8. Production Control
Production Overview
Production Order Management
Production Planning and Scheduling
Material and Inventory Management
Production Process Management
Real-time Monitoring
Production Quality Management
Equipment Maintenance Management
Production Performance Management
Production Cost Management
Yield and Productivity Management
Safety and Compliance Management
Production Reporting
8.1. Production Overview
- Displays an overview of production status, including the number of orders in production, completed, and pending.
- Charts production performance over time, including OEE (Overall Equipment Effectiveness) metrics.
- Monitors the operational status of production lines and critical equipment.
- Hiển thị tổng quan về tình trạng sản xuất, bao gồm số lượng đơn hàng đang sản xuất, hoàn thành, và chờ xử lý.
- Biểu đồ hiệu suất sản xuất theo thời gian, bao gồm chỉ số OEE (Overall Equipment Effectiveness).
- Theo dõi tình trạng hoạt động của các dây chuyền sản xuất và các thiết bị quan trọng.
Orders in Production
15 Orders
Completed Orders
10 Orders
Pending Orders
5 Orders
Production Performance
Production Line Status
| Line | Status | Current Order | OEE (%) |
|---|---|---|---|
| Line 1 | Running | Order #12345 | 85.6% |
| Line 2 | Maintenance | Order #12346 | 75.3% |
| Line 3 | Stopped | Order #12347 | 60.2% |
8.2. Production Order Management
- Manages production orders from receipt to completion.
- Tracks the status of each order, expected completion times, and production stages.
- Displays production progress for each order and alerts if there is a risk of delays.
- Quản lý các đơn hàng sản xuất từ khi nhận đơn đến khi hoàn thành.
- Theo dõi tình trạng đơn hàng, thời gian hoàn thành dự kiến, và các giai đoạn sản xuất.
- Hiển thị tiến độ sản xuất cho từng đơn hàng và cảnh báo nếu có nguy cơ chậm tiến độ.
Production Orders Overview
| Order ID | Product | Status | Estimated Completion | Production Stages | Progress |
|---|---|---|---|---|---|
| #PO12345 | Widget A | In Progress | August 30, 2024 |
|
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| #PO12346 | Gadget B | Delayed | September 5, 2024 |
|
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| #PO12347 | Component C | At Risk | August 28, 2024 |
|
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| #PO12348 | Device D | Completed | August 25, 2024 |
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Order #PO12345 Details
Product: Widget A
Status: In Progress
Estimated Completion: August 30, 2024
Production Stages
- Design: Completed
- Manufacturing: Ongoing
- Assembly: Pending
- Quality Check: Pending
Progress
Alerts
Warning: Manufacturing is taking longer than expected. Possible delay in completion.
8.3. Production Planning and Scheduling
- Manages and schedules production by day, week, or month.
- Monitors production schedules and adjusts plans based on changes in demand or resources.
- Optimizes production scheduling to maximize resource use and minimize wait times.
- Quản lý và lập kế hoạch sản xuất theo ngày, tuần, tháng.
- Theo dõi lịch trình sản xuất và điều chỉnh kế hoạch nếu có thay đổi về nhu cầu hoặc nguồn lực.
- Tối ưu hóa lịch trình sản xuất để sử dụng tối đa nguồn lực và giảm thời gian chờ đợi.
Schedule Overview
Day
Current Date: 2024-08-27
- Order #001: Scheduled
- Order #002: Delayed
- Order #003: In Progress
Week
Current Week: 34
- Order #004: On Track
- Order #005: At Risk
- Order #006: Scheduled
Month
Current Month: August 2024
- Order #007: On Schedule
- Order #008: Requires Adjustment
- Order #009: Pending
Production Calendar
| Date | Shift 1 | Shift 2 | Shift 3 | Status |
|---|---|---|---|---|
| 2024-08-27 | Order #001 | Order #003 | Maintenance | On Schedule |
| 2024-08-28 | Order #002 | Order #004 | Order #005 | Adjust Required |
| 2024-08-29 | Order #006 | Order #007 | Order #008 | Behind Schedule |
Resource Optimization
Current Utilization: 85%
Recommended Adjustments:
- Shift resources from Order #002 to Order #007 to optimize production flow.
