Shop Floor Reporting

In IFS Applications, the shop floor reporting functionality provides a great variety of manufacturing related reporting possibilities for the shop floor personnel. It also provides important and relevant real time manufacturing related information.

The shop floor personnel should only use one window for all their daily activities i.e., the Shop Floor Workbench window. This window contains all information and all functions needed for the daily work on the shop floor. It is also possible to integrate the solution with 3rd party terminals by using the Biz Api s provided.

The shop floor reporting functionality can be used in conjunction with IFS Human Resources. If IFS Human Resources is used, a number of additional features, such as, auto stop or auto resume operations, reconciliation of manufacturing hours and attendance hours will also be available.

Depending on the demand of accuracy on the reporting results there are different ways to setup and use the shop floor reporting solution such as:

The head pane works as a filter for the list of operations. If you enter filtering criteria in the head pane, the list will display operations according to these criteria. You can also choose to view operations within a limited time interval and sort them according to different dispatch rules.

For instance, you can view executable operations connected to a certain work center for the coming week sorted according to earliest due date.

If you are working in employee reporting mode, either an employee or a team must be entered in the head pane. You can enter the employee or team either by manually clicking Enter As, or setting the system up to automatically launch the identification dialog box when the Shop Floor Workbench window has been left idle for a defined number of seconds.

It is possible to predefine filters in the Shop Floor Workbench Filters window and connect them to either an employee or a team. If connected, the list of operations will be automatically populated according to the filtering criterion when the employee or team enters the Shop Floor Workbench.

The operation list displays all relevant shop order operations. If you select an operation in the list, you can take different actions for this operation. You can reach the actions using the buttons or the right-click options. You can filter the operation list by using the head pane and/or by using the standard search functionality.

An operation in the operation list can have symbols to the left to indicate the current status of the operation:

You can view media, such as pictures, and documents connected to a number of object related to the operation line from the Attachment panel.

When you select an operation, different options will be enabled depending on the actions that are currently available for the operation.

If you want to spend minimal time on system setup and on reporting you should use anonymous reporting. Labor time can be reported, but will not be registered on individual employees.

In Shop Floor Workbench window, you manually enter appropriate filter criteria to filter out the operations you want to work with.

When you register labor time you must enter the number of persons that's working on the operation, the time is not registered on individual employees.

To minimize time spent on reporting you can select and start several operations simultaneously (in sequence). When you register the stop, the total duration is calculated and divided between the operations according to their remaining hours:

Example of operations reported in sequence:

Three operations (not previously reported on) with the planned time as below are selected and production with machine and labor with crew size 2 is simultaneously started 8:00 and stopped 12:00.

Operation	Planned Labor Runtime	Planned Machine Runtime
1	2h	2h
2	4h	2h
3	0h	4h

The total duration of 4 hours are divided between the operations according to the planned values above:

Operation	Actual Labor Time	Actual Machine Time
1	4 x (2 / (2 + 4 + 0)) = 1,33h	2h
2	4 x (4 / (2 + 4 + 0)) = 2,67h	4 x (2 / (2 + 2 + 4)) = 1,00h
3	4 x (0 / (2 + 4 + 0)) = 0,00h	4 x (4 / (2 + 2 + 4)) = 2,00h
Total	4,00h	4,00h

Since Crew Size was 2 the Labor Time in Man Hours which the cost is based on will become the Labor Time x 2.

Compare with the example of operations reported in parallel.

If the setup or production has to be interrupted you can stop the operation as interrupted and select the cause of the interruption. This will start an interruption clocking which is automatically stopped once the operation is started again.

If you want to follow up time result on individual employees and have the possibility to report indirect time you should use employee reporting.

When IFS Human Resources is not used, you define employees directly under the company. To allow the employees to report on shop order operations and indirect jobs you must also connect them to a labor class and optionally to a filter.

Each employee must be identified when entering the Shop Floor Workbench, either manually or using barcode. You can setup the identification dialog box to automatically trigger after the window has been left idle for some time. The list of operations will be populated according to the connected filter and the employee ID is saved with all subsequent transactions.

