Introduction
Theprocessroute,EnglishisRouting,isatechnicaldocumentdescribingtheoperationsequenceofmaterialprocessingandcomponentassembly,andisasequenceofmultipleprocesses.Aprocessisanactionoraseriesofactionsperformedbyaproductionworkerormachineequipmenttocompleteaspecifiedtask.Itisthemostbasicprocessingmethodforprocessingmaterialsandassemblingproducts.Itisdirectlyrelatedtolocationinformationsuchasworkcentersandoutsourcedsuppliers.Thedataisthebasicunitoftheprocessroute.Forexample,anassemblylineisaprocessroute,andthisassemblylinecontainsmanyprocesses.
IntheERPsystem,theprocessroutefileisgenerallydescribedbythefollowingcontent:itemcode,processnumber,processdescription,workcentercode,queuingtime,preparationtime,processingtime,waitingtime,transmissiontime,Fieldssuchasminimumtransfervolume,outsourcingmark(Y/N),standardoutsourcingfeeandprocessinspectionmark(Y/N).Thematerialcodeisusedtoindicatewhichmaterialtheroutingisfor.Theprocessnumberisusedtoindicatehowmanyprocessesthematerialneedstogothroughduringprocessing,andtheprocessnumbershouldbearrangedinaccordancewiththeprocessingsequence.Workcentercode,usedtoindicateinwhichworkcentertheoperationisprocessed.Therearefivetypesofoperatingtime:queuingtime,preparationtime,processingtime,waitingtime,andtransmissiontime,whicharemainlyusedtodescribetheoperatingtimeoftheprocessforcapacitycalculationandworkshopscheduling.Theoutsourcingmarkandstandardoutsourcingfeemeansthatiftheprocess(suchaselectroplating)isanoutsourcingprocessforthecompany,itneedstobespecifiedintheprocessroute.
Designanddrafting
Theprocessroutemainlyincludesthefollowingdata:processnumber,jobdescription,workcenterused,varioustimequotas(suchaspreparationtime,processingtime,transmissiontime,etc.)),thetimeandcostoftheoutsourcingprocess.Alsoexplainthealternativeworkcenters,mainprocessequipmentcodes,etc.,asareferenceforissuingproductionordersandadjustingprocedures.
InthetraditionalERPsystem,theprocessrouteisaconceptinproduction,processingandassembly.Infact,theconceptofprocessroutesshouldbeexpandedtoincludemanagementprocesses.Managementwork,ormanagementwork,shouldbelikeproductionwork,withstandardizedworkprocedures,cleartimequotasandcostsforeachactivity,andtheworkcenterinvolvedineachactivity.
Iftheprocessrouteisnotassociatedwithspecificmaterialprocessing,thisprocessrouteisthestandardprocessroute.Undernormalcircumstances,theprocessrouteisassociatedwiththespecificmaterialprocessing,onlythencantherebeaccurateleadtimedata.Therefore,theprocessroutedataincludestheprocessedmaterialdata.
Forexample,thestandardassemblyprocessoftheevaporatorandcondensercomponentsinanairconditionerincludesstringingU-tubes,tubeexpansion,bending,cleaning,tubesealing,airtightnesstesting,finishingandpackagingStorageandsoon.TheprocessingsequenceoftheU-shapedtubeis:blanking,bending,pipecutting,pipeclosingandburring,etc.
Undernormalcircumstances,theprocessroutedatamainlyincludesprocessroutecode,processroutename,processroutetype,manufacturingunit,materialcode,materialname,processcode,processname,processingcentercode,whethertooutsource,Timeunit,preparationtime,processingtime,movingtime,waitingtime,fixedtime,changetime,fixedpersontime,changedpersontime,codeinreplacementwork,effectivedate,expirationdateandinspectionmark,etc.
Theprocessofwritingtheprocessrouteincludesdeterminingtherawmaterialsandblanks;basedontheproductdesigndata,consultingtheenterpriseinventorymaterialstandardcatalog;determiningthespecificationsandmodelsoftherawmaterialsandblanksaccordingtotheprocessrequirements;determiningtheprocessingandassemblysequenceistheprocess;Accordingtothecompany’sexistingconditionsandpossiblefutureconditions,similarworkpieces,standardprocessroutesandsimilarprocessroutesandexperience,determinetheorderofprocessingandassembly;selectaworkcenterbasedonthecompany’sexistingcapabilitiesandfuturePossibleconditions;basedonthesizeandaccuracyrequirements,determinetheratedworkinghoursofeachjob,etc.
Processroutesandproceduresarenotstatic,butchangewiththecontinuousimprovementofproductiontypes,technologicalprogress,productdevelopment,andemployeequality.
Typeclassification
Mainprocessroute
Themainprocessrouteisagroupofprocessesthataremostfrequentlyusedtomanufactureproducts.Youcandefineonemainroutingandmultiplealternativeroutingsforaproject.Whendefininganewmainrouting,youcanspecifyonlyitems(withoutalternativenames),andyoucanspecifyaroutingversion.Forexample,youcandefineaprocessrouteforaprojectthatincludestwooperations—assemblypartsandtestoperations.Generally,theseoperationsareusedtomanufactureproducts,soyoucandefinethisprojectoperationasthemainrouting.
Alternativeprocessroute
Youcandefinealternativeprocessroutestodescribedifferentmanufacturingprocessesforproducingthesameproduct.Differentfromthenewlycreatedmainprocessroute,thealternativeprocessroutemustbedefinedbyspecifyingtheprojectandthealternativename.Beforedefiningalternativeroutings,youcanalsodefineanynumberofroutingsforaproject,youmustdefinethemainroutings.Forexample,youhavethreetestequipment,ofwhichthenewequipmentcanperformtestAandtestBatthesametime,whilethetwooldequipmentcanonlyperformtestAortestB.Thebestwayistouseanewdevicethatcanperformbothtests,butifthisisnotfeasible,youcanalsousetheothertwodevicestocompletethetask.
AlternativetagsListsandroutingscansharealternatetags.Ifyoucreateanalternativelistwiththesamelabelasthealternativeroute,thecomponentwillbeassignedtotheoperationonthealternativeroute.Ifthereisnoroutingwiththesamereplacementlabel,thecomponentwillbeassignedtotheoperationonthemainrouting.
Engineeringprocessroute
Youcandefinetheengineeringprocessrouteasanalternativetothemanufacturingprocessroute.Thissituationisgenerallyusedtoproduceavariantoftheprocessroutefromthemainprocessrouteformanufacturingthesameassembly.
Engineeringandmanufacturingprocessroutessharethesameresources,departments,andstandardprocessinformation.
Function
Theprocessrouteisanimportantbasicdatarelatedtobasicdatasuchasworkcenter,leadtimeandmaterialconsumptionquota,anditisanimportantmeansofimplementinglaborquotamanagement.Intermsofnature,theprocessrouteisameanstoguidethemanufacturingunittocompletetheproductiontasksinaccordancewiththeprescribedoperatingprocedures.InMRP,youcancalculatethestartdateofcomponents,parts,andmaterials,aswellasthecompletiondatesofsub-items,basedonthecompletiondates,processroutes,andprocessleadtimesofproducts,components,andparts.InCRP,theload(consumedman-hours)ofaworkcentercanbecalculatedbasedonoperationsandroutings.Therefore,theprocessrouteisalsothebasisforcalculatingthecapacityrequirementsoftheworkcenter.Accordingtotheactualcompletiondatacollectedineachprocess,enterprisemanagerscanunderstandandmonitorthecompletionoftheproductionschedule.Thestandardman-hourdataforcalculatingtheprocessingcostprovidedbytheprocessrouteisthebasisandbasisofcostaccounting.Theprocessrouteisanimportantdocument,whichrepresentsthewayajobrunsinthefactory.Ifthebillofmaterialsisusedtodescribehowthematerialsareconnectedtogetherinahierarchicalstructure,thentheprocessrouteistodescribetheproductionstepsandprocessesofmanufacturingeachmaterial,andisusedtodeterminethedetailedproductionschedule.Thefunctionoftheprocessrouteisasfollows:
Basisofaccumulatedleadtimeofinventoryassembly
WhendefiningITEMintheinventorymodule,youcandefinetheleadtimeofeachITEMTimeinformation:
Forpurchasedmaterials,wecandefinethepre-processingleadtime(thelengthoftimefromthetimeapurchaserequestismadetothereleaseofthepurchaseorder)andprocessingleadtime(thetimerequiredforthesuppliertodeliverwhenthepurchaseorderisplaced),Post-processingleadtime(thetimefromreceivingthegoodstothetimewhenthegoodsareavailable,suchasqualityinspectiontime),theleadtimeofthepurchasedpartsneedstobemanuallyentered.
Formanufacturingmaterials,theleadtimeinformationcanbeaccumulatedthroughtheprocessroute:bydefiningthetimerequiredforeachstepontheprocessroute,theleadtimeinformationisgraduallyaccumulated.TheleadtimeinformationisthebasicdataforMRPplanning:throughtheleadtimesetting,thesystemcalculatesthepurchasestartdateandproductionstartdate.Onlywhenthematerialleadtimeinformationissetcanthesystemrealizethefunctionofautomaticallyissuingpurchaseordersbydate(Bysettingtheconditionsforautomaticrelease(suchasthreedaysinadvance),thesystemwillautomaticallyreleasepurchaseordersonthecorrectdate).
Thebasisofthecostofthemodulevolumeassemblyparts
Thecostoftheassemblypartsiscomposedofmaterialcosts,laborhours,andexpensecosts.Thebillofmaterialsinthesystempointsoutthematerialsandquantitiesrequiredtoproduceacertainassembly.Forthestandardconsumptionofman-hoursandexpenses,thesystemdefinestheprocessroutetospecify:anyinputotherthanrawmaterialscanbedefinedasresources(suchas:labor,equipment,fuel,plant,amount,etc.),andindirectinputasexpenses(Managementexpenses,etc.),bydefiningtheresourcesusedineachprocessstep,theexpensesarerecordedinthematerialcost.
ThefoundationofMRPmoduleforcapabilitycalculationandassessment
ORACLEsystemprovidescapabilityplanningmodule,andtheprocessrouteisthebasicdatatorealizecapabilityplanning.WhenthesystemperformsMRPcalculations,productioncapacitycanbeconsideredatthesametime.Theproductioncapacityinthesystemisrepresentedbythedefinitionoftime-basedresources:suchashumantimeandmachinetime,whicharerepresentedbydefiningthenumberofresourcesownedbyeachproductionworkshopTheproductioncapacityoftheproductionworkshop.Whencarryingoutcapacityplanning,thesystemwillconsidertheamountofresourcespossessedbytheproductionworkshop,obtaintheamountofresourcesrequiredtoproducetheproductfromtheprocessroute,andcomprehensivelyconsiderwhethertheworkshophasenoughtimetoproducetheproductasplannedwithinacertainperiodoftime.
BasicconditionsforWIPreal-timerecordingandcontrol
Ifthemanagementdepartmentwantsthesystemtoreflectthereal-timeproductionprogress,itisnecessarytodefineadetailedproductionprocess.Inactualproduction,theproductiontaskcanbemovedbetweenthevariousproceduresoftheprocessroutetoindicatewhichstatetheproductiontaskisin.
IfyouwanttoachieveprocessinspectionthroughQA,youmustdefinetheprocessroutesothattheproductiontaskcanrealizethemobiletransactionprocessing(theproductiontaskwithouttheprocessroutecannotbeprocessedbythemobiletransaction),andyoucandirectlyinputwhentheproductiontaskismovedThequalitycollectionplanassociatedwithit.
Ifcostaccountingneedstorecordproductioncostssuchasman-hoursandexpensesinthesysteminrealtime,aprocessroutemustbedefinedsothateachproductiontaskcanprocessresourcetransactions.
Implementsystemstandardoutsourcingfunction
Thestandardoutsourcingfunctioninthesystemisrealizedbydefiningoutsourcingresourcesandoutsourcingmaterials:Whentheproductiontaskisreleasedormovedinthesystem,thesystemautomaticallygeneratesthepurchaseorderoftherelatedexternalmaterialaccordingtotheexternalresourceusedbytheproductiontask.Whenthepurchaseorderoftheexternalmaterialisreceived,thesystemAutomaticallyrecordthecostofoutsourcedmaterialsintotheproductiontask.