- Reschedule Order #008 to avoid conflicts with maintenance activities.
- Increase workforce on Shift 3 for better utilization.
Schedule Adjustment
8.4. Material and Inventory Management
- Tracks and manages the amount of materials and supplies needed for production.
- Displays inventory levels of required materials and ensures no shortages occur.
- Integrates with inventory management systems to automatically replenish materials when needed.
- Theo dõi và quản lý lượng nguyên liệu và vật liệu cần thiết cho sản xuất.
- Hiển thị tình trạng tồn kho nguyên liệu và vật liệu cần thiết, đảm bảo không xảy ra tình trạng thiếu hụt.
- Tích hợp với hệ thống quản lý kho để tự động bổ sung nguyên liệu khi cần thiết.
Raw Material Inventory
Total: 15,000 kg
Status: Sufficient
Critical Material Inventory
Total: 500 units
Status: Low - Reorder Required
Finished Goods Inventory
Total: 2,500 units
Status: Ready for Shipping
Inventory Details
| Material ID | Material Name | Category | Quantity | Unit | Status | Reorder Level | Action |
|---|---|---|---|---|---|---|---|
| RM001 | Steel Sheets | Raw Material | 8,000 | kg | Sufficient | 2,000 kg | |
| RM002 | Aluminum Rods | Raw Material | 1,500 | kg | Low | 1,000 kg | |
| FG001 | Finished Widget A | Finished Goods | 1,200 | units | Ready for Shipping | N/A | |
| CM001 | Lubricant Oil | Critical Material | 200 | liters | Very Low | 500 liters |
Warehouse Integration
Auto-replenishment of materials is enabled. The system will automatically place reorder requests when inventory levels fall below the reorder level.
8.5. Production Process Management
- Manages detailed production processes, including steps and guidelines.
- Monitors compliance with processes by staff and equipment to ensure product quality.
- Adjusts and optimizes production processes to enhance performance.
- Quản lý các quy trình sản xuất chi tiết, bao gồm các bước cần thực hiện và tài liệu hướng dẫn.
- Theo dõi sự tuân thủ quy trình của nhân viên và thiết bị để đảm bảo chất lượng sản phẩm.
- Điều chỉnh và tối ưu hóa quy trình sản xuất để nâng cao hiệu suất.
Current Production Processes
-
Process Name: Assembly Line A
Steps: 5
Status: In Progress -
Process Name: Welding Line B
Steps: 4
Status: Completed -
Process Name: Painting Line C
Steps: 6
Status: Pending
Compliance Tracking
| Process Name | Employee | Compliance Status | Equipment | Compliance Status |
|---|---|---|---|---|
| Assembly Line A | John Doe | Compliant | Machine A1 | Compliant |
| Welding Line B | Jane Smith | Partial Compliance | Machine B2 | Non-Compliant |
| Painting Line C | Mike Johnson | Non-Compliant | Machine C3 | Compliant |
Process Documentation
Step 1: Preparation of materials (PDF)
Step 2: Assembling components (PDF)
Step 3: Quality check (PDF)
Step 1: Set up welding equipment (PDF)
Step 2: Welding components (PDF)
Step 3: Cooling and inspection (PDF)
Step 1: Surface preparation (PDF)
Step 2: Paint application (PDF)
Step 3: Drying and finishing (PDF)
Process Optimization
Recent optimization efforts have led to a 15% increase in production efficiency on Assembly Line A. Further adjustments are being tested on Welding Line B to improve compliance and reduce downtime.
8.6. Real-time Monitoring
- Monitors production activities in real-time, including equipment status, work progress, and production efficiency.
- Displays alerts if issues occur during production, such as equipment failures or reduced output.
- Provides real-time data to make timely decisions.
- Theo dõi các hoạt động sản xuất theo thời gian thực, bao gồm trạng thái thiết bị, tiến độ công việc, và hiệu suất sản xuất.
- Hiển thị cảnh báo nếu có sự cố xảy ra trong quá trình sản xuất, như thiết bị hỏng hóc hoặc sản lượng giảm.
