WIP and Plan vs Actual — Progress, Bottlenecks, Overtime 및 Weekly Plan vs Actual의 작업

1. 창문이 무엇을 위한 것인가

한 곳에서 세 가지 질문에 대답합니다 : 얼마나 많은 작업을 진행하는지 (WIP) 작업 사이를 기다리고 있으며, 앞에서 기계 작업이 흐르고 있는; 이번 주에 충분한 용량이 있거나, 과도한 시간 또는 추가 움직임이 필요합니다.; 얼마나 많은 지난 주 계획이 시간에 완료되었는지, 왜 늦은 주문이 늦은 시간. 모든 것이 기존 데이터에서 유래합니다 : MES 시작/결과 이벤트, 운영 시작 및 완료 날짜, 확인, APS 일정 및 기계 일정, Stuck Work 홀더 및 유지 보수 붕괴.

탭 : WIP 그리고 병 · 과도한 시간 및 추가 움직임 · 일주일 계획 vs 실제 · 지연 이유. 창문은 그 안에 있다. 생산 도크의 그룹

2. WIP: 작업을 기다리는 과정에서 진행

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.

명령줄을 클릭하면 열립니다. 운영 체인: 각 작업이 무엇을 했는지, 그리고 두 작업 사이의 총에, 기다림량과 기다림 시간. 생산에 열려있다 생산 창에서 주문을 표시합니다.

3. 앞에 있는

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. 작은 법의 크로스 체크

마지막으로 완성된 주문에서 28 날짜 통과 (λ, 주문/일) 및 평균 흐름 시간 (W, 첫 번째 작업 시작 날짜 - 또는 주문 개설 날짜 - 마지막 확인까지) 계산됩니다; L = λ × W 시스템에서 주문한 수의 예상수입니다. 주문이 시작되었지만 지금 완료되지 않은 경우, 이 추정치에서 더 많은 25% "흐름이 균형 잡히지 않는다" 경고가 나타납니다 : 위의 방법 WIP 아래는 라인이 텅 비어 있음을 의미합니다. 체크는 다른 제품의 양을 추가 할 수 없기 때문에 주문 계산을 사용합니다.

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. 과도한 시간 및 추가 움직임 필요

네트워크가 보여주고 있다 일주일간의 작업 센터 부하 (작업 센터가 없는 기계는 자신의 순서가 있다). 능력 그것은 오기 때문에 APS 기계 일정 (변경, 휴식, 계획된 유지 보수, 퇴근 시간, 하루의 과잉). 부담 공무원에서 열린 작업으로부터 APS 일정; 일정에 포함되지 않은 오픈 작업의 나머지 시간은 운영 계획, 주문 계획 또는 지정 날짜의 주에 추가됩니다 (일정 날짜는 이번 주로 이동). 85% 노란색으로 녹색으로 100위에 빨간색이 니다.

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. 일주일 계획 vs 실제 페이지

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. 지연 이유 : 하나의 카탈로그와 우선 순위

카탈로그에는 개의 시스템 이유가 있습니다 : 재료 부족, 기계 붕괴, 직원 부족, 품질 문제, 계획 변경, 공급자 지연, 고객 변경, 다른; 새로운 추가할 수 있으며, 시스템 원인은 결코 삭제되지 않습니다 (다른을 제외하고는 비활성화될 수 있습니다). 출처 코드 맵링 링크 스튜크 작업은 이유를 유지하고, MES 이 카탈로그에 대한 시간의 원인 (또는 그 범주) 및 유지 보수 실패 코드 (또는 그 범주); 맵화되지 않은 코드는 다른 사람에게 속합니다.

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. 전화에 있는

작은 화면에서 창문이 정원 배열으로 전환됩니다 : 요약 (주간의 일상 KPI 카드, 가장 넓은 작업 센터, 이유 파레토), 늦은 (카드 목록; 하나를 탭하면 단계 마법사가 열립니다 : 1 명령 · 2 이유 · 3 결과) 그리고 WIP (기계 퀴즈 카드에 대한 정보) 적어도 타겟은 44 픽셀을

9. Boss Dashboard, Pulse 및 주간 작업

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. 허가

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.