Yordam › Ishlab chiqarish › WIP Yiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiy

WIP va Reja-Haqiqiy — Tugallanmagan ishlab chiqarish, Tor joylar, Qo‘shimcha ish va Haftalik reja-haqiqiy

1. Bu okni ni‘zadi

Uch savol: operatsiyalar orasida qancha yarim tayyor (WIP), qaysi mashinada navbat; bu hafta sig‘im yetadimi, ortiqcha soat yoki smena kerakmi; oldingi hafta rejasining qanchasi vaqtida tugadi, kechikish nega. Hisoblar mavjud MES boshlash/tugatish, operatsiya sanalari, tasdiqlar, APS jadval/taqvim, To‘xtagan ish bloklari, parvarish nosozligidan.

Tabs : WIP Bottleneck o‘z · Ekstra saatlar və transferlar · Tadiq bilan vs real · Yatmaqdanga. Okumda o‘zadi Produccion Dock’u qizim.

2. WIP: operatsiyalar orasida kutayotgan yarim tayyor mahsulot

• 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.

Buyurtma satriga bosganda operatsiya zanjiri: har operatsiya bajargani, orasidagi o‘qda kutayotgan miqdor va kutish vaqti ochiladi. Ishlab chiqarishda ochish buyurtmani Ishlab chiqarishda ko‘rsatadi.

3. Bishanikdan bo‘zadi.

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. Lili's Law cross-check koʻshayni

Oxirgi 28 kunda tugagan buyruqlardan chiqish tezligi (λ, buyruq/kun), o‘rtacha oqim vaqti (W, ilk operatsiya boshlanishidan — bo‘lmasa buyruq ochilishidan — oxirgi tasdiqqacha kun) hisoblanadi; L = λ × W tizimdagi kutilgan buyruq soni. Boshlangan, tugamaganlar undan 25% dan ortiq farq qilsa «Oqim muvozanatsiz»: yuqori bo‘lsa WIP yig‘iladi, past bo‘lsa liniya bo‘shaydi. Turli mahsulot miqdorini qo‘shib bo‘lmagani uchun buyruq soni tekshiriladi.

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. Yat-yat, yat-yat qurtlarga qaytarga va'qlar

Kataklar ish markazi × hafta yukini ko‘rsatadi; markazsiz mashina alohida satrda. Sig‘im APS mashina taqvimidan (smena, tanaffus, rejali parvarish, to‘xtash, kunni almashtirish). Yuk rasmiy jadvalning ochiq operatsiyalaridan; jadvalsiz ochiq operatsiya qolgan vaqti operatsiya rejasi, buyruq rejasi yoki muddat haftasiga, o‘tgan bo‘lsa shu haftaga qo‘shiladi. 85%gacha yashil, 100%gacha sariq, yuqorisi qizil.

• 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. Yennadi bilan vs real page

• 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. Yatma: katalog və priority

Katalogda sakkiz tizim sababi: Material yetishmasligi, Mashina nosozligi, Xodim yetishmasligi, Sifat muammosi, Reja o‘zgarishi, Yetkazuvchi kechikishi, Mijoz o‘zgarishi, Boshqa. Yangisini qo‘shasiz, tizim sababi o‘chmaydi; Boshqadan tashqari faolsizlantiriladi. Manba kodini moslashtirish To‘xtagan ish, MES sababi/toifasi, parvarish nosozlik kodi/toifasini katalogga bog‘laydi; moslanmagani Boshqaga tushadi.

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. Telefonda

Kichik ekranda oyna Bog‘ tartibiga o‘tadi: Xulosa (hafta KPI kartalari, eng band ish markazi, sabab Pareto), Kechikkanlar (kartalar; bosishda uch bosqichli yordamchi: 1 Buyruq · 2 Sabab · 3 Natija) va WIP (mashina navbat kartalari). Bosish maydonlari kamida 44 piksel.

9. Boss Dashboard, pulsi, yedimlik bilan bilan bilan bilan

• 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. Uluqlar

• 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.