- Cung cấp dữ liệu thời gian thực để đưa ra quyết định kịp thời.
Active Production Lines
5
Units Produced
1,450
Current Alerts
2
Equipment Status
| Equipment ID | Status | Output (Units) | Uptime (%) | Last Maintenance |
|---|---|---|---|---|
| EQ-001 | Operational | 320 | 98% | 2024-08-15 |
| EQ-002 | Idle | -- | 100% | 2024-08-10 |
| EQ-003 | Faulty | 85 | 65% | 2024-08-18 |
Work Progress
| Production Line | Order ID | Product | Progress (%) | Estimated Completion |
|---|---|---|---|---|
| Line 1 | ORD-1234 | Widget A | 70% | 2024-08-28 16:00 |
| Line 2 | ORD-1235 | Widget B | 45% | 2024-08-28 18:00 |
| Line 3 | ORD-1236 | Widget C | 20% | 2024-08-29 09:00 |
Active Alerts
Alert: Equipment EQ-003 has reported a fault. Production output has been reduced.
Alert: Production Line 2 is experiencing delays due to low material stock.
8.7. Production Quality Management
- Manages and monitors product quality during production.
- Inspects and records product defects and corrective actions.
- Tracks the rate of products meeting standards and addresses quality issues to improve production processes.
- Quản lý và theo dõi chất lượng sản phẩm trong quá trình sản xuất.
- Kiểm tra và ghi nhận các lỗi sản phẩm và các biện pháp khắc phục.
- Theo dõi tỷ lệ sản phẩm đạt tiêu chuẩn và các vấn đề chất lượng để cải thiện quy trình sản xuất.
Total Products Inspected
2,150
Products Passed
2,000
Products Failed
150
Defect Management
| Defect ID | Product | Defect Type | Severity | Corrective Action | Status | Date Reported |
|---|---|---|---|---|---|---|
| DF-001 | Widget A | Surface Scratch | Minor | Polishing | Resolved | 2024-08-20 |
| DF-002 | Widget B | Misalignment | Major | Reassembly | In Progress | 2024-08-21 |
| DF-003 | Widget C | Color Deviation | Minor | Repainting | Unresolved | 2024-08-22 |
Quality Improvement
| Issue | Cause | Action Taken | Outcome | Status | Date Implemented |
|---|---|---|---|---|---|
| High Reject Rate | Machine Calibration | Recalibration | Reject rate reduced by 15% | Effective | 2024-08-19 |
| Frequent Surface Defects | Material Quality | Switched Supplier | Defects reduced by 10% | Effective | 2024-08-20 |
| Assembly Errors | Operator Training | Training Program | Error rate reduced by 20% | Needs Review | 2024-08-21 |
8.8. Equipment Maintenance Management
- Manages the scheduling of equipment maintenance and repairs to ensure continuous operation of production lines.
- Tracks equipment conditions, records issues, and actions taken.
- Integrates with maintenance systems to schedule regular maintenance and predict issues.
- Quản lý lịch trình bảo trì và sửa chữa thiết bị để đảm bảo hoạt động liên tục của dây chuyền sản xuất.
- Theo dõi tình trạng thiết bị, ghi nhận các sự cố và các biện pháp sửa chữa đã thực hiện.
- Tích hợp với hệ thống bảo trì để tự động lên lịch bảo trì định kỳ và dự đoán sự cố.
Upcoming Maintenance Tasks
- Machine A - Lubrication Due in 3 days
- Machine B - Belt Replacement Due in 7 days
- Machine C - Calibration Due in 10 days
Recently Completed Maintenance
- Machine D - Sensor Replacement Completed 2 days ago
- Machine E - Oil Change Completed 5 days ago
- Machine F - Electrical Inspection Completed 1 week ago
Equipment Status and Maintenance Tracking
| Equipment ID | Equipment Name | Status | Last Maintenance | Next Scheduled Maintenance | Recent Issues | Actions Taken |
|---|---|---|---|---|---|---|
| EQ-001 | Machine A | Operational | 2024-08-15 | 2024-09-01 | Overheating | Coolant Refilled |
| EQ-002 | Machine B | Maintenance Due | 2024-08-10 | 2024-08-28 | Belt Wear | Belt Replaced |
| EQ-003 | Machine C | Out of Service | 2024-08-12 | 2024-09-05 | Calibration Failure | Pending Calibration |
Predictive Maintenance Integration
| Equipment ID | Equipment Name | Predicted Issue | Predicted Failure Date | Recommended Action | Status |
|---|---|---|---|---|---|
| EQ-004 | Machine D | Motor Degradation | 2024-09-10 | Motor Replacement | Scheduled |
| EQ-005 | Machine E | Oil Contamination | 2024-09-15 | Oil Change | Scheduled |
| EQ-006 | Machine F | Electrical Fault | 2024-09-20 | Electrical Inspection | Pending |
8.9. Production Performance Management
- Monitors key production performance indicators (KPIs) such as OEE, labor productivity, and production time.
- Compares actual performance with set goals and analyzes discrepancies.
- Provides reports and improvement suggestions to enhance production performance.
- Theo dõi các chỉ số hiệu suất sản xuất chính (KPI) như OEE, năng suất lao động, và thời gian sản xuất.
- So sánh hiệu suất thực tế với mục tiêu đã đề ra và phân tích các nguyên nhân của sự chênh lệch.
- Cung cấp báo cáo và đề xuất cải tiến để nâng cao hiệu suất sản xuất.
Overall Equipment Effectiveness (OEE)
OEE: 85% Good
Target: 90%
Gap: -5%
Labor Productivity
Labor Productivity: 75 units/hour
Target: 80 units/hour
Gap: -5 units/hour
Production Time Efficiency
Cycle Time: 45 minutes
Target: 40 minutes
Gap: +5 minutes
Performance Analysis
The production performance metrics show a slight deviation from the set targets. The primary reasons for these gaps are:
- OEE: Equipment downtime due to unexpected maintenance.
- Labor Productivity: Inconsistent labor shifts affecting output.
- Cycle Time Efficiency: Delays in material supply chain.
Recommended actions:
- Improve preventive maintenance scheduling to reduce unexpected equipment failures.
- Standardize labor shifts and provide additional training to maintain consistent productivity.
- Optimize material procurement processes to ensure timely availability of resources.
Performance Trends
OEE Over the Last Week
Performance Reports
8.10. Production Cost Management
- Tracks and analyzes production costs, including material, labor, and energy costs.
- Compares actual costs with the budget and identifies ways to optimize to reduce production costs.
- Manages and analyzes cost-driving factors to make strategic decisions.
- Theo dõi và phân tích chi phí sản xuất, bao gồm chi phí nguyên liệu, lao động, và năng lượng.
- So sánh chi phí thực tế với ngân sách và tìm cách tối ưu hóa để giảm chi phí sản xuất.
- Quản lý và phân tích các yếu tố ảnh hưởng đến chi phí sản xuất để đưa ra các quyết định chiến lược.
Material Cost
Cost: $120,000
Budget: $110,000
Over Budget: +$10,000
Labor Cost
Cost: $80,000
Budget: $85,000
Under Budget: -$5,000
Energy Cost
Cost: $50,000
Budget: $45,000
Over Budget: +$5,000
Cost Analysis
The current production costs indicate the following:
- Material Cost: Over budget due to increased raw material prices.
- Labor Cost: Under budget due to higher efficiency and reduced overtime.
- Energy Cost: Over budget due to higher energy consumption in peak hours.
Optimization Suggestions:
- Negotiate better pricing with suppliers or find alternative raw material sources.
- Continue monitoring labor efficiency and consider performance incentives.
- Implement energy-saving initiatives during peak hours to reduce costs.
Cost Comparison
Actual Costs vs. Budget
Cost Reports
8.11. Yield and Productivity Management
- Monitors production yields and the percentage of products meeting quality standards.
- Analyzes factors affecting productivity, including material and equipment efficiency.
- Develops strategies to improve production yields and productivity.
- Theo dõi sản lượng sản xuất và tỷ lệ sản phẩm đạt chuẩn.
- Phân tích các yếu tố ảnh hưởng đến năng suất, bao gồm hiệu quả sử dụng nguyên liệu và thiết bị.
