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Engineering Release Control
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This function involves the coordination of the release of new products, processes, tools, and engineering changes to manufacturing. A major checkpoint in the product cycle is obtaining assurance that all necessary documentation is available, after which the information is released to manufacturing. Input is received from product and process development activities. Specific output, including product and tool drawings, process and quality specifications, NC programs, and bills of material, is transferred to production planning and plant operations.
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Among the activities of engineering management are introducing engineering releases, controlling product definition data, estimating cost, entering and controlling process data, and defining production resources.
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Input and output for engineering management include exchanging designs and descriptions with engineering design; reviewing product data, routings, and schedules with production planning; and accepting engineering change requests from plant operations.
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Production planning can be viewed as five related functional areas (Fig. 5.4).
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In master production planning, information is consolidated from customer order forecasts, distribution centers, and multiple plans in order to anticipate and satisfy demands for the enterprise s products. Output includes time-phased requirements sent to the material planning function, as well as the final assembly schedule.
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FIGURE 5.4
Production planning.
T h e R o l e o f S e n s o r s a n d C o n t r o l Te c h n o l o g y i n C I M
Material Planning and Resource Planning
Material planning and resource planning are two areas that require timely and accurate information demand schedules, production commitment, inventory and work-in-progress status, scrap, actual versus planning receipts, shortages, and equipment breakdowns in order to keep planning up to date with product demands. Product and process definition data come from the engineering areas. Output is to plant operation and procurement and includes production schedules, order releases, and plans for manufactured and purchased items.
Procurement
Procurement involves selecting suppliers and handling purchase requirements and purchase orders for parts and materials. Among the input, is material requirements from material planning and justin-time delivery requests from plant operations. Other input includes shipping notices, invoices, and freight bills. Output to suppliers includes contracts, schedules, drawings, purchase orders, acknowledgments, requests for quotations, release of vendor payments, and part and process specifications. In order to streamline this output, as well as support just-in-time concepts, many enterprises rely on sensors for electronic data interchange with vendors.
Plant Release
The functions of this area can vary, depending on the type of manufacturing environment. In continuous-flow environments, for example, this area produces schedules, recipes to optimize use of capacity, specifications, and process routings. For job-shop fabrication and assembly environments, this area prefers electronic or paperless-shop documents consisting of engineering change levels; part, assembly, setup, and test drawings and specifications; manufacturing routings; order and project control numbers; and bar codes, tags, or order-identification documents. However, large-volume industries are evolving from typical jobshop operations to continuous-flow operations, even for fabrication and assembly-type processes. Input typically an exploded production plan detailing required manufacturing items comes from material planning. Output schedules, recipes, or shop packets is used in plant operations for scheduling.
Plant Operations
Production Management
Plant operations can be described in terms of nine functions (Fig. 5.5). The production management area provides dynamic scheduling functions for the plant floor by assigning priorities, personnel, and
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FIGURE 5.5
Plant operations.
machines. Other activities include sending material and tool requests for just-in-time delivery. Input for production management includes new orders and schedules from production planning and real-time feedback from plant operation. Output includes dynamic schedules and priorities used to manage operations on the plant floor.
Material Receiving
The material receiving function includes accepting and tracking goods, materials, supplies, and equipment from outside suppliers or other locations within the enterprise. Input to this area includes receiving reports and purchase order notices. Output includes identifying receipts with appropriate documentation, then routing materials to the proper destination. Data are also sent to accounting, procurement, and production management. Production management can also direct materials based on more immediate needs.
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