WIP 和计划与现实 - 工作进展,Bottlenecks,过时和每周计划与现实

1. 什么是窗口

答案在一个地方: 多少人能做得好(WIP) 等待操作之间,在机器工作正在进行的前面; 这个星期有足够的容量,需要过时或额外的转换; 上周计划的数量是多少完成时间,为什么迟到的订单晚点. 所有这些都是从现有数据中产生的: MES 起点/终点事件、运营开始和完成日期、确认、 APS 时间表和机器日历,Stuck Work持有和维护分裂。

标签: WIP 瓶子 · 超时及额外转换 · 每周计划 vs 实际 · 延迟原因. 窗口在生产到达的团体。

2. WIP: 工作在进展等待行动之间

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.

点击一个命令行打开 运营链: 每一次操作都做了什么,在两次操作之间的箭头上,等待量和等待时间。 开放生产 显示生产窗口中的订单。

3. 瓶子前的

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. 小人的法律交叉检查

最后完成的订单 28 发货日(λ、订单/日)和平均流量时间(W、从第一次运营开始的日子或订单开启日期到最后一次确认日期)计算; 字符:L = λ × W 是系统中的预期订单数量。如果订单的数量开始但没有完成,则从这个估计中偏离了更多 25百分比“流不平衡”警告出现:上方的 WIP 是加油,下面的意思是线是空的。检查使用订单计算,因为不同产品的数量不能添加。

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. 过时和额外的转换需要

网格展示 工作中心 × 周 负载(没有工作中心的机器有自己的行列)。能力來自The APS 机械日历(变更、休息、计划维护、停车时间、日过度)。加载由官方开放行动所产生的 APS 时间表;未在时间表中开放的剩余时间添加到运营计划、订单计划或预订日期的周(过期日期到本周)。 85黄色到黄色 100红色上方。

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. 每周计划 vs 实际页面

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. 延迟原因:一个目录和优先事项

该目录有八种系统原因: 材料不足,机械破裂,员工缺陷,质量问题,计划变更,供应商延迟,客户变更,其他; 新可以添加,系统原因永远不会被删除(它们可以被禁用,除了其他)。 源代码地图 连接的Stuck工作保持理性, MES 故障时间原因(或其类别)和维护故障代码(或其类别)到此目录;一个未地图的代码属于其他。

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. 电话上

在小屏幕上,窗口转向花园布局: 总结 (本周的 KPI 卡片,最忙碌的工作中心,理由帕雷托), 晚 (卡列表;打一个打开一个三步魔法师: 1 命令 · 2 理由 · 3 结果) 和 WIP (机械品牌) 至少触摸目标 44 像素

9. 主板,脉冲和每周工作

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. 许可

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.