In employee reporting mode, you must define the employees that will work with the operation. The crew size is calculated as a result of the number of employees and cannot be manually adjusted. If an employee is working on several operations with overlapping intervals, the value in Crew Size field is automatically divided between the operations according to the planned crew size.

Three operations has the planned crew size as below:

Operation	Planned Crew Size
1	0.5
2	2
3	1

If the crew size > 1, it indicates several employees are planned to work on the operation

If the crew size < 1, it indicates an employee is planned to work on several operations simultaneously

An employee reports on the operation as below:

Operation	Start Time	Stop Time
1	8.00	10
2	9.00	10.30
3	9.00	11

The system will divide overlapping intervals into subsections and calculate the crew size for each subsection weighted according to the planned crew size of the overlapping operations. The total crew size for an employee each subsection is always 1. Finally an average crew size for the entire clocking interval is calculated.

Note that a crew size > 1 is not considered in the calculations since one employee never is considered to do more than one persons work. Instead we can expect additional employees to report on these operations.

Example	8.00 - 9.00	9.00 - 10.00	10:00 - 10:30	10:30 - 11:00	Average Crew Size
Operation 1	0,5 / 0,5 = 1,0	0,5 / (0,5 + 1 + 1) = 0,2	-	-	((1 x 1) + (1 x 0,2)) / 2 = 0,60
Operation 2	-	1 / (0,5 + 1 + 1) = 0,4	1 / (1 + 1) = 0,5	-	((1 x 0,4) + (0,5 x 0,5)) / 1,5 = 0,43
Operation 3	-	1 / (0,5 + 1 + 1) = 0,4	1 / (1 + 1) = 0,5	1 / 1	((1 x 0,4) + (0,5 x 0,5) + (0,5 x 1) / 2 = 0,57
Total	1,0	1,0	1,0	1

The average Crew Size multiplied with the duration of the interval gives the Labor Time in Man Hours which the cost is based on.

Compare this example with the example of operations reported in sequence mentioned above in example 1.

Note that the above example is valid for labor time only. If you report machine time on operations executed overlapping on the same machine resource each operation will receive the full hourly cost for the machine. If you wish to divide the cost of the machine on the operations you must start them in sequence.

If you use shop floor reporting in conjunction with IFS Human Resources, a number of additional features will be available.

When a group of persons working physically on the same location and/or with similar tasks, the team reporting can be used. Team reporting allows you to follow up time result on an employee level just as for employee reporting, but it is required only for one person in the team to manage the reporting as reported time will apply for all team members.

Teams are defined as basic data and you can connect a filter similar as for employees. The members of the team is not setup as basic data but changes dynamically as employees clock in and out from the team.

In Shop Floor Workbench window, you identify as a team either manually or by reading barcode, the list of operations is populated according to the connected filter and the team identity is saved with all subsequent transactions.

Employees are registered as they join and leave the team. This action automatically starts and stops the time on the operations or indirect job the team currently working on. When you register start of an operation or indirect job for the team, time will be started for all members currently in the team. When the team runs several operations in parallel, the man hours and cost for each employee will be divided between these operations according to the planned crew size. When an employee is clocked in to a team he/she is not allowed to report operations individually.

If you clock out from Time Clock while in a team, you will be automatically clocked out from the team. When you clock in again, you can be automatically clocked in to the team depending on the settings.

It is preferred that you scale down and hide non used features in the Shop Floor Workbench window to simplify reporting as much as possible.

If you want to lock the head pane values so that the predefined filter cannot be changed, you can hide fields or set them to read-only by opening the Properties dialog box by right-clicking and clicking Properties.
You can also choose to not use the filter and instead identify the operation to work with by reading the operation barcode. You can find the operation barcode on the Work Instructions report. It is then recommended to hide all other fields in the head pane and not connect any filter to the employee or team.

You can hide non relevant columns and arrange them in a suitable order by using the Column Chooser option available from the right mouse button.
Choose which tabs to be displayed by using the Change the tab visibility option available in the Layout tab in the Object Properties dialog box available from the right mouse button menu when clicking in the tab area of the Shop Floor Workbench window.

You can configure which buttons to be displayed and in which order they should be arranged by using the Layout tab in the Object Properties dialog box available from the right mouse button menu.

Tab	Contents
Guidelines	In this tab, you can view instructions and subtasks connected to the selected operation. Subtasks can be signed off using the right mouse button options.
Tools	In this tab, you can view tools connected to the selected operation.
Material	In this tab, you can view components connected to the selected operation. By using the relevant right mouse button option you can also view components for the entire order and take material actions such as reserve and issue. Symbols to the left indicates if there is a shortage: White explanation mark - The available quantity on inbound location is lower than the remaining quantity Red explanation mark - The available quantity is lower than the remaining quantity
Op Reports	In this tab, you can view labor, machine, and scrap transactions created for the selected operation. By using the right mouse button options you can add or cancel a result.
Clockings	In this tab, you can view clocking records for the selected operation which are created during the start and stop activities. By using the right mouse button options you can cancel, modify, and add clockings.
Mtrl Guidelines	In this tab, you can view guidelines entered for any component belonging to the shop order to which the selected operation belongs.
Tracked Structure	In this tab: You can view and manage the structure for tracked parts by using drag and drop feature. It is also possible to connect component parts to parent serials by using right mouse button options.
Control Plan	In this tab, you can view the control plan data points connected to the selected operation. This tab is only visible if the IFS/ Quality management component is installed.
CBS Resources	In this tab, you can view employees, tool instances, and the machine resource assigned to the selected operation. This tab is only visible if IFS/Constraint Based Resources is installed.

Button	Contents
Start Production Start Setup	Using these buttons, you can register that labor and/or machine setup or production has been started. This action will create one or several clocking records with a start time for the selected operation/operations.
Stop Production Stop Setup	Using these buttons, you can register that setup or production has been stopped for the selected operation. If the operation was started in sequence with others, all will be stopped. The active clockings will receive a stop time. The time result will be calculated and saved with the operation history transaction. If the operation was stopped due to some problem it can be registered as interrupted with a suitable cause given. The interruption time will be recorded.
Start Indirect	Using this button, you can register that an employee or team has started to work on an indirect job. This action will create one indirect clocking for each employee.
Stop Indirect	Using this button, you can register that an employee or team has stopped working on an indirect job. The active clocking for each employee will receive a stop time and the time result is calculated and indirect labor history transactions are created.
Approve Op	Using this button, you can report time and completed quantity for the selected operation. If the operation is the last on the shop order, you can also receive parts into inventory. It is also possible to automatically report time and quantity on previous operations and to backflush material.
Report Scrap	Using this button, you can report part scrap as well as component scrap for the selected operation.
Join Team	Using this button, you can register that an employee has joined a team. If the team is running an operation(s) or indirect job, clocking records will be started on this operation(s) or indirect job for the employee.
Leave Team	Using this button, you register that an employee has left a team. If the team is running an operation(s) or indirect job, active clockings on this operation(s) or indirect job will be stopped for the employee. Time result will be calculated and saved with the operation history transaction.
Modify Ong Op	Using this button, you can register a change on an already started operation. For instance when an employee joins the operation or when the resource is changed.
Issue Material	Using this button, you can issue material for the shop order to which the selected operation belongs.
Kanban	Using this button, you can create a kanban replenishment request. This button is only available if IFS/Kanban is installed
Inspection	Using this button, you can either create an analysis or you can report analysis results for the selected operation. This button is only available if IFS/ Quality Management is installed.
Report Control	Using this button, you can print various reports related to the shop order which the selected operation belongs to, such as, work instruction and pick list.
Shop Order	Using this button, you can open the shop order to which the selected operation belongs.
Receive into Inventory	Using this button, you can manually receive products into inventory for the shop order to which the selected operation belongs.
Check Material	Using this button, you can check the material accessibility of the shop order to which the selected operation belongs.
Change WC	Using this button, you can select a new work center for the operation to be executed on.