Accuratelydefinethebillofmaterials
Afterdefiningtheprocessroute,youcandefinethebillofmaterialsmoreaccurately:youcandefinetheinputprocessofeachrawmaterial,andmoreAccuratelycalculatethetimerequiredforthematerial.InWIP,specificmaterialscanbeautomaticallydeductedatspecificstepsaccordingtotheprocessroute.Makeinventoryonhandmoreaccurate.
Requirements
Therequirementsfortheaccuracyoftheprocessroutedataarethesameasthebillofmaterials.Itshouldalsobeabove98%.Iftheprocesssequenceiswrongandtheworkinghourquotaisnotaccurate,itwilldirectlyaffecttheMRP.AndthecalculationresultofCRP,causetheproductionordertobeissuedtooearlyortoolate,ortheissuedquantityisinaccurate.Ifanoperationappearsonthedispatchordersenttoacertaindepartment,butinfacttheoperationisnotinthedepartment,oranoperationisinthedepartmentbutnotonthedispatchorder,theprocessroutemaybewrongsource.Thewrongprocessroutecanalsocauseproblemssuchasunbalancedworkcenterload,backlogofwork-in-process,poorlogistics,andincorrectcalculationofprocessingcosts.Bycalculatingthenumberofprocessroutesreachingtheworkshopeachweekandthenumberofincorrectroutesreportedbytheforemaneachweek,theaccuracyoftheprocessroutescanbemeasured.
Calibration
Formanycompanies,oneofthebiggestobstaclesbeforeMRPisputintooperationistocalibratetheprocessroute.Mostprocessroutedocumentsconformtothe80/20principle,thatis,80%oftheactivitiesoccuron20%oftheprocessroutes.ItwillbedifficultformanycompaniestocalibrateallprocessroutesbeforeinstallingMRP.However,withthehelpofMRP,therearepracticalsolutions.
(1)BeforetheMRPpilot,checkandcorrectthe20%processroutethataccountsfor80%oftheactivities.
(2)WhenMRPisgraduallyputintooperation,usetheplantoplaceanorderseveralweeksinadvancetoindicatewhichprocessroutewillhavetobecheckedandcorrected.
(3)Intheearlystageofpreparingcapacityplansanddispatchingworkorders,itshouldbeensuredthattheprocessroutethatwillbeusedinthenearfutureiscorrect.
Maintenance
Theprocessrouteisthesameasthebillofmaterials,whichisusuallyestablishedandmaintainedbytheengineeringdepartment.Forexample,theworkcenterused,equipmentinstallationtime,andunitproductiontimequotaarealldeterminedbyDeterminedbytheengineeringdesigndepartment.Atthesametime,theactualworkandtheexecutionoftheprocessrouteshouldbefrequentlycompared,andtheproductionprocessshouldbereviewedindetail.Therearemanyreasonsforthechangeoftheprocessroute,suchasproductandproductionprocessmaychange,equipmentinstallationtimeandsinglepieceproductiontimestandardsmayneedtobeadjustedaccordingtonewoperatingdata,newproductsandnewcomponentsmayrequirenewprocessroutes.Theprocessrouteisestablishedandmaintainedbytheengineeringdesigndepartmentandusedbytheproductiondepartment.AftertheMRPisputintooperation,lettheforemanreportthediscoveredprocessrouteerrorsatanytimeaccordingtothedispatchorder,soastocontinuouslymaintaintheprocessroute.Thechangeoftheprocessrouteshouldbenegotiatedbythetwodepartments.
Machiningorder
(1) Followtheprincipleof"referencefirst,thenothers",firstprocessthefinereference—thebottomsurfaceandseveralholesonthebottomsurface.
(2) Followtheprincipleof"roughingfirstandthenfinishing",firstarrangetheroughingprocess,andthenarrangethefinishingprocess.
(3) Followingtheprincipleof“primaryfirstandthensecond”,themainsurface—leftendsurfaceandbacksidesurfaceisprocessedfirst,andthesecondarysurface—rightendsurfaceandfour-cornerendsurfaceareprocessedlater.
(4) Followingtheprincipleof“facefirst,holesecond”,milleachfacefirst,andthendrilltheholeontheface.