Much like a Harry Potter obsession, manufacturing is all-encompassing. It requires the acumen of McGonagall, the agility of a Quidditch keeper and the experience of Dumbledore. Shop floor control is one method manufacturers use to make things a little easier.
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No process is an island in manufacturing. Implementing a new system, like shop floor control, can make the fear of the butterfly effect real. This article provides a functional understanding of what to expect.
Table of Contents
- What Is Shop Floor Control?
- Functions
- Phases
- Benefits
- Batch vs. Real-time Shop Floor Control
- Best Practices
- Shop Floor Manufacturing Software
What Is Shop Floor Control?
Shop floor control is a method used to track, optimize, run and report work done in manufacturing operations. It gives manufacturers real-time insights into labor, machine and material usage to streamline production processes.
Previously, managers compiled this information manually, but automation and MES systems make this process much more manageable. To break it down in the most basic terms, it covers operations management post the ERP stage.
Functions
A well-oiled football team has roles and responsibilities to fulfill to win games. In the same way, these are the functions necessary to ensure successful shop floor control.
Labor and Quantity Tracking
How do you determine how much labor a work order needs? Tracking and comparing actual hours versus expected hours is one way to start. Get an accurate idea of quantities produced and scrapped. Add quantity tracking and labor used to work orders.
Material Tracking
Creating a parts list when you get a new order is passé. View up-to-date information on components required so you can create a shortage list. Allocate parts to work orders either manually or using preflushing.
Work Order and Rate Creation
Work order creation is arguably one of the most important parts of the manufacturing process. You want to be certain all the i’s are dotted and the t’s are crossed. You can do this by creating work orders and rates using sales orders to reduce errors.
Process Instructions
Consistency is key. Clear instructions and blueprints go a long way toward high-quality output, regardless of changes in staff and modifications. Automate routing when you produce a work order. Adjust routing instructions in real-time with clear indications of where to use each item.
Reporting
You know the saying, “reports maketh the manufacturing” (paraphrasing slightly)? Identify differences in actual versus planned values, pinpoint constraints in manufacturing using shortage reports and monitor daily shop work lists.
Phases
Just like a product life cycle, shop floor control also has phases. Three to be exact: order release, order scheduling and order control.
1. Order Release
If you don’t have a sturdy foundation, your building’s sure to be a bit wonky. Getting the details and documentation right is a crucial part of this phase. Documentation includes compiling:
- Route Sheets: Set up the process plan for order production.
- Job Cards: Report and allocate labor time needed for the order.
- Material Requisitions: Allot raw materials needed from inventory.
- Move Tickets: Designate where material handling personnel should move materials, parts or other items between production areas in your facility.
2. Order Scheduling
Once you’ve got your plan of action, it’s time to get the show on the road (or, in this case, on to the work center).
In this phase, you execute and assign production orders to work centers in your facility. This process involves creating a dispatch list indicating what to complete and where. It also provides due dates on jobs so you can prioritize.
A dispatch list gives your foreman a helping hand with work assignments, job sequencing and machine loading.
3. Order Control
After an order is underway, you’ll need to keep an eye on things. That’s where order control comes into the picture. Monitor production processes and progress with the help of data collection. View summarized information in the following reports:
- Work Order Status Reports: View the status of production orders and access information on the location of the work center your order is currently at. Monitor processing hours left before your job is complete, determine whether tasks are running on schedule and view priority levels.
- Progress Reports: Check the performance of your shop floor for a specified period. Keep tabs on order performance and productivity during various time frames.
- Exception Reports: Monitor deviations in production schedules and errors in operations.
Primary Benefits
In racing, a change in your set-up can be highly advantageous. It may cost you initially, but the payout at the end is sweet indeed (just ask Max Verstappen). Adjusting operations to make room for shop floor control can be tedious and expensive. Here are four reasons to make it worth your while.
Real-time Information
Raise your hand if delayed status updates, postponed emails or missed follow-ups can be a problem for you.
We’ve all been there. However, up-to-the-minute information is crucial in manufacturing. Automated and semi-automated data collection means you view production statuses and job progress in real-time.
Ensure everyone is on the same page by sending updated information across departments.
Added Traceability and Accountability
Want to have your cake, eat it, and know where all the ingredients came from and how it’s made? Shop floor control gives you the data and project insights to trace production statuses and see whether processes are followed. You can also identify where exceptions have occurred and which processes need improvement.
Cost Reduction
Cutting costs can be a bit like getting money for nothing. We all want to do it, but it’s easier said than done. Shop floor control helps minimize manual data entry, pinpoint low-efficiency areas and eradicate overtime costs. Project managers can save time by focusing on areas with low productivity, making better decisions when changing processes, and reducing shipping delays, overheads, and lead times.
Process Improvement
In manufacturing, as in life, change is the only constant. However, it’s important to remedy the root cause and not just a symptom of the problem. Real-time visibility into production statuses and automated data collection can help identify bottlenecks and tweak areas that need to be improved.
Increased Efficiency
A stitch in time saves nine. Monitor information remotely, track supply chain information in real-time and access data to improve labor productivity and empower operators to make better, faster decisions.
More Sustainability
Customers are in the market for sustainably produced goods. Better communication flows, real-time information and more efficient production cycles help produce environmentally friendly products that reduce wastage and minimize pollution and mistakes.
Batch vs. Real-time Shop Floor Control
Data is king in shop floor control. However, there are two ways to process data: batch and real-time.
Batch Processing: Data is collected and stored in high volumes until it’s processed in batches. It usually requires a substantial amount of data entry and can sometimes involve paper records. There can be a lag in updating master databases so information can be outdated.
Real-time Processing: As its name suggests, data is processed immediately but in smaller batches. It promotes efficiency, but it can be labor-intensive and time-consuming without automation.
Best Practices
Implementing shop floor control is one thing, but keeping things running smoothly is quite another. Here are the best practices to follow to optimize operations and keep things ticking like a well-trained pit stop crew:
Update Processes: In manufacturing, you’ve got to stay current or get left behind. You need to be consistently updating and generating new processes. Make change management and innovation a priority.
Improve Data Collection: Making decisions based on bad data is like picking a quarterback using last year’s stats. Accurate, automated data collection and historical trends help access processes effectively.
Outline and Integrate SOPs: Define your SOPs (standard operating procedures) per your company’s mission and vision. Create clear guidelines, policies and procedures to eliminate miscommunications and errors and stick to industry regulations.
Boost Employee Welfare: Happy employees are more likely to adapt to new processes, learn how to use software and stay motivated. Boosting staff morale with incentives, skill development and career advancement can go a long way toward improving your shop floor.
Shop Floor Control Manufacturing Software
Now that you know why shop floor control is the bee’s knees, you may want to know how to best feature it in your company. Shop floor control is usually a module of manufacturing software systems like ERP or MES and, more rarely, a stand-alone product.
The following are some perks of implementing a shop floor control module:
- Easy usability
- Real-time updates
- Mobile accessibility
- Centralized database
- Automated data collection
- Additional traceability
Here are some features you should look out for when shopping for shop floor control software:
- Production Monitoring
- Production Planning
- Work Orders
- Inventory Management
- Native Application
- User-based Permissions
- Quality Inspection
- Work History Data
- Reports and Analysis
Considerations
Before you spring for software that may or may not break the bank, you must keep a few things in mind.
- Shop floor control relies heavily on data collection, so data management is key.
- Set a clear data readiness plan to ensure you don’t slip back into poor process practices and manual entry.
- You’ll need to determine if your new system integrates with current systems like CMMS, supply chain management and CPQ. You don’t want to be left metaphorically with a car but no gas.
Next Steps
Understanding and implementing shop floor control can seem like your journey to Mordor (without Samwise for company). If this article has opened your eyes to the merits of shop floor control when choosing MES or ERP software, we’ve got you covered. Check out our free requirements template to simplify finding and reviewing the best solution for your operations.
How can shop floor control benefit your operations? What software are you considering using to make the job easier? Let us know with a comment!