Exercise - Create process activities for lean manufacturing

  • 20 minutes

Create a process activity for lean manufacturing.

Prerequisites:

  • A production flow and version that is not active must be created.

  • A work cell must be created.

Find the production flow version

  1. Go to Production control > Setup > Lean production flow > Production flows.
  2. In the list, find and select the desired record.
  3. In the list, select the link in the selected row.

Create a new activity

  1. Select Activities.

    • Ensure that the selected production flow has a version in draft and select that version.

  2. Select Create new plan activity.

  3. Select Next.

  4. In the Name field, type a value.

  5. In the Name field, type a value.

    Note

    The name must be unique for a given production flow for all versions.

  6. In the Process quantity field, enter a number.

    Note

    No matter what job quantity will be processed, this is the minimum quantity per job to calculate the labor cost. If job quantities deviate from this quantity, labor cost variance will be created.

  7. Select Next.

Select the work cell

  1. In the Work cell field, Select the drop-down button to open the lookup.
  2. In the list, Select the link in the selected row.

Define the inventory updates

  1. Select or clear the Update on hand receipt check box.
    • If Update On hand = No, you can define the activity to receive a semi-finished product (the activity does not reach the next BOM level). You can also select to consume semi-finished products.

Define the picking activities

  1. Select Next.
  2. In the list, mark the selected row.
    • A default picking activity is created for the input location of the selected work cell.
  3. Select Add.
    • You can create additional picking activities for specific products, that are not staged at the work cell input activity.
  4. In the list, find and select the desired record.
  5. In the Item number field, type a value.
  6. In the Warehouse field, Select the drop-down button to open the lookup.
    • With this definition, all materials consumed in the activity are picked from the default input warehouse and location except the item that is defined in the second picking activity. This item will be picked from a different warehouse and location.
  7. In the list, find and select the desired record.
  8. In the list, Select the link in the selected row.
  9. Select or clear the Register scrap check box.
  10. Select Next.

Define the activity times

  1. In the list, find and select the desired record.
    • The definition of a Runtime is required. The Runtime is used to calculate costs and the throughput times of the kanban jobs. Runtimes are not used to calculate capacity load and consumption, this is calculated by cycle time, derived from the production flow version task.
  2. In the Time field, enter a number.
  3. In the Unit field, type a value.
  4. Select the Time unit.
  5. In the Per quantity field, enter a number.
  6. In the list, find and select the desired record.
    • Queue times are optional.
  7. In the Time field, enter a number.
  8. In the Unit field, type a value.
  9. Select the Time unit.
  10. In the Per quantity field, enter a number.
  11. Select Next.
  12. Select Finish.
  13. Close the page.

Create a production flow

  1. Go to Production control > Setup > Lean production flow > Production flows.
  2. Select New.
  3. In the Name field, type a value.
  4. In the Description field, type a value.
  5. In the Name field, Select the drop-down button to open the lookup.
  6. In the list, Select the link in the selected row.
    • Select an operating unit of type value stream. A value stream is an operating unit that spans all activities and flows of the value stream. At this stage, operating units are limited to a legal entity and have no further functionality.
  7. In the Production group field, Select the drop-down button to open the lookup.
  8. In the list, Select the link in the selected row.
    • Select a production group for the production flow. Production groups allow the definition of material, labor, and WIP accounts for a production process. To associate the accounting context to a production flow, a production group must be selected.
  9. Select Save.

Create a production flow version

  1. Select Add.
  2. In the Expiration date field, enter a date and time.
    • If required, define an Expiration date for the version. You can update it at any given time, even for active versions. You can use it to plan to phase out a version.
  3. Select OK.
  4. In the list, mark the selected row.
  5. In the Unit field, type a value.
  6. ResolveChanges the Takt unit.
  7. In the Average takt time field, enter a number.
    • Define the Average takt time of the version. For the takt control of the production flow version, define a targeted average takt time. The takt is defined as quantity per time period. In the example, the takt time is 0.2 hours per 10 pieces. For a working time of 8 hours, this corresponds to a daily throughput capacity of 400 pieces.
  8. In the Quantity per cycle field, enter a number.
    • Define the quantity per cycle related to the Average takt time.
  9. Toggle the expansion of the Version details section.
  10. In the Minimum takt time field, enter a number.
    • Define the minimum takt time. The minimum takt time must be less than or equal to the average takt time.
  11. In the Maximum takt time field, enter a number.
    • The maximum takt time must be higher than or equal to the Average takt time.
  12. In the Period for actual cycle time (days) field, enter a number.
    • Enter the number of days in the Period for actual cycle time. The period for actual cycle time is the number of days that jobs are aggregated from the actual minute backwards to calculate the actual cycle time. The value can be changed at any time and is only used for the calculation of the actual cycle times.
  13. Select Save.