Automation of production workflows: Execution status

A hot topic in all the economic sectors is the automation of activities and data flows, both at the organizational and execution stages. Here’s a closer look at what automation is, what the benefits of production automation are and how the execution status of manufacturing operations can be monitored.

What is production and production workflow?

For a more efficient production process, the best solution is to create a automation system throughout the entire workflow. The larger the company, the more difficult it is to plan each operation in detail. Human errors occur and they are costly.

The alternative is full task automation for teams. There are applications that can be customized to the company needs and structure, so that each person knows exactly what to do. That way, there will be fewer mistakes due to carelessness or ignorance and fewer rejects/scraps. Not only will employee motivation and work productivity increase, but the profits as well.

The production process involves:

• production planning;
• execution of production orders;
• monitoring the status of all technological operations.

In order to track the execution status of technological operations, it is necessary to use an MES application – in our case, xTrack MES. To make you understand how to achieve automatic updates within this production planning and execution monitoring system, we need explain the “architecture” of production orders.

Types of production orders

Production orders are classified, depending on their complexity, into four main classes:

• The operation is the basic type of production order, which is executed on a single machine or by a single worker;
• A job is an order that produces a specific component of a finished product and comprises one or more operations;
• A master job includes a series of jobs and results in the production of a specific type of finished product in the quantity specified in the aggregate list;
• The aggregate list is the aggregation of several master jobs and is defined as the general production order which involves the production of a series of finished products (of the same or different kind) specified in various orders received from the customer.

How are technological processes monitored in real time?

The system continuously monitors the state of completion of the next lower-level production orders (child commands) and updates the next higher-level orders (parent commands).

In other words, as manufacturing operations are completed, the status of the jobs is updated, the completion of the jobs leads to the update of the master jobs, and the completion of the master jobs leads to the update of the execution status of the aggregate list.

Production order planning and execution modules are integrated into the xTrack WMS application. In this way, consumption and output are strictly monitored.  And you are always aware of the status of your products, from the receiving in the raw materials warehouse to delivery from the finished goods warehouse.

What are the benefits of monitoring order execution?

Avoid stock-outs of raw materials and WIP

The application records what stage of execution each manufacturing operation in your factory is at. Monitoring consumption as production orders are executed allows you to anticipate supply needs. Thus, you manage your stocks and avoid running out of raw materials or WIP.

Meet or update the initial completion date of the products in the customer order

Continuous monitoring of the execution stages compared to the execution schedule resulted from planning shows you in real time whether you will be able to meet the delivery date originally set or not.

If you notice early on that you won’t make it, you have two options: either agree a different delivery date with your customer or take corrective action and re-plan production so you can keep your original deadline.

Real-time recording of production consumption and output

Materials or products resulted during manufacturing operations can be recorded in the system and retrieved in a desktop-based or web-based xTrack WMS by scanning them with mobile computers as soon as they are ready. You don’t have to wait until all the WIP (Work In Progress) or products you’ve set out to manufacture are fully completed.

Get a clear picture of the status of production orders, anytime, anywhere

Office operators and managers can see graphically what stage of execution manufacturing operations a master job comprises are at.

The dashboard presented in a GANTT chart format uses a color code; the rectangles, that is, the graphical representation of manufacturing operations, change color as the activities are being completed. The degree of completion is also measured in percentage terms.

Here’s what a diagram showing the stages of completion of manufacturing operations for a master job looks like.

Each rectangle represents a manufacturing operation, the red dots mark raw material and/or WIP replenishment and the blue dot indicates the resulting finished product.

The color code is used in parallel with the percentage marking of the degree of operation completion:

• blue – operation 100% completed,
• orange – operation in progress,
• grey – operation not started.

Data on replenishment activities and confirmation of execution of manufacturing operations are entered into the application using handheld terminals. As a manager, you can see the results of activities on your laptop – anytime, anywhere – in the form of GANTT charts. Digitalization brings efficiency and flexibility throughout the production flow.

xTrack MES application and the benefits of automation

By integrating the xTrack MES application modules for planning and executing production orders into the WMS application, you have complete traceability of all items (raw materials, WIP, finished products) from the entry to the exit of the production facility. Everyone who accesses the application can see at any time information about quantities, input/processing data, responsible operators, machines used, etc.

In conclusion, tracking the execution status of all manufacturing operations with xTrack applications helps you:

• know at any time how much you have consumed and how much you have produced;
• see the status of products ordered by your customers;
• efficiently manage warehouses so that you don’t run out of raw materials and supplies;
• meet or change order delivery deadlines in good time.

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