Shop floor planning concerns the management of your operations, inventory, equipment, and workers.
And your shop floor planning and control will go through these three phases:
Order scheduling; and
Phase 1 – Order Release
Using shop floor applications, the master production schedule will inform which manufacturing order needs to be generated.
Then from there, the order release document will inform the shop floor management boards of the resources and manufacturing processes needed to complete the order.
Phase 2 – Order Scheduling
Once the order release has been generated, shop floor applications will schedule the production of the order, while providing you with a detailed workflow of the manufacturing route the order will pass through.
The order scheduling phase will explain:
The work stations the order passes through; and
The materials and quantity needed for the order.
This allows managers and employees to understand what needs to be done, who needs to do it, and how it needs to be done.
Increase your profit margin by avoiding delays from unexpected problems emerging.
3. Resource Planning
One of the other advantages of shop floor control is how easy it is to allocate resources to other tasks as the software can handle the production process efficiently.
Not only will shop floor planning software help you automate your resource allocation and workflow but because it helps you perform these tasks quicker, you remove the need to have a team member stuck in inefficient spreadsheets developing the master production schedule.
4. Problems and Variations Become Transparent
Shop floor management boards give managers and operators an overview of any relevant information, open topics, and manufacturing orders in production, so everyone can be on the same page, and work toward a shared goal.
This means everyone can start their workday with a complete understanding of what is happening along the production line.
5. Direct Support of Management
Everyone within the business can communicate with each other quickly and efficiently, which will allow them to solve issues faster, and keep production going without delays.
Having your shop floor data in one place, and easily accessible, means you don’t have to waste time trying to explain issues or waste time giving feedback to other departments when trying to address an issue.
6. Key Performance Indicators (KPI)
It probably goes without saying, but a skilled and experienced team with be crucial for a successful production run.
Using shop floor applications will allow you to communicate back to your team on performance levels, and help provide more training for those underperforming, boosting productivity.
7. Quality Control
Shop floor control software gives your managers the ability to trace:
Material waste; and
Separate repairable batch failures from the main inventory.
While your operators will be easily able to measure and report material waste, while identifying batch failures as recoverable or not.
8. Price Products Fairly
As already mentioned under KPI’s, improved analytics and reporting means you can gather data on:
Adopting shop floor planning on your production lines allows you to achieve a paperless manufacturing workflow, by giving you the tools to:
Track progress; and
Manage your entire business from a smartphone, tablet, or computer.
So, that’s the 10 advantages of shop floor control. But, what are the other aspects you need to be aware of with shop floor planning?
Can Production Environment Influence Shop Floor Control?
How you tackle your shop floor control will all depend on the type of industry you operate in, as we have briefly touched on with the different manufacturing workflows.
Depending on the workflow you follow, or the manufacturing processes you adopt, your shop floor control will change to incorporate:
Promised delivery dates; and
The sequencing of manufacturing orders through the manufacturing route.
For example, a make-to-stock workflow handles a high volume of finished goods. To achieve this high-volume, the manufacturer will make products in a flow shop or continuous manufacturing flow, which will require the shop floor planning software to perform flow control.
Production Activity Control
Production activity control in shop floor planning is the process of coordinating your: