. This number determines the order in the question list for an operation if more than one question is active.
• Mandatory. To enforce that the answer is given, the question can be made mandatory. Time registration from the shop floor is not possible without giving the answer.

Question List

In addition to specifying a single 'Question no.', a list of questions can also be chosen. These lists can be maintained in: MKG Time Registration Process Tables Question List. This way, questions do not have to be entered every time, but can be drawn from established standard sets. The questions can be adjusted per VC operation line after saving or changed in order. See also Manually Entering Hours.

Production Management: index

Related

• Add Materials to a Production Order
• Enter a Production Order