Routing



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.

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