- Đưa ra các chiến lược để cải thiện sản lượng và năng suất sản xuất.
Production Yield
Total Production: 10,000 units
Compliant Products: 9,500 units
Yield Rate: 95% High
Material Utilization
Material Used: 12,000 kg
Material Wastage: 500 kg
Utilization Rate: 95.8% Efficient
Equipment Efficiency
Operating Time: 95 hours
Downtime: 5 hours
Efficiency Rate: 95% High
Productivity Analysis
Analysis of factors affecting productivity:
- Material Utilization: High efficiency with minimal wastage indicates optimal material usage.
- Equipment Efficiency: High operating time with low downtime suggests good maintenance and operational practices.
- Production Yield: A high yield rate indicates effective production processes with minimal defects.
Improvement Strategies:
- Continue regular equipment maintenance to maintain high efficiency.
- Monitor material quality to further reduce wastage and increase yield.
- Implement training programs to ensure consistent production practices.
Yield and Productivity Trends
Yield Rate vs. Equipment Efficiency
Reports
8.12. Safety and Compliance Management
- Manages safety regulations in production and ensures compliance.
- Tracks safety incidents and implements corrective actions.
- Manages safety processes and training to minimize production risks.
- Quản lý các quy định an toàn lao động trong sản xuất và đảm bảo tuân thủ.
- Theo dõi các sự cố liên quan đến an toàn và thực hiện các biện pháp khắc phục.
- Quản lý các quy trình và đào tạo về an toàn để giảm thiểu rủi ro trong sản xuất.
Safety Regulations
Ensure compliance with labor safety regulations:
- Regulation 1: Mandatory use of personal protective equipment (PPE).
- Regulation 2: Regular equipment safety checks.
- Regulation 3: Emergency evacuation procedures must be practiced quarterly.
- Regulation 4: Proper labeling and storage of hazardous materials.
Safety Training
Upcoming Training Sessions
- Fire Safety Training - September 15, 2024
- PPE Usage and Compliance - October 5, 2024
- Hazardous Materials Handling - October 20, 2024
Safety Incidents Tracking
Recent Safety Incidents
| Date | Incident | Severity | Corrective Action | Status |
|---|---|---|---|---|
| August 25, 2024 | Worker slipped due to oil spill | Moderate | Cleaned spill, reviewed safety procedures | Resolved |
| August 10, 2024 | Electrical short-circuit in equipment | Severe | Repaired wiring, conducted safety inspection | Resolved |
| July 30, 2024 | Worker not wearing PPE | Moderate | Issued warning, conducted PPE training | Resolved |
Safety Compliance Dashboard
Total Incidents This Month
5 High
Compliance Rate
98% Excellent
Pending Corrective Actions
1 Pending
Reports
8.13. Production Reporting
- Provides detailed reports on production progress, quality, performance, and costs.
- Exports reports in PDF or Excel format for analysis or presentation.
- Analyzes production trends and efficiency over time to improve processes.
- Cung cấp các báo cáo chi tiết về tiến độ sản xuất, chất lượng, hiệu suất, và chi phí.
- Xuất báo cáo dưới dạng PDF hoặc Excel để phân tích hoặc trình bày.
- Phân tích xu hướng sản xuất và hiệu quả theo thời gian để cải thiện quy trình.
Production Progress Report
Report on the current progress of production orders:
- Orders in Production: 15
- Completed Orders: 45
- Pending Orders: 8
Production Quality Report
Summary of product quality during production:
- Total Products Inspected: 1200
- Defective Products: 25
- Quality Compliance Rate: 97.9%
Efficiency Report
Analysis of production efficiency:
- OEE (Overall Equipment Effectiveness): 88%
- Average Downtime: 5 hours/week
- Production Rate: 85 units/hour
Cost Report
Detailed analysis of production costs:
- Total Material Cost: $45,000
- Total Labor Cost: $30,000
- Energy Costs: $8,000
Export Reports
Export reports in the following formats for analysis or presentation:
Download as PDF Download as ExcelProduction Trend Analysis
Analyze production trends over time to identify areas for improvement: