راهنما › تولید › WIP برنامه در مقابل فعلی

WIP و برنامه در مقابل فعلی – کار در پیشرفت، بوتلنیک ها، زمان بیش از حد و برنامه هفتگی در مقابل فعلی

1. پنجره برای چه چیزی است

این پرسش ها در یک مکان سه سوال را مطرح می کند: در حال حاضر تعداد کارهای انجام شده (WIP) در انتظار بین عملیات و پیش از آن که کار ماشین در حال پر کردن است; این هفته به اندازه کافی ظرفیت دارد، زمان اضافی یا تغییر اضافی لازم است.; چه مقدار از برنامه هفته گذشته به موقع تکمیل شد و چرا سفارشات دیر شده بود دیر. همه چیز از داده های موجود به دست آمده است: MES آغاز / پایان رویدادهای، تاریخ شروع و تکمیل عملیات، تأییدها، APS برنامه و تقویم ماشین، Stuck Work نگه داشتن و تعمیر و نگهداری شکست.

تگ ها : WIP و بطری · زمان اضافی و تغییرات اضافی · برنامه های هفتگی در مقابل واقعی · دلایل تاخیر. پنجره در آن است تولید گروه داک

2. WIP: کار در انتظار پیشرفت بین عملیات

• Quantity done: for each operation, good + rework quantity in MES finish events; without MES a completed operation counts as the order quantity and the last operation is combined with confirmations. An earlier operation can never appear to have done less than a later one.
• Waiting = quantity done by an operation − quantity done by the next. WIP quantity = done by the first operation − done by the last.
• WIP value = waiting × unit cost × completion ratio. Unit cost comes first from the standard cost (nearest period); completion ratio = material share + labour/overhead share × share of routing time up to that operation. Without a standard the actual cost is used as a full unit and the row is marked with * (upper bound).
• Wait time: time from one operation finishing to the next one starting; if the next has not started the wait is still running (…). Colour: under 1 day green, up to 3 days yellow, above red.

با کلیک کردن یک ردیف سفارش، باز می شود زنجیره عملیات: چه کاری انجام داده است و در میان دو عملیات، مقدار انتظار و زمان انتظار. باز در تولید سفارش را در پنجره تولید نشان می دهد.

3. در مقابل بطری چوبی

The work in progress piled up in front of an operation (what the previous operation made and this operation has not processed yet, partial lots included) is that machine's queue; even if the operation has started, the remaining parts are in the queue. The first operation's input is raw material, so it is not counted as queue. Per machine you see the number of queued orders, queue hours (operation time × quantity piled up in front; + setup if the operation has not started), the oldest wait and the queue days (queue minutes ÷ the machine's daily capacity this week, from the APS calendar). The daily capacity of work center boxes is the APS work center capacity (efficiency included). The queue in front of a machine with unknown capacity (an undefined machine) is red because it can never be processed. Queue days under 1 are green, up to 3 yellow, 3 or more red — the worst machine is shown as the bottleneck. Open in APS goes to the Bottleneck tab of the Production Schedule, where the "Add 1 shift" scenario calculates the effect.

4. قانون کوچک چک

سفارشات انجام شده در آخرین 28 روزهای عبور (λ، سفارشات/روز) و زمان متوسط جریان (W، روزها از آغاز عملیات اول – یا تاریخ باز کردن سفارش – تا آخرین تأیید) محاسبه می شود؛ L = λ × W تعداد سفارشات مورد انتظار در سیستم اگر تعداد سفارشات آغاز شده اما در حال حاضر به پایان نرسیده باشد، از این تخمین با بیش از یک 25%، یک هشدار "نابود است" ظاهر می شود: در بالا WIP این خط خالی است، در زیر به معنی خط خالی است. چک از حساب سفارش استفاده می کند زیرا مقدار محصولات مختلف نمی تواند اضافه شود.

The verdict depends on the absolute difference. If the difference between observed and estimated is less than 3 work orders, the flow counts as balanced. If it is 3 or more: when the estimate is at least 1 order the percentage deviation must also exceed 25%; when the estimate is under 1 order (a workshop with few orders, or data where confirmations were entered in bulk) the percentage is meaningless and is not shown, but a build-up is still reported with the "not balanced" warning.

5. نیاز به زمان اضافی و تغییر

شبکه نشان می دهد مرکز کار هفته بار (یک ماشین بدون مرکز کار خط خود را دارد). توانایی از آن آمده است APS تقویم ماشین (تغییرها، شکاف ها، تعمیر و نگهداری برنامه ریزی شده، زمان انقضا، روزهای فراتر از حد) بارگذاری از عملیات های باز در اداره APS برنامه؛ زمان باقی مانده عملیات باز در برنامه اضافه نمی شود به هفته برنامه عملیاتی، برنامه سفارش یا تاریخ تعیین شده (تاریخ های عبور به این هفته می رود). 85% زرد تا 100% سرخ بالا

• Overload = load − capacity (member machines of a work center share each other's load).
• OT capacity = crew × weekly overtime cap per person; the cap is read from the active HR regulation (daily × working days, weekly cap, the remaining yearly allowance spread over the remaining weeks — Türkiye 3 h/day and 270 h/year, Indonesia 4 h/day and 18 h/week). Overtime already used this year is read from timekeeping. It is also limited by the machine's free calendar time.
• Extra shifts = ⌈overload ÷ shift length⌉ (shift length from the calendar).
• Suggestion: Overtime is enough · OT not enough: extra shift · OT and extra shifts not enough: subcontract or move load · No capacity: move the load to another machine (machine under maintenance or inactive).

The current week counts from today. This week's capacity and overtime allowance are calculated only from the days between today and the end of the week; capacity of days already past can no longer be used, while overdue load is written into this week. If a row has no capacity at all in the remaining days of the week (for example at the weekend), the load falling into that week is moved to the first week with capacity; if no row has remaining capacity, the Boss Dashboard and the weekly page show the overtime need for next week. The "No capacity" suggestion stays only on a row that has no capacity anywhere in the horizon. A work center row's capacity is the APS work center capacity (efficiency included). The Company reports › Machine utilization and OEE button above the grid opens the actual machine utilization for the same weeks.

6. برنامه هفتگی در مقابل صفحه واقعی

• Planned finish, in order: the APS operation plan → the official APS schedule / capacity plan → the order's planned start + planned duration → the due date. The bottom of the page says how many orders came from each source.
• Planned: orders whose planned finish falls in this week (count, quantity, total operation time). Actual: orders completed in the week, confirmed quantity and working hours in the week (MES net run time + confirmation time not linked to MES).
• On time % = completed on or before the planned finish ÷ evaluated (orders whose planned day has not come yet count as "waiting").
• Late: orders planned for this week that finished late or are still open + carried over open orders from earlier weeks; delay days are counted from the planned finish.
• The delay reason Pareto, this week's overtime / extra shift need, the WIP summary and next week's risks (Stuck Work due-date radar) are on the same page.

Print opens the page in A4 layout; the PDF is produced on the server (print from the browser if the message service is off). Numbers are written in the format of the document's language. Save snapshot freezes the week's figures — saving the same week again updates the same record, no new record is created; the version goes up only if the figures changed. Send: an in-app message to the chosen users, an e-mail with the PDF attached to the e-mail addresses, a short summary to the WhatsApp numbers.

Drilling into the company report. The Company reports › Planned and actual production button at the top of the page opens, in the Reports window, the planned / actual comparison of the same week by work order and operation (permission: general reports).

Past weeks. On the page of a past week the WIP and overtime figures are not calculated from today; they are shown only from a snapshot taken during that week (the weekly job takes the new week's snapshot every Monday). If there is no such snapshot these two boxes stay empty and a note appears on the page.

7. دلیل تاخیر: یک کاتالوگ و اولویت

این کاتالوگ دارای هشت دلیل سیستم است: کمبود مواد، شکست ماشین، کمبود کارکنان، مشکل کیفیت، تغییر طرح، تاخیر در عرضه، تغییر مشتری، دیگر; جدیدها می توانند اضافه شوند، دلایل سیستم هرگز حذف نمی شوند (آنها می توانند غیرفعال شوند، به جز دیگران). کد منبع نقشه برداری در این کار، کارهای متقابل، منطق را حفظ می کنند. MES علت انقضا (یا دسته آن) و کد شکست نگهداری (یا دسته آن) به این کاتالوگ؛ یک کد غیر نقشه برداری به دیگران می رسد.

The reason for a late order is found in this order: correction (a reason overridden manually with plan_gercek_yonet) > manual assignment (an assigned reason comes before all automatic sources) > Stuck Work hold (with a known reason) > MES downtime (a downtime event linked to the order) > maintenance breakdown (a breakdown work order on the order's machine overlapping the order's time) > "unknown" hold (a hold the Stuck Work job opens on its own for late orders, carrying no reason — used only when there is no other evidence, falls to Other). Within a source the longest record wins. If none exists the row shows "No reason assigned" in yellow; choose one with Assign reason. Each assignment deactivates the previous one (nothing is deleted) and stays in the log.

8. در تلفن

در یک صفحه نمایش کوچک، پنجره به طرح باغ می چرخد: خلاصه (در این هفته KPI کارگاه های کار، مرکز کار بوسه، دلیل پارتو) دیر (فهرست کارت؛ با ضربه زدن به یک باز می کند یک جادوگر سه مرحله: 1 دستور · 2 دلیل · 3 نتیجه) و WIP (تصویب کارت های ماشین آلات) هدف های مربوط به دست کم 44 پیکسل ها

9. Boss Dashboard، Pulse و کار هفتگی

• The Boss Dashboard's attention box shows money tied up in WIP and this week's overtime / extra shift need (red if overtime and extra shifts are not enough; at the weekend for next week).
• In the Pulse mobile interface a work center over capacity this week appears as an attention row.
• The weekly job is off by default (PLAN_GERCEK_GOREV=1). When on, on Monday morning (PLAN_GERCEK_GUN, PLAN_GERCEK_SAAT) it saves the snapshot of last week and of the new week — at most once a day per week, and the version goes up only when the figures change; the new week's record keeps that week's WIP and overtime figures as measured during the week. Once a week it writes an in-app summary message to managers and users with plan_gercek_yonet or production planning permission. E-mail and WhatsApp are not sent by the job; use Send on the page.

10. مجوزها

• View: plan_gercek, plan_gercek_yonet or one of the production permissions.
• Assign a reason to a late order: plan_gercek (or production planning).
• Correct the automatic reason, catalogue, mapping, saving and sending snapshots: plan_gercek_yonet.
• Run the job manually: system administrator. Writing also requires the write gate to be open and the user not to be read-only.