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Factory Control System

Fcs - Encyclopedia

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The author of this presentation has created the virtual model of a batch manufacturing factory, using an enterprise architecture tool. Processes, applications, infrastructures, data models, etal, are stored in a repository called encyclopedia. Due to the impossibility of publishing the encyclopedia I decided to publish at least the diagrams, that constitute only one facet of the whole. This presentation is the collection of such diagrams.

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Page 1: Fcs - Encyclopedia

Factory Control System

Page 2: Fcs - Encyclopedia

BUSINESS LAYER

Page 3: Fcs - Encyclopedia

Production Organigram

Transportations

ProductionManager

ManufacturingEngineering

Manufacturing ManufacturingCosts Control

Maintenance

Inspections

WorkCenter

Operations

Mfg UnitOperations

Machine

ProductionPlanning& Control

Job ShopServices

Factory

ProductionPlanning

ProductionControl

ToolCrib

Job ShopStores

WorkCenter

AssemblyShop Floor

Job Shop

Operator

Page 4: Fcs - Encyclopedia

Production Processes

PrductionProcesses

Production &MaterialsPlanning

ManufacturingMaterials

Procurement

ManufacturingOversight

Subcontracting

ManufacturingStrategy Setting

Assemble /PackageProducts Plant Inventory

Management

Make or BuyPlanning

Make Products

Page 5: Fcs - Encyclopedia

Fabrication Flow

Logistics Processes

Make Sub-Assemblies

ReceiveMaterial

DeliverMake FinalAssemblies

Semi Finished

MakeComponents

FinishedProducts

ComponentsRaw Material

Page 6: Fcs - Encyclopedia

Logistics Processes

LogisticsProcesses

InventoryPlanning

LogisticsStrategy Setting

WarehousesDesign and

Layout

MaintainLogistics

Information

ReceiveCustumerReturns

StoreCustumerReturns

DeliverProduction

Material

WarehouseMgmt

ReceiveProducts

LogisticsPlanning

Off-siteServices

Execution

StoreCustomerReturns

Assortmentand Space Mgt

Store Products

Page 7: Fcs - Encyclopedia

Product Aggregation

ManufacturingEngineering

Work CenterJob Shop MachineFactory

Part PieceProcessing

Routing

Assembly

Routing Step Process Plan

Product

performs

makesmakes

createscreates

monitors

performs

makes

performs

makes

monitors

Page 8: Fcs - Encyclopedia

Shop Floor Control

Shop Floor

WorkCenter

Machine

Job Shop

ProductionControl

Factory

Product

Part / Lot

MachineStep

RoutingStep

Page 9: Fcs - Encyclopedia

Factory Process

Outsourc ing

OrderExecution

Des ign &SimulateRoutings

Update JobShops Load

Plan

Issue JobShops Orders

IssueOutsourc ing

Order

UpdateEmpirical Data

AnalyzePerformance

Monitor OrdersRate of Flow

Design Lots &Routings

Monitor JobShops

Requests

Del iverProducts

Make FactoryDec is ions

Request MPSChange

Work OrderRate of Flow

Job ShopsLoad Plan

Job ShopPerformance

FactoryInformation

FactoryEmpirical Data

Factory RoutingJob ShopCapac ity

Make or BuyData

Process Plan

Job ShopCapac ity

Work Orders

MPS

Batch Lot

Bill of Material

ProductProduct Status OrderExecuted

Production Order

MPS

Change

Upon Order

Completion

Job Shops

Feedback

Job Shop

Overload

Job Shop

Overload

Page 10: Fcs - Encyclopedia

Factory Material Flow

In ProcessMaterial

Factory

DeliveredGoods

Product Delivery

ProductsWarehousing

HotWarehousing

Customer Activ ities

SupplierReturn

Product Invoicing

Supplier Activ ities

ProductionPlanning

PurchaseOrder

ColdWarehousing

SalesPurchasing

Parts

MaterialReqs

ProductReqs

Demand

Product

Order

Invoice

Page 11: Fcs - Encyclopedia

Factory Locations Map

Factory Locations

Suppliers

(Cold)

GoodsWarehouse

Job Shop CJob Shop B

Customers

(Cold)

ProductsWarehouse

Job Shop A

AssemblyJob Shop

Page 12: Fcs - Encyclopedia

Shop Floor

Shop Floor

WorkCenter

Machine

Job Shop

ProductionControl

Factory

Product

Part / Lot

MachineStep

RoutingStep

Page 13: Fcs - Encyclopedia

Job Shop Context

Job Shop

Job ShopServices

(input)

Raw Material Detail

(output)

CompletedDetailed

Components

(Parts/Lots/Routing StepExecution)

Work Orders fromFactory

Feedback fromWork Centers

(Parts/Lots/Routing StepExecution)

Work Orders toWork Center

Routing Steps

Page 14: Fcs - Encyclopedia

Job Shop Locations Map

Job Shop Work Centers

Job Shop Services

Work Centers Control Office

ServicesControl Office

Work Center 1 Work Center 2

Stores

Work Center 3

InspectionDepartment

TransportationDepartment

MaintenanceDepartment

ToolCrib

Page 15: Fcs - Encyclopedia

Job Shop Process

Order Execution

FactoryWorkOrder

WorkOrderCompleted

Rescheduling

CheckAllocations

Notify FactoryControl

Design &SimulateRoutings

Monitor WorkCenters

Requests

Equipment &Tools Allocation

Update WorkCenters Load

Plan

Monitor WorkOrders

Job ShopDecisionsMaking

Part OrderCompletion

Notice

AnalyzePerformance

Empirical DataUpdate

ManpowerAllocation

MaterialAssignment

Work CenterManpower

Work CenterLoad Plan

MaterialAllocation

Job ShopEmpirical Data

Work CenterCapacity

Job ShopInformation

Work CenterPerformance

Feedback fromWork Centers

Work CenterRoutings

PartPerformance

Tools Allocation

Batch Lot

Work Orders

FactoryWorkOrder

Parts in Store

Parts Storage

AssignOrders

Upon Order

Completion

Upon Parts

Receipt

Work Center

Overload

Page 16: Fcs - Encyclopedia

Job Shop Context

Job Shop

Job ShopServices

(input)

Raw Material Detail

(output)

CompletedDetailed

Components

(Parts/Lots/Routing StepExecution)

Work Orders fromFactory

Feedback fromWork Centers

(Parts/Lots/Routing StepExecution)

Work Orders toWork Center

Routing Steps

Page 17: Fcs - Encyclopedia

Job Shop Services

Job ShopServices

MaintenanceInspection TransportStores

InspectionProcess

Tool Crib

MaintenanceProcess

StoresProcess

TransportProcess

Tool CribProcess

Page 18: Fcs - Encyclopedia

Inspection Process

Inspection

Rescheduling

Inspection

Completed

Inspections

PlanningRandom

Patterns

Generation

Inspection

Results

Reporting

In Process

Inspection

Inspection

Sequences

Planning

Inspection

Exception

Reporting

Allocatie

ResourcesImpact Analysis Parts/Lot

Receiving

Inspection

Execution

Lot Releasing Equipment

ReleasingInspector

Engagement

Inspection Tasks

Equipment Status

Part Status

Lot Statistics

Inspection

Exception

Inspection

Resource

Allocation

Inspection

Impact

Inspections Plan Random

Pattern

Page 19: Fcs - Encyclopedia

In Process Inspection

Operator &ForemanNotified

Liason EngineerNotified

Inspector Returns

Quality ControlStatistics Updated

Inspect PartsDispatchInspector to Floor

Parts Approved Parts Rejected

AllocateInspectionResources

Plan In-Process

Inspection

InspectionResource

Status

Page 20: Fcs - Encyclopedia

Job Shop Services

Job ShopServices

MaintenanceInspection TransportStores

InspectionProcess

Tool Crib

MaintenanceProcess

StoresProcess

TransportProcess

Tool CribProcess

Page 21: Fcs - Encyclopedia

Stores Process

Shop OrderIn ProcessMaterial

Requested

Shop OrderReplacement

MaterialRequested

FloorStockedMaterial

Requested

Operator MaterialPicking

OperatorCarriesMaterial

Wait forInstructions

MaterialAvailability

RequestFulfilled

Material Storage

Raise Exception

Material Status

MaterialAllocation

Check SpaceAvailability

Picking List

MaterialRequest

MaterialAssignment

No Space

Page 22: Fcs - Encyclopedia

Material Assignment

Assign Material

Issue Exception Report

Material Assignment

Inventory Checking

Store ExceptionStore Plan

Wait forInstructions

Material and AlternateMaterial not Available

Page 23: Fcs - Encyclopedia

Stores Process

Shop OrderIn ProcessMaterial

Requested

Shop OrderReplacement

MaterialRequested

FloorStockedMaterial

Requested

Operator MaterialPicking

OperatorCarriesMaterial

Wait forInstructions

MaterialAvailability

RequestFulfilled

Material Storage

Raise Exception

Material Status

MaterialAllocation

Check SpaceAvailability

Picking List

MaterialRequest

MaterialAssignment

No Space

Page 24: Fcs - Encyclopedia

Operator Material Picking

RequestTransportation

Container LoadingPicking Work List

Material Status

Loading Status

Move Request

Container Status

Upon LoadCompletion

Page 25: Fcs - Encyclopedia

Stores Process

Shop OrderIn ProcessMaterial

Requested

Shop OrderReplacement

MaterialRequested

FloorStockedMaterial

Requested

Operator MaterialPicking

OperatorCarriesMaterial

Wait forInstructions

MaterialAvailability

RequestFulfilled

Material Storage

Raise Exception

Material Status

MaterialAllocation

Check SpaceAvailability

Picking List

MaterialRequest

MaterialAssignment

No Space

Page 26: Fcs - Encyclopedia

Material Storage

ContainerWaiting

RaiseException

ContainerUnloading

MaterialShelving

IncomingMaterial

Classification

StoragePlanning

InventoryUpdating

SpaceChecking

Part Inventory

Stored PartStatus

Store Plan

ContainerStatus

Material TypeNo Space

Store Order

Page 27: Fcs - Encyclopedia

Job Shop Services

Job ShopServices

MaintenanceInspection TransportStores

InspectionProcess

Tool Crib

MaintenanceProcess

StoresProcess

TransportProcess

Tool CribProcess

Page 28: Fcs - Encyclopedia

Maintenance Process

DefectReported by

MachineMonitor

DefectReported by

Operator

Defect Adjusted onSpot

Defect Reported toMaster Mechanic

Maint InspectorDiscovers Defect

Examine PM Plan

Request forAttention

TimeReporting

RepairmanActivities

PM PlanExecution

CostDepartment

Activities

MasterMechanicActivities

Repair OrderIssuing

SecureApproval

MaintenanceOperations

MinorRepair

ExamineRepair Type

PM Plan

MajorRepair

EngineeringActivity

Page 29: Fcs - Encyclopedia

Maintenance Operations

RepairRescheduling

Request

Equipment &

Material Transfer

Repair Parts

Purchase

Request Issuing

Repair Order

AnalysisRepair Parts

Availabil ity

Checking

Machine

Allocation

Requesting

Maintenance

StartingMachine

StoppingTools Allocation

TransportExecuted

Machine Status

Update

Repair Part

InventoryTransport

Request

Maintenance

Plan

Repair Part

Request

Machine

Allocation

Maintenance

Information

Tools Allocation

Repair Order

Repairman

Charging

Work CenterGo-ahead

No Av ailability

Page 30: Fcs - Encyclopedia

Maintenance Process

DefectReported by

MachineMonitor

DefectReported by

Operator

Defect Adjusted onSpot

Defect Reported toMaster Mechanic

Maint InspectorDiscovers Defect

Examine PM Plan

Request forAttention

TimeReporting

RepairmanActivities

PM PlanExecution

CostDepartment

Activities

MasterMechanicActivities

Repair OrderIssuing

SecureApproval

MaintenanceOperations

MinorRepair

ExamineRepair Type

PM Plan

MajorRepair

EngineeringActivity

Page 31: Fcs - Encyclopedia

Repairman Activities

Sign for materials Turn in time tickets Execute Repair

Maint ExceptionReporting

Mark last ticket'complete'

Maint Exception Wait forInstructions

Upon Exception

Page 32: Fcs - Encyclopedia

Maintenance Process

DefectReported by

MachineMonitor

DefectReported by

Operator

Defect Adjusted onSpot

Defect Reported toMaster Mechanic

Maint InspectorDiscovers Defect

Examine PM Plan

Request forAttention

TimeReporting

RepairmanActivities

PM PlanExecution

CostDepartment

Activities

MasterMechanicActivities

Repair OrderIssuing

SecureApproval

MaintenanceOperations

MinorRepair

ExamineRepair Type

PM Plan

MajorRepair

EngineeringActivity

Page 33: Fcs - Encyclopedia

Master Mechanic Activities

Maint PlanUpdating

Equipment &Repair Parts

Storage

MaintenanceReporting

ToolsAvailability

MaintenancePlan

EquipmentMachineStatus

Repair PartInventory

Page 34: Fcs - Encyclopedia

Job Shop Services

Job ShopServices

MaintenanceInspection TransportStores

InspectionProcess

Tool Crib

MaintenanceProcess

StoresProcess

TransportProcess

Tool CribProcess

Page 35: Fcs - Encyclopedia

Tool Crib Process

Tool AllocationPlanning

Keep Tool History

Tool Receiving

Tool issuingTools Set out

for Maintenance

Shop FloorTool

RequestReceived

Tools Scrapping

Tool InventoryUpdated

Tool Inventory

Tool Status /Location

ToolFabricated /Purchased

Tool fromShop Floor

ToolsArrival

Tool History

If New Tool

If DamagedIf BadTool

Page 36: Fcs - Encyclopedia

Tool Receiving

Storage Order

SpaceChecking

Tool ReceivingException

ContainerUnloading

IncomingTools Analysis

ContainerQueued

StoragePlanning

CreatingStorage Order

Tool CribStore Space

Storage Plan

In Case ofException

If No Space

Page 37: Fcs - Encyclopedia

Tool Crib Process

Tool AllocationPlanning

Keep Tool History

Tool Receiving

Tool issuingTools Set out

for Maintenance

Shop FloorTool

RequestReceived

Tools Scrapping

Tool InventoryUpdated

Tool Inventory

Tool Status /Location

ToolFabricated /Purchased

Tool fromShop Floor

ToolsArrival

Tool History

If New Tool

If DamagedIf BadTool

Page 38: Fcs - Encyclopedia

Tool Allocation Planning

Allocate Tools

Reordering Planning Issue PurchaseRequest

Notify Shop Floor

Stock Checking

Tool Allocation

Tool Inventory

Tool Assignment

If Tool and AlternateTool UnaivalableIf Tool Available

Page 39: Fcs - Encyclopedia

Tool Crib Process

Tool AllocationPlanning

Keep Tool History

Tool Receiving

Tool issuingTools Set out

for Maintenance

Shop FloorTool

RequestReceived

Tools Scrapping

Tool InventoryUpdated

Tool Inventory

Tool Status /Location

ToolFabricated /Purchased

Tool fromShop Floor

ToolsArrival

Tool History

If New Tool

If DamagedIf BadTool

Page 40: Fcs - Encyclopedia

Tool issuing

Request Transport

Container Loading Loading Rate ofFlow

Tools TransportRequest

Tool Crib WorkList

Upon Load

Completion

Page 41: Fcs - Encyclopedia

Job Shop Services

Job ShopServices

MaintenanceInspection TransportStores

InspectionProcess

Tool Crib

MaintenanceProcess

StoresProcess

TransportProcess

Tool CribProcess

Page 42: Fcs - Encyclopedia

Transport Process

Direct Control ofAutomated Transport

Dev ices

Transport Trend Data

Assignment Acceptedby Mat'l Handler

Set Mov e Standards

Transport EmpiricalData

TransportResorcesAllocated

Mov e ExecutingMov e OrderDispatched toMat'l Handler

Ev aluate TransportPerf ormance

Update EmpiricalData

Allocatie Resources TransportOrder

Executed

TransportResources

TransportRequestReceiv ed

Status Update

Page 43: Fcs - Encyclopedia

Allocate Resources

Transport SequencingMove RequestAnalysis

Assign TransportResources

Transport Order TransportAssignments

Transport PlanTransport Request

Page 44: Fcs - Encyclopedia

Transport Process

Direct Control ofAutomated Transport

Dev ices

Transport Trend Data

Assignment Acceptedby Mat'l Handler

Set Mov e Standards

Transport EmpiricalData

TransportResorcesAllocated

Mov e ExecutingMov e OrderDispatched toMat'l Handler

Ev aluate TransportPerf ormance

Update EmpiricalData

Allocatie Resources TransportOrder

Executed

TransportResources

TransportRequestReceiv ed

Status Update

Page 45: Fcs - Encyclopedia

Move Executing

Transp ExceptionReporting

Transp ResourcesReleasing

Start MovingReceive Items to beMoved

Transport PlanAnalysis

TransportResources

Container StatusMaterials & ToolsStatus

Transport Plan

On Exception

Upon MoveCompletion

Page 46: Fcs - Encyclopedia

Shop Floor

Shop Floor

WorkCenter

Machine

Job Shop

ProductionControl

Factory

Product

Part / Lot

MachineStep

RoutingStep

Page 47: Fcs - Encyclopedia

Work Center Context

Work Center Next WorkCenter

Last WorkCenter

Processing Steps

(Parts/Lots/Routing Step Execution)

Work Orders fromJob Shop

Feedback fromMachine

(Job/Process Step Execution)

Work Orders toMachine

Page 48: Fcs - Encyclopedia

Work Center Locations Map

Work Center Locations

Work CenterBuffer

Machine 1 Machine 2Machine 3

Conveyor

Page 49: Fcs - Encyclopedia

Work Center Process

WorkOrder

from Job

Shop

Work Center

Order

Completion

Notice

MU Requests

Monitoring

WorkCenter

Empirical Data

Update

Notify Problem to

Job ShopWork Center

Decisions Making

Assign Jobs to

Machines

Monitor Buffer

Operations

Parts StorageJob Monitoring

Require Lot

Transport

Work Center

Capacity Update

MU Performance

Analysis

Job Performance

Work Center

Empirical Data

Lot Transport

Request

Mfg. Unit

Performance

Service Order

Job Assignments

Work Center

Capacity

Job Rate of Flow

WorkOrder

Completed

Waiting for

Instructions

Upon Lot Completion

Upon Job Completion

Upon Parts

Receipt

Request from

Machine

Cannot

Proceed

Page 50: Fcs - Encyclopedia

Work Center Decisions Making

Schedule JobUpdate Queue

Work Center DecisionsMaking

Page 51: Fcs - Encyclopedia

Schedule Job

Machine Allocation

Requests Analysis

Evaluate Alternate

Machine and / or

Process Plan

Machine Capacity

Check

Job Sequencing

Job Queue Update

Machines

Assignments

Checking

Job & Buffer

Scheduling

No Action

Stop SchedulingRaise Exception

Raise Rerouting

Request

Machines

Assignments

Machine Load

Plan

Job Assignment

Machine

Requests

Machine

Capacity

Process Plan

Job Steps

Buffer Load Plan

No Availability

MachineOverload

MachineOverload

Page 52: Fcs - Encyclopedia

Work Center Process

WorkOrder

from Job

Shop

Work Center

Order

Completion

Notice

MU Requests

Monitoring

WorkCenter

Empirical Data

Update

Notify Problem to

Job ShopWork Center

Decisions Making

Assign Jobs to

Machines

Monitor Buffer

Operations

Parts StorageJob Monitoring

Require Lot

Transport

Work Center

Capacity Update

MU Performance

Analysis

Job Performance

Work Center

Empirical Data

Lot Transport

Request

Mfg. Unit

Performance

Service Order

Job Assignments

Work Center

Capacity

Job Rate of Flow

WorkOrder

Completed

Waiting for

Instructions

Upon Lot Completion

Upon Job Completion

Upon Parts

Receipt

Request from

Machine

Cannot

Proceed

Page 53: Fcs - Encyclopedia

Monitor Buffer Operations

Monitor BufferOperations

Buffer PickingBuffer Receiving

Page 54: Fcs - Encyclopedia

Buffer Receiving

Wait for

Instructions

Operator

Leaves

Buffer Area

Exception

Reporting

Operator Carries

Material

Finished

Lots/Parts

Storing

In-area Storage

Returned Tools

Storing

Scrap Storing

Lots / Parts

StatusTool StatusScrap Status

Operator

enters

Buffer

Area

Space not

Available

Page 55: Fcs - Encyclopedia

Monitor Buffer Operations

Monitor BufferOperations

Buffer PickingBuffer Receiving

Page 56: Fcs - Encyclopedia

Buffer Picking

Wait for

Instructions

Operator

Leaves

Buffer Area

Operator

enters

Buffer Area

Request Special

Equipment from

Job Shop

Special

Equipment

Receiving

Operator

Analyzes

Instructions

Material/Tools

Status Updating

Load

AccumulationException

Reporting

Delay ReportingMaterial / Tools

Status Update

Equipment

Request

Invalid Items

Buffer Pickup

Instructions

In Case of

Invalid Items

In Case of

Delay

Special Equipment

Required

Page 57: Fcs - Encyclopedia

Shop Floor

Shop Floor

WorkCenter

Machine

Job Shop

ProductionControl

Factory

Product

Part / Lot

MachineStep

RoutingStep

Page 58: Fcs - Encyclopedia

Machine Context

MachineBuffer Picking BufferReceiving

Work Ordersfrom

Work Center

ProcessingInstructions

Semi-Finished Semi-Finished / Finished

Page 59: Fcs - Encyclopedia

Machine Process

Wait f orInstructions

Operator InspectionReport Job CompletionNotif y Tool Control Tool Removal Request

Transportation

Update Job Status

Update MachineStatus

Notif y Foreman

Update OperatorStatus

Load / Run /Remov e Work

Piece

Job Arrives OperatorAv ailable

Report Start-up Setup MachineAcquire Tools

Upon Job Completion

In Case ofException

Page 60: Fcs - Encyclopedia

Machine Setup

Buffer Content

Pickup new Toolsfrom Buffer

Previous SetupTeardown

Store Old Toolsin Buffer

Notify toForeman

Machine Ready

Tools Setup

Setup Tuning

Pickup TestParts from

Buffer

First-PieceMachining

First-PieceInspecting

Machine Status

NegativeInspection

Page 61: Fcs - Encyclopedia

Machine Process

Wait f orInstructions

Operator InspectionReport Job CompletionNotif y Tool Control Tool Removal Request

Transportation

Update Job Status

Update MachineStatus

Notif y Foreman

Update OperatorStatus

Load / Run /Remov e Work

Piece

Job Arrives OperatorAv ailable

Report Start-up Setup MachineAcquire Tools

Upon Job Completion

In Case ofException

Page 62: Fcs - Encyclopedia

Load / Run / Remove Work Piece

Job Step Analysis

Replace ProcessPlan

Process PlanAnalysis

Wait forInstructions

Job Steps

House KeepingMachining

Raise Exception

Process Plan

Process PlanDeviations

No Replacement

InvalidProcess Plan

Page 63: Fcs - Encyclopedia

Machining Process

(For NC machines only)

Feed RateOverride

Parts Removalfrom the Machine

Inspection byOperator

Chip Making

Part Positioning

Tool Change

Part Setup

Job Rate ofFlow

Page 64: Fcs - Encyclopedia

Machine Process

Wait f orInstructions

Operator InspectionReport Job CompletionNotif y Tool Control Tool Removal Request

Transportation

Update Job Status

Update MachineStatus

Notif y Foreman

Update OperatorStatus

Load / Run /Remov e Work

Piece

Job Arrives OperatorAv ailable

Report Start-up Setup MachineAcquire Tools

Upon Job Completion

In Case ofException

Page 65: Fcs - Encyclopedia

Operator Inspection

Part Inspection Bad PartHandling

Lot StatisticsPart Counting

Part

Rework

Lot Statistics

Conditioning

Scrap

Part Status

LotCompleted

Lot not Completed

Part notCompliant

Page 66: Fcs - Encyclopedia

APPLICATION LAYER

Page 67: Fcs - Encyclopedia

Batch Manufacturing

ManufacturingAutomation

ManufacturingTools

BatchManufacturing

Shop FloorControl System

Shop FloorControl

MfgEngineering

Page 68: Fcs - Encyclopedia

Manufacturing Engineering

ProcessPlanning

MfgEngineering

NCProgramming

Robotics GroupTechnology

Plant LayoutRouting

Page 69: Fcs - Encyclopedia

Batch Manufacturing

ManufacturingAutomation

ManufacturingTools

BatchManufacturing

Shop FloorControl System

Shop FloorControl

MfgEngineering

Page 70: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 71: Fcs - Encyclopedia

Production Control

Factory toProduction

Production toFactory

FactoryPerformance

Production PlanProduction Costs

Engineering Data

Manpower

Facility

Work Order

Product

Production

Control

ProductionShared Data crud

readscreates

updates

uses

creates

cu

crud

crud

creates

crud

Page 72: Fcs - Encyclopedia

Production Order Control

Production Control

HoursAccounting

Finance

ProductionOrder Control

Purchasing

InventoryControl

Hours Spent

Production Order

ProductionOrder Closing

Purchase Order

Supplier

IntegrationTransaction

Material

fulfills

Page 73: Fcs - Encyclopedia

Inventory Control

Inventory Control

Stock Flow

FactoryControl

Purchase Order

Material IssueRegistration

Material

Purchasing

(SIC)

StatisticalInventoryControl

issues

fulfills

Page 74: Fcs - Encyclopedia

Production Control

Factory toProduction

Production toFactory

FactoryPerformance

Production PlanProduction Costs

Engineering Data

Manpower

Facility

Work Order

Product

Production

Control

ProductionShared Data crud

readscreates

updates

uses

creates

cu

crud

crud

creates

crud

Page 75: Fcs - Encyclopedia

Factory to Production Flow

Factory toProduction

Accounting Data

ManpowerPerformance

Inventory Cost

Facility Usage MPS/MRP ChangeRequest

Material Usage

ProductionCompletions

CapacityConstraints

Factory RoF

Page 76: Fcs - Encyclopedia

Production Control

Factory toProduction

Production toFactory

FactoryPerformance

Production PlanProduction Costs

Engineering Data

Manpower

Facility

Work Order

Product

Production

Control

ProductionShared Data crud

readscreates

updates

uses

creates

cu

crud

crud

creates

crud

Page 77: Fcs - Encyclopedia

Work Order Flow

Work Order

ProductionControl

Work CenterControl

Job ShopControl

Factory Control

MasterProduction and

InventoryPlanning

RequirementsPlanning

AssemblyScheduling

StatisticalInventoryControl

translates product reqm'tinto part reqm't and

issues WO to job shop

splits factory WO intoworkcenter WO forspecific part reqm't

translates jobshop WOinto jobs to be assigned

to specific machines

issues to factory withproduct reqm't

Page 78: Fcs - Encyclopedia

Work Order Data Structure

Work Order Part In-process

Work Order RoFWork Order Timing

Work Center WorkOrder

Job Shop Work OrderProduction WorkOrder

Factory Work Order

Page 79: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 80: Fcs - Encyclopedia

Factory Control Context

FactoryControl

Product

Job Shop toFactory

Factory to JobShop

Routing

Facility

Job Shop LoadPlan

Production toFactory

Work Order

Dynamic FactoryData

Factory toProduction

Lot

crud

creates

creates

creates

updates

updatesupdates

creates

readscreates

reads

Page 81: Fcs - Encyclopedia

Factory Data Structure

Factory

Job Shop Performance

Factory Service Order

Factory Plans

Factory Empirical Data

Factory Service

Factory Trend Data

Product InventoryRaw MaterialInventory

Production Plan

Make or Buy Data

Manufacturing Costs

ProductMaterial

Page 82: Fcs - Encyclopedia

Manufacturing Costs

(Item)

Issue Cost

(Resource Units)

Maintenance Cost

(Lot)

Quality Cost

Manufacturing Costs

(Lot)

Move Cost

(Item)

Plastics Cost

(Activity)

Receipt Cost

(lot)

OutsideProcessing Cost

Resource Cost

(Item)

Metals Cost

(Item)

Direct Labor Cost

(Item)

All Other Costs

(Item)

Benefit Cost

Material Cost MaterialOverhead Cost

ResourceOverhead Cost

(Resource Value)

Equip. Depreciation Cost

Page 83: Fcs - Encyclopedia

Factory Control Sub-functions

Factory Control

JobShopControl Decision

Models

JobShopManpowerAllocationSupport

StatusReporting of

Special Tools &FixturesReceipts

Explosion of ProductReqmts into Parts

Finished PartsShippingReqmts

Planning

ProductPerformance

Analysis

Finished PartsInventory Planning

Parts Completion DateScheduling

Receive ProductCompletion

Requirements

JobShopCapacityPlanning

ProductsCompletion

Status Reporting

ReceiveJobShopFeedback

StatusReporting ofPurchased

Parts & Materials

JobShopPerformance

Analysis

JobShop ActualCapacityAnalysis

ProductCompletionNoti fication

Report ProductStatus

FactoryDecision Data

Updating

TransmitRequirements

Make/Buy AnalysisProduct ManufacturingSimulation

Grouping ofParts into Lots

Page 84: Fcs - Encyclopedia

Factory Control Context

FactoryControl

Product

Job Shop toFactory

Factory to JobShop

Facility

Job Shop LoadPlan

Production toFactory

Work Order

Routing

Dynamic FactoryData

Factory toProduction

Lot

crud

creates

creates

creates

updates

updatesupdates

creates

readscreates

reads

Page 85: Fcs - Encyclopedia

Production to Factory Flow

Equipment & FacilityBudget

Production toFactory

Product Reqm't

Manpower Budget

Page 86: Fcs - Encyclopedia

Factory Control Context

FactoryControl

Product

Job Shop toFactory

Factory to JobShop

Routing

Facility

Job Shop LoadPlan

Production toFactory

Work Order

Dynamic FactoryData

Factory toProduction

Lot

crud

creates

creates

creates

updates

updatesupdates

creates

readscreates

reads

Page 87: Fcs - Encyclopedia

Factory to Job Shop Flow

Factory to Job Shop

Job Shop Capacity Plan

Manpower Budget

Raw Material Availability

Part Reqm't

Equipment & FacilityBudget

Page 88: Fcs - Encyclopedia

Factory Control Context

FactoryControl

Product

Job Shop toFactory

Factory to JobShop

Routing

Facility

Job Shop LoadPlan

Production toFactory

Work Order

Dynamic FactoryData

Factory toProduction

Lot

crud

creates

creates

creates

updates

updatesupdates

creates

readscreates

reads

Page 89: Fcs - Encyclopedia

Job Shop to Factory Flow

Job Shop toFactory

Inventory Cost

Facility Usage

Material Usage

Part Completion

CapacityConstraints

Job Shop RoF

AssemblyCompletion

Accounting Data

ManpowerPerformance

Page 90: Fcs - Encyclopedia

Factory Control Context

FactoryControl

Product

Job Shop toFactory

Factory to JobShop

Routing

Facility

Job Shop LoadPlan

Production toFactory

Work Order

Dynamic FactoryData

Factory toProduction

Lot

crud

creates

creates

creates

updates

updatesupdates

creates

readscreates

reads

Page 91: Fcs - Encyclopedia

Dynamic Factory Data

Product LocationPart Location

Factory TrendData

Dynamic FactoryData

Make or Buy DataFactory EmpiricalData

Page 92: Fcs - Encyclopedia

Factory Control

FactoryControl

Product

Job Shop toFactory

Factory to JobShop

Routing

Facility

Job Shop LoadPlan

Production toFactory

Work Order

Dynamic FactoryData

Factory toProduction

Lot

crud

creates

creates

creates

updates

updatesupdates

creates

readscreates

reads

Page 93: Fcs - Encyclopedia

Routing Flow

Routing

Machine

Control

Work

Center

Control

Job Shop

Control

Factory

Control

deviations from routings may be neededto cope with manufacturing constraintsthey must be reported back for routingadjustment

assigns routing steps tothe workcenters

assigns routing steps tothe jobshops

defines the sequence ofoperation to be executed

to produce a product

Page 94: Fcs - Encyclopedia

Routing Data Structure

Routing

Factory Routing

Routing Step Routing PerformanceRouting Deviations

Work Center RoutingEquipment

Tool

Material

Job Shop Routing

Page 95: Fcs - Encyclopedia

Batch Manufacturing

ManufacturingAutomation

ManufacturingTools

BatchManufacturing

Shop FloorControl System

Shop FloorControl

MfgEngineering

Page 96: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 97: Fcs - Encyclopedia

Job Shop Control

Work Center to JobShop

Factory to JobShop

Job Shop to WorkCenter

Job Shop toFactory

Job ShopControl

Service Request

ManpowerJob Shop Service

Order

Material

Work Order

Job Shop SharedData

Dynamic JobShop Data

crud

readscreates

readscreates

crud

creates

crud

updates

updates

updates

Page 98: Fcs - Encyclopedia

Job Shop Control Sub-functions

Job Shop Control

Job Shop

Floor StoragePlanning

WorkCenterRouting-stepCompletionSchedule

WorkCenterManpowerAllocationSupport

WorkCenterActual Capacity

Analysis

Part Explosioninto

WorkCenterRqmts

WorkCenterPerformance

Analysis

Receive WorkCenters

Feedback

CriticalResourcesPlanning

WorkCenterCapacityPlanning

OrderCompletion

StatusReporting

Service GroupPerformance

Analysis

ReceiveFeedback from

Services

Receive PartCompletion

Reqmts

Work-in-process

InventoryPlanning

WorkCenterControl

DecisionModels

TransmitOrders to Work

Center

PartPerformance

Analysis

TransmitService

Requests

JobShopDecision Data

Updating

AlternateRouting

Selection

Material on-hand StatusReporting

PartCompletionReporting

Tool AvailabilityStatus

Reporting

Report PartStatus

Material & ToolAllocation

WorkCenterLoad Planning

Part MfgSimulation

Page 99: Fcs - Encyclopedia

Job Shop Data Structure

Job ShopJob Shop

Empirical Data

Job Shop Trend

Data

Service Groups

Material

Allocation Plan

Work Center

Capacity PlanWork Center

Load Plan

Critical

Resources PlanWIP Inventory

Plan

Job Shop Plans

Job Shop to

Factory

Tool Allocation

Plan

Job Shop to

Work Center

Page 100: Fcs - Encyclopedia

Service Groups Data Structure

Inspection TransportMaintenance Stores Tool Crib

Service Groups

Page 101: Fcs - Encyclopedia

Job Shop Control

Work Center to JobShop

Factory to JobShop

Job Shop to WorkCenter

Job Shop toFactory

Job ShopControl

Service Request

ManpowerJob Shop Service

Order

Material

Work Order

Job Shop SharedData

Dynamic JobShop Data

crud

readscreates

readscreates

crud

creates

crud

updates

updates

updates

Page 102: Fcs - Encyclopedia

Dynamic Job Shop Data

(for assigningworkcenters)

Job Shop Empirical Data

(withinjobshop)

Material LocationJob Shop Trend Data

Job Shop Load Plan

Dynamic Job Shop Data

Page 103: Fcs - Encyclopedia

Job Shop Control

Work Center to JobShop

Factory to JobShop

Job Shop to WorkCenter

Job Shop toFactory

Job ShopControl

Service Request

ManpowerJob Shop Service

Order

Material

Work Order

Job Shop SharedData

Dynamic JobShop Data

crud

readscreates

readscreates

crud

creates

crud

updates

updates

updates

Page 104: Fcs - Encyclopedia

Service Request Flow

Service Request

Maintenance

Control

Inspection

ControlTransport

Control

Production

ControlFactory

Control

Job Shop

Control

Work

Center

Control

Buffer

ControlMachine

Control

Tool Crib

ControlStores

Control

Inspection

Request

Tool Crib

RequestTransport

Request

Maintenance

RequestStores Request

fulfills the request

issues a request toworkcenter control

fulfills the requestfulfills the request

issues a request toworkcenter control

dispatches the requests frommachine and buffer to

jobshop

dispatches the request tothe relevant service

fulfills the request fulfills the request

Page 105: Fcs - Encyclopedia

Job Shop Control

Work Center to JobShop

Factory to JobShop

Job Shop to WorkCenter

Job Shop toFactory

Job ShopControl

Service Request

ManpowerJob Shop Service

Order

Material

Work Order

Job Shop SharedData

Dynamic JobShop Data

crud

readscreates

readscreates

crud

creates

crud

updates

updates

updates

Page 106: Fcs - Encyclopedia

Work Center to Job Shop Flow

(arrival / departure)

Lot Schedule

Work Center to

Job Shop

Accounting DataWork Center

Utilization

Work Center

EfficiencyCapacity

Constraints

Service Received

(arrival)

Material

Schedule

Problems /

Delays

Service Group

RequestProcess Step

CompletionWork Center

Capacity

Work Center

RoF

Page 107: Fcs - Encyclopedia

Job Shop Control

Work Center to JobShop

Factory to JobShop

Job Shop to WorkCenter

Job Shop toFactory

Job ShopControl

Service Request

ManpowerJob Shop Service

Order

Material

Work Order

Job Shop SharedData

Dynamic JobShop Data

crud

readscreates

readscreates

crud

creates

crud

updates

updates

updates

Page 108: Fcs - Encyclopedia

Job Shop to Work Center Flow

Job Shop to Work Center

(arrival / departure)

Lot Schedule

(to workcenter)

Manpower Assignment

Page 109: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 110: Fcs - Encyclopedia

Job Shop Services Sub-functions

Job Shop Services

Receive

Service

Requests

Repair Parts

Inventory

Planning

Service

Requests

Scheduling

Service

Requests

Classification

Tool Inventory

Planning

Equipment

Allocation

Material

Allocation to

Requests

Analyze

Stores

Requests

Conditions

Random

Patterns

Generation

Display

Service Status

Inspection

Impact

Analysis

Resources

Allocation

Service Plans

Creation

Material

Inventory

Planning

Tools

Allocation

Transmit

Service

Requests

Page 111: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 112: Fcs - Encyclopedia

Tool Crib Control

Tool CribControl

Work Center toTool Crib

Tool Crib to WorkCenter

Tool Crib to JobShop

Job Shop to ToolCrib

Equipment

Tool Crib SharedData

Container In-use

Manpower

Tool Crib Job

Dynamic Tool CribData

Tool Crib Request

readscreates

readscreates

crud

crud

updates

crud

crud

crud

updates

Page 113: Fcs - Encyclopedia

Tool Crib Data Structure

Tool Crib

Empirical Data

Tool Crib Order Tool Crib Plan Tool Crib

Exception

Tool Crib Job

Tool Crib Store

Tool Crib Trend

Data

Tool Crib

Tool Crib

Capacity

Page 114: Fcs - Encyclopedia

Tool Crib Control Sub-functions

Tool CribControlDisplay ToolCrib

OrdersDisplay ToolAssignment

Status

Report ToolsPickUp / Delivery

Record ToolsReceived

Report InvalidToolCrib Items

RecordOutgoing Tools

Log-off ToolCribOperator

Record SpecialToolCrib Charge

Log-on ToolCribOperator

Page 115: Fcs - Encyclopedia

Tool Crib Control

Tool CribControl

Work Center toTool Crib

Tool Crib to WorkCenter

Tool Crib to JobShop

Job Shop to ToolCrib

Equipment

Tool Crib SharedData

Container In-use

Manpower

Tool Crib Job

Dynamic Tool CribData

Tool Crib Request

readscreates

readscreates

crud

crud

updates

crud

crud

crud

updates

Page 116: Fcs - Encyclopedia

Tool Crib to Job Shop Flow

Tool Crib to Job Shop

(sent toworkcenter)

ToolTool Availability Tool Crib RoF

Page 117: Fcs - Encyclopedia

Tool Crib Control

Tool CribControl

Work Center toTool Crib

Tool Crib to WorkCenter

Tool Crib to JobShop

Job Shop to ToolCrib

Equipment

Tool Crib SharedData

Container In-use

Manpower

Tool Crib Job

Dynamic Tool CribData

Tool Crib Request

readscreates

readscreates

crud

crud

updates

crud

crud

crud

updates

Page 118: Fcs - Encyclopedia

Work Center to Tool Crib Flow

Tool UsageTool BreakageTool Reqm't

Work Center to ToolCrib

Page 119: Fcs - Encyclopedia

Tool Crib Control

Tool CribControl

Work Center toTool Crib

Tool Crib to WorkCenter

Tool Crib to JobShop

Job Shop to ToolCrib

Equipment

Tool Crib SharedData

Container In-use

Manpower

Tool Crib Job

Dynamic Tool CribData

Tool Crib Request

readscreates

readscreates

crud

crud

updates

crud

crud

crud

updates

Page 120: Fcs - Encyclopedia

Tool Crib to Work Center Flow

Tool Return RequestTool Sent Notice

Tool Crib to Work Center

Page 121: Fcs - Encyclopedia

Tool Crib Control

Tool CribControl

Work Center toTool Crib

Tool Crib to WorkCenter

Tool Crib to JobShop

Job Shop to ToolCrib

Equipment

Tool Crib SharedData

Container In-use

Manpower

Tool Crib Job

Dynamic Tool CribData

Tool Crib Request

readscreates

readscreates

crud

crud

updates

crud

crud

crud

updates

Page 122: Fcs - Encyclopedia

Dynamic Tool Crib Data

(includesNC tapes)

Tool Location

Tool Crib Worklist

ResourcesAllocation

Tool Life Data

Tool Maint Data

Tool CribEmpirical Data

Dynamic ToolCrib Data

Page 123: Fcs - Encyclopedia

Tool Crib Control

Tool CribControl

Work Center toTool Crib

Tool Crib to WorkCenter

Tool Crib to JobShop

Job Shop to ToolCrib

Equipment

Tool Crib SharedData

Container In-use

Manpower

Tool Crib Job

Dynamic Tool CribData

Tool Crib Request

readscreates

readscreates

crud

crud

updates

crud

crud

crud

updates

Page 124: Fcs - Encyclopedia

Tool Crib Shared Data

Expected NewTools

(data)

Tool Application

Tool RepairRequest

Tool InventoryTool Shortage

Accounting Data

ManpowerAttendance

Tool Crib SharedData

Page 125: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 126: Fcs - Encyclopedia

Stores Control

Job Shop to

Stores

Stores to Work

Center

Stores to Job

Shop

Work Center to

Stores

Stores

Control

Dynamic Stores

DataContainer In-use

Equipment In-use

Material

Stores Capacity

Stores Shared

Data

Manpower

Stores Job

creates reads

readscreates

crud

crudupdates

updates

updates

reads

updates

updates

Page 127: Fcs - Encyclopedia

Stores Data Structure

Stores Empirical

Data

Stores Inventory

Stores Job

Stores ExceptionStores Plan

Stores Trend

Data

Stores Order

Stores

Stores Request

Page 128: Fcs - Encyclopedia

Stores Control Sub-functions

Stores Control

Log-on Stores

Operator

Record

Material

Assignment

Display

Material

Assignments

Report

Material

Stored

Report

Material

Picked

Record

Special

Stores Charge

Report Invalid

Stores Items

Report Ready

Container

Log-off Stores

OperatorReport

Service Order

Status

Report Lot

Status

Display

Service Orders

Page 129: Fcs - Encyclopedia

Stores Control

Job Shop to

Stores

Stores to Work

Center

Stores to Job

Shop

Work Center to

Stores

Stores

Control

Dynamic Stores

DataContainer In-use

Equipment In-use

Material

Stores Capacity

Stores Shared

Data

Manpower

Stores Job

creates reads

readscreates

crud

crudupdates

updates

updates

reads

updates

updates

Page 130: Fcs - Encyclopedia

Stores to Job Shop Flow

Stores to Job Shop

Stores RoF

(received)

Paperwork

<filled>

Material Reqm't Capacity Constraints

Page 131: Fcs - Encyclopedia

Stores Control

Job Shop to

Stores

Stores to Work

Center

Stores to Job

Shop

Work Center to

Stores

Stores

Control

Dynamic Stores

DataContainer In-use

Equipment In-use

Material

Stores Capacity

Stores Shared

Data

Manpower

Stores Job

creates reads

readscreates

crud

crudupdates

updates

updates

reads

updates

updates

Page 132: Fcs - Encyclopedia

Job Shop to Stores Flow

Job Shop to Stores

Stores Order

Stores OrderQuantity

Stores OrderTiming

(required)

Raw Material

Page 133: Fcs - Encyclopedia

Stores Control

Job Shop to

Stores

Stores to Work

Center

Stores to Job

Shop

Work Center to

Stores

Stores

Control

Dynamic Stores

DataContainer In-use

Equipment In-use

Material

Stores Capacity

Stores Shared

Data

Manpower

Stores Job

creates reads

readscreates

crud

crudupdates

updates

updates

reads

updates

updates

Page 134: Fcs - Encyclopedia

Stores to Work Center Flow

Stores to Work Center

(sent)

Material Replacement

(sent)

Material In-processStores Order Status

Page 135: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 136: Fcs - Encyclopedia

Maintenance Control

MaintenanceControl

Manpower

DynamicMaintenance Data

Repair Part

Maint Shared Data

Maint Job

Machine

Material

Equipment

Maint to JobShop

Maint to WorkCenter

Maint RequestJob Shop toMaint

Work Center toMaint

creates

readscreates

updates

crud

crud

updates

updates

updates

crud

updates

Page 137: Fcs - Encyclopedia

Maintenance Data Structure

Maintenance

Maint Store

Maint ExceptionMaint Order Maint Plan

Repair PartMaint Trend Data

Maint EmpiricalData

Maint Job

Page 138: Fcs - Encyclopedia

Repair Part Data Structure

Repair Part Inventory Repair Part Request Repair Part Delivery

Repair Part

Page 139: Fcs - Encyclopedia

Maintenance Control Sub-functions

MaintenanceControl

Record MaiterialReceived

ReportMaintenance

Type

Record MaterialReturned /

Stored

DisplayMaintenance

Plan

Report InvalidMaint Items

Log-offMaintainer

Report MachineStatus

Display MaintAssignments

Status

Record SpecialMaint Charge

Log-onMaintainer

Record MaterialPicked

Page 140: Fcs - Encyclopedia

Maintenance Control

MaintenanceControl

Manpower

DynamicMaintenance Data

Repair Part

Maint Shared Data

Maint Job

Machine

Material

Equipment

Maint to JobShop

Maint to WorkCenter

Maint RequestJob Shop toMaint

Work Center toMaint

creates

readscreates

updates

crud

crud

updates

updates

updates

crud

updates

Page 141: Fcs - Encyclopedia

Maint to Job Shop Flow

Maint to Job Shop

Machine DownPM RequestMaint CompletionMaint RoFEstimated RepairTime

Page 142: Fcs - Encyclopedia

Maintenance Control

MaintenanceControl

Manpower

DynamicMaintenance Data

Repair Part

Maint Shared Data

Maint Job

Machine

Material

Equipment

Maint to JobShop

Maint to WorkCenter

Maint RequestJob Shop toMaint

Work Center toMaint

creates

readscreates

updates

crud

crud

updates

updates

updates

crud

updates

Page 143: Fcs - Encyclopedia

Work Center to Maint Flow

Work Center to Maint

Machine Utilization

(for PM)

Machine Allocation

Page 144: Fcs - Encyclopedia

Maintenance Control

MaintenanceControl

Manpower

DynamicMaintenance Data

Repair Part

Maint Shared Data

Maint Job

Machine

Material

Equipment

Maint to JobShop

Work Center toMaint

Maint to WorkCenter

Maint RequestJob Shop toMaint

creates

readscreates

updates

crud

crud

updates

updates

updates

crud

updates

Page 145: Fcs - Encyclopedia

Maint to Work Center Flow

Maint to Work Center

PM Request Maint TimesEstimate

Machine Down

Page 146: Fcs - Encyclopedia

Maintenance Control

MaintenanceControl

Manpower

DynamicMaintenance Data

Repair Part

Maint Shared Data

Maint Job

Machine

Material

Equipment

Maint to JobShop

Work Center toMaint

Maint to WorkCenter

Maint RequestJob Shop toMaint

creates

readscreates

updates

crud

crud

updates

updates

updates

crud

updates

Page 147: Fcs - Encyclopedia

Dynamic Maintenance Data

Maint Trend Data

Repair PartInventory

ResourcesAllocation

RepairmenWorklist

PM Plan

Maint EmpiricalData

DynamicMaintenance Data

Page 148: Fcs - Encyclopedia

Maintenance Control

MaintenanceControl

Manpower

DynamicMaintenance Data

Repair Part

Maint Shared Data

Maint Job

Machine

Material

Equipment

Maint to JobShop

Work Center toMaint

Maint to WorkCenter

Maint RequestJob Shop toMaint

creates

readscreates

updates

crud

crud

updates

updates

updates

crud

updates

Page 149: Fcs - Encyclopedia

Maintenance Shared Data

Equipment Order

Accounting DataMaterial Order

Manpower Attendance

(status)

Repair Part Inventory Repair Part Order

Maint Shared Data

Page 150: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 151: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 152: Fcs - Encyclopedia

Transport Data Structure

Transport

Transport Exception

Transport Order

TransportEmpirical Data

TransportAssignment

Transport Plan

Transport TrendData

Transport Request

Transport Job

Transport Store

Page 153: Fcs - Encyclopedia

Transport Control Sub-functions

RecordTransport

Special Charge

Record ReadyLoad

ReportComplete Move

Report LoadSorting Finished

DisplayTransport

Assignments

Report InvalidTransport Items

Log-offTransporter

RecordTransport

EquipmentAssignment

Log-onTransporter

TransportControl

Page 154: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 155: Fcs - Encyclopedia

Transport to Job Shop Flow

Transport to Job Shop

TransportStandards

<in transit>

Material

<complete>

Transport JobTransport RoF

(expectedarrival time)

TransportSchedule

Page 156: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 157: Fcs - Encyclopedia

Job Shop to Transport Flow

Job Shop to Transport

Material SizeContainer Reqm'tTransport Request

Page 158: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 159: Fcs - Encyclopedia

Work Center to Transport Flow

Work Center to Transport

Material Size Container Reqm'tTransport Request

Page 160: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 161: Fcs - Encyclopedia

Transport to Work Center Flow

Transport to Work Center

Delivery TimePick-up Time

Page 162: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 163: Fcs - Encyclopedia

Dynamic Transportation Data

(worker)

Manpower Assignment

Resources Allocation

Transport Empirical Data

Route Instructions

Dynamic TransportationData

Page 164: Fcs - Encyclopedia

Transport Control

Work Center toTransport

Job Shop toTransport

Transport to WorkCenter

Transport to JobShop

TransportControl

Facility

Equipment In-use

Container In-use

Transport Load

Manpower

Transport SharedData

TransportResources

DynamicTransportationData

readscreates

readscreates

crud

crudupdates

updates

crud

reads

updates

Page 165: Fcs - Encyclopedia

Transport Shared Data

(in for)

Facility LayoutAccounting Data Manpower Attendance

Transport SharedData

Page 166: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 167: Fcs - Encyclopedia

Inspection Control

Work CenterControl

Job ShopControl

InspectionControl

Work Center toInspection

Inspection to WorkCenter

Inspection to JobShop

Job Shop toInspection

reads creates

reads creates

readscreates

readscreates

Page 168: Fcs - Encyclopedia

Inspection Application Functions

Report InvalidInspection

Item

ReportInspected

Part Status

ReportInspection In-

process

RecordEquipmentAss ignment

ReportReady

Machine

DisplayInspection

Plan

Report Itemsto be Moved

Record LotsReady

ReportReady

Equipment

EquipmentReleas ing

LotReleas ing

InspectionExecution

Parts /LotReceiving

AllocatieResources

InspectionExceptionReporting

In ProcessInspection

InspectionsPlanning

Page 169: Fcs - Encyclopedia

Inspection Data Structure

Inspection Plan

Inspection Order

Inspection Job

Inspection

Resources

Inspection

Request

Inspection

Empirical Data

Inspection Trend

Data

Inspection Store

Inspection

Dynamic

Inspection Data

Inspection

Shared Data

Page 170: Fcs - Encyclopedia

Resources Data Structure

Tool MaterialManpower Equipment Container

Lot Part

Resources

Consumable Raw Material

Page 171: Fcs - Encyclopedia

Manpower Data Structure

Manpower Request

Manpower Attendance Manpower

ManpowerPerformance

Manpower Availability

Manpower Usage Manpower Assignment Manpower Allocation

Manpower Location

Page 172: Fcs - Encyclopedia

Resources Data Structure

Tool MaterialManpower Equipment Container

Lot Part

Resources

Consumable Raw Material

Page 173: Fcs - Encyclopedia

Tool Data Structure

Tool

Engineering Data

Tool In-shop

Tool AvailabilityTool Assignment Tool Allocation

Tool UsageTool In-store

Tool Crib

Page 174: Fcs - Encyclopedia

Resources Data Structure

Tool MaterialManpower Equipment Container

Lot Part

Resources

Consumable Raw Material

Page 175: Fcs - Encyclopedia

Material Data Structure

Material Allocation MaterialAssignment

Material Order

Consumable Lot

Material

Raw Material

Page 176: Fcs - Encyclopedia

Resources Data Structure

Tool MaterialManpower Equipment Container

Lot Part

Resources

Consumable Raw Material

Page 177: Fcs - Encyclopedia

Equipment Data Structure

Equipment In-useEquipment

Equipment In-store

EquipmentCalibration

EquipmentStatus

EquipmentAvailability

EquipmentAssignment

EquipmentReqm't

EquipmentUsage

EquipmentAllocation

Work Order

EquipmentLocation

for

Page 178: Fcs - Encyclopedia

Resources Data Structure

Tool MaterialManpower Equipment Container

Lot Part

Resources

Consumable Raw Material

Page 179: Fcs - Encyclopedia

Container Data Structure

Container In-use Container Reqm't

Container

Container In-store

Container Status

ContainerAssignment

ContainerAllocation

Container UsageContainerAvailability

Page 180: Fcs - Encyclopedia

Resources Data Structure

Tool MaterialManpower Equipment Container

Lot Part

Resources

Consumable Raw Material

Page 181: Fcs - Encyclopedia

Part Data Structure

Lot Part In-processPart

Part Performance

Part Reqm't PartAssignment

Part Allocation

Quality Assurance

Part In-store

Part Availability

Test Procedure

Quality Specs

QualityProcedure

Page 182: Fcs - Encyclopedia

Lot Data Structure

Material

Lot In-store

Lot

Lot In-process

Part

Page 183: Fcs - Encyclopedia

Inspection Data Structure

Inspection Plan

Inspection Order

Inspection Job

Inspection

Resources

Inspection

Request

Inspection

Empirical Data

Inspection Trend

Data

Inspection Store

Inspection

Dynamic

Inspection Data

Inspection

Shared Data

Page 184: Fcs - Encyclopedia

Dynamic Inspection Data

Dynamic Inspection Data

Random SelectionPatterns

Inspection WorklistResources Status

Resources Allocation

Page 185: Fcs - Encyclopedia

Inspection Data Structure

Inspection Plan

Inspection Order

Inspection Job

Inspection

Resources

Inspection

Request

Inspection

Empirical Data

Inspection Trend

Data

Inspection Store

Inspection

Dynamic

Inspection Data

Inspection

Shared Data

Page 186: Fcs - Encyclopedia

Inspection Shared Data

Inspection Criteria

Quality Trend

Inspection SharedData

Accounting Data

Manpower Attendance

Page 187: Fcs - Encyclopedia

Inspection Control Functions

Log-off

Inspector

Record

Special

Inspection

Charge

Record Lots

Ready

Report Items

to be Moved

Display

Inspection

Plan

Report Ready

Machine

Record

Equipment

Assignment

Report

Inspection In-

process

Report

Inspected

Part Status

Report Invalid

Inspection

Item

Report Ready

Equipment

Log-on

Inspector

Inspection

Control

Inspection

Control

Component

Page 188: Fcs - Encyclopedia

Inspection Control

Work CenterControl

Job ShopControl

InspectionControl

Work Center toInspection

Inspection to WorkCenter

Inspection to JobShop

Job Shop toInspection

reads creates

reads creates

readscreates

readscreates

Page 189: Fcs - Encyclopedia

Inspection to Job Shop Flow

Inspection to Job Shop

(arrival / departure)

Lot ScheduleInspection DelaysInspectionCompletion

Inspection RoF

Page 190: Fcs - Encyclopedia

Inspection Control

Work CenterControl

Job ShopControl

InspectionControl

Work Center toInspection

Inspection to WorkCenter

Inspection to JobShop

Job Shop toInspection

reads creates

reads creates

readscreates

readscreates

Page 191: Fcs - Encyclopedia

Inspection to Work Center Flow

Inspection CompletionBad Machine Notice

Inspection to Work Center

Page 192: Fcs - Encyclopedia

Inspection Control

Work CenterControl

Job ShopControl

InspectionControl

Work Center toInspection

Inspection to WorkCenter

Inspection to JobShop

Job Shop toInspection

reads creates

reads creates

readscreates

readscreates

Page 193: Fcs - Encyclopedia

Job Shop to Inspection Flow

Job Shop to Inspection

(arrivaldeparture)

Lot RequirementsInspection Request

Page 194: Fcs - Encyclopedia

Inspection Control

Work CenterControl

Job ShopControl

InspectionControl

Work Center toInspection

Inspection to WorkCenter

Inspection to JobShop

Job Shop toInspection

reads creates

reads creates

readscreates

readscreates

Page 195: Fcs - Encyclopedia

Work Center to Inspection Flow

Work Center to Inspection

Machine CodeInspection Request

Page 196: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 197: Fcs - Encyclopedia

Work Center Control

Work CenterControl

Work Center to JobShop

Job Shop to WorkCenter

Machine to WorkCenter

Work Center toMachine

Dynamic WorkCenter Data

Work CenterShared Data

Process Plan

Job

Part In-process

Work OrderCapacity Plan

Buffer

Material

Service Groups

readscreates

crud

crud

createsreads

ru

ru

crud

crud

creates

crud

updates

Page 198: Fcs - Encyclopedia

Work Center Data Structure

Work Center

Work Center Rollup

Work CenterAssignment

Work CenterExceptions

Work Center Plans

Work CenterPerformance

Work CenterAllocation

Work CenterManpower

Work Center TrendData

Service Request

Machine ControlDecision Model

Work CenterCapacity

Work CenterEmpirical Data

Work OrderCompletion

Process PlanDeviations

Facility Usage

Resource Utilization

Area Status

Work CenterLocation

Page 199: Fcs - Encyclopedia

Work Center Plans

Work Center Plans

Machine Load PlanManpower Capacity Plan In-area Storage PlanMachine Capacity Plan

Page 200: Fcs - Encyclopedia

Work Center Control Sub-functions

Work Center Control

Report Routeand Processing

Status

Part ProcessingPerformance

Analysis

Receive Routingand Processing

Reqmts

In-area StatusReporting of

Materials, Parts& Tools

WorkCenterProcessingCompletionReporting

Simulation &Decision Data

Updating

StatisticalAnalysis

MfgUnit ControlDecision Model

Job Assignmentto Man /Machine

Man toMachine

Assignment

MachineCapacityPlanning

StagingInstructions

ManpowerAvailabil ityMonitoring

MfgUnitRateOfFlow

Measurement

Process PlanStep

Scheduling

ManpowerCapacityPlanning

Receive Mfg.Unit Feedback

Single RoutingStep

Simulation

Job StagingPerformance

Analysis

MachineLoading

ManpowerLoading

MfgUnitPerformance

Analysis

TransmitReqmts &

Instructions

MachineAvailabil ityMonitoring

In-areaStoragePlanning

Machine Off-loading

Routing StepExplosion

Job Prioritizing

Page 201: Fcs - Encyclopedia

Work Center Operations

Load / Run /Remove

Work Piece

Work CenterOperations

MachineControl

Job Control

OperatorInspection

Process PlanDeviations

BufferControl

Part ProcessPlan

Assign Jobto Operator /

Machine

Part Job Steps

Lot Statistics

MachineAssignment

MachineBacklog

SpecialCondition

Note toForeman

updates

Page 202: Fcs - Encyclopedia

Work Center Control

Work CenterControl

Work Center to JobShop

Job Shop to WorkCenter

Machine to WorkCenter

Work Center toMachine

Dynamic WorkCenter Data

Work CenterShared Data

Process Plan

Job

Part In-process

Work OrderCapacity Plan

Buffer

Material

Service Groups

readscreates

crud

crud

createsreads

ru

ru

crud

crud

creates

crud

updates

Page 203: Fcs - Encyclopedia

Machine to Work Center Flow

Machine to Work Center Accounting Data

Rework Request Job Completion

<operator available>

ManpowerAvailability

Lot Split Request

Service Request

(machine available)

Machine Availability

Assistance Request

Tool Release

Tool Breakage

Job Acceptance

Page 204: Fcs - Encyclopedia

Work Center Control

Work CenterControl

Work Center to JobShop

Job Shop to WorkCenter

Machine to WorkCenter

Work Center toMachine

Dynamic WorkCenter Data

Work CenterShared Data

Process Plan

Job

Part In-process

Work OrderCapacity Plan

Buffer

Material

Service Groups

readscreates

crud

crud

createsreads

ru

ru

crud

crud

creates

crud

updates

Page 205: Fcs - Encyclopedia

Work Center to Machine Flow

Work Center to Machine

Job Assignment Job PriorityMachine OperatorAssignment

Page 206: Fcs - Encyclopedia

Work Center Control

Work CenterControl

Work Center to JobShop

Job Shop to WorkCenter

Machine to WorkCenter

Work Center toMachine

Dynamic WorkCenter Data

Work CenterShared Data

Process Plan

Job

Part In-process

Work OrderCapacity Plan

Buffer

Material

Service Groups

readscreates

crud

crud

createsreads

ru

ru

crud

crud

creates

crud

updates

Page 207: Fcs - Encyclopedia

Dynamic Work Center Data

Work Center TrendData

(for loadingmachines)

Work CenterEmpirical Data

(withinworkcenter)

Material LocationAlternate Machines

(mfg. capacity)

Work CenterCapacity

Work Center LoadPlan

Dynamic WorkCenter Data

Page 208: Fcs - Encyclopedia

Work Center Control

Work CenterControl

Work Center to JobShop

Job Shop to WorkCenter

Machine to WorkCenter

Work Center toMachine

Dynamic WorkCenter Data

Work CenterShared Data

Process Plan

Job

Part In-process

Work OrderCapacity Plan

Buffer

Material

Service Groups

readscreates

crud

crud

createsreads

ru

ru

crud

crud

creates

crud

updates

Page 209: Fcs - Encyclopedia

Work Center Shared Data

Work Center Shared Data Process Plan DeviationsAccounting Data

Page 210: Fcs - Encyclopedia

Work Center Control

Work CenterControl

Work Center to JobShop

Job Shop to WorkCenter

Machine to WorkCenter

Work Center toMachine

Dynamic WorkCenter Data

Work CenterShared Data

Process Plan

Job

Part In-process

Work OrderCapacity Plan

Buffer

Material

Service Groups

readscreates

crud

crud

createsreads

ru

ru

crud

crud

creates

crud

updates

Page 211: Fcs - Encyclopedia

Process Plan Flow

Process Plan

Production

ControlFactory

Control

Job Shop

Control

Work

Center

Control

Machine

Control

deviations from PP may occur during jobexecution.

they must be reported back for PP adjustment

despatches the PP toworkcenter accordingto operations routing

selects the PP needed bythe work orders and make

them available to jobshop

recives PP from mfg.engineering and

makesthem iavailable to

factory control

despatches PP steps tomachines according to

the assigned jobs

Page 212: Fcs - Encyclopedia

Process Plan Data Structure

Process Performance

Process PlanDeviations

Process Plan Step

Process Plan

Process StepDeviation

Process

Production ProcessPlan

Job Shop ProcessPlan

Machine Process PlanFactory Process Plan Work Center ProcessPlan

Page 213: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 214: Fcs - Encyclopedia

Buffer Control Sub-functions

Buffer Control

Log-on Buffer

Operator

Record Buffer

Equipment

Assignment

Reprt

Complete

Buffer

Operation

Record

Equipment

Location

Report Invalid

ItemsReport Ready

Buffer Items

Report

Transfer

Material

Display Buffer

Assignments

Record

Special Buffer

Charge

Log-off Buffer

Operator

Receive

Incoming Load

Analyze

Buffer

Requests

Receive

Outgoing Load

Buffer

Buffer Request

Equipment In-

use

Page 215: Fcs - Encyclopedia

Buffer Data Structure

BufferBuffer Order

Pick-upInstructions

StorageInstructions

Buffer Request

EquipmentReqm't

BufferDelay Report

Equipment In-use

Buffer Item StagingInstructions

Buffer Load Plan

Buffer Capacity

Buffer Shelf

Page 216: Fcs - Encyclopedia

Buffer Order Data Structure

Buffer Order

Buffer Item

Buffer StorageOrder

Buffer Pick-upOrder

Buffer OrderTiming

Pick-upInstructions

Buffer DeliveryOrder

Page 217: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 218: Fcs - Encyclopedia

Machine Control

Setup

Machine Control

(split request)

Lot In-process

Capacity Plan

Machine Rollup Data

Job Step

Resources

Machine to WorkCenter

Work Center toMachineDynamic Machine

Data

readscreatescrud

updates

crud

updates

updates

updates

updates

Page 219: Fcs - Encyclopedia

Machine Data Structure

MachinePerformance

Machine

MachineAssignment

Machine Request

Machine TrendData

Machine FeedbackMachine Exceptions

Machine Allocation

Machine EmpiricalData

Machine Availability

Service Request

Page 220: Fcs - Encyclopedia

Machine Control Sub-functions

Machine Control

Display Machine

Assignment to

Operator

Record Ready

Job

Submit

Container or

Special Handling

Equipment Reqs

Display

Projected Job

Schedule

Record Ready

Lots / Rework /

Scrap

Report

Performance to

OperatorProjected

Completion Time

Display Tool &

Material

Assignment

Display Backlog

Assignment

Record

Operation in Area

Record Operator

Interrupts

Record

Inspection

Exception

Record Machine

Interrupts

Submit Setup

Change-over

Reqmts

Display Job

Assignment to

Operator

Record Machine

Up Status

Report Job

Status

Record Alternate

Process

Record Process

Plan Deviations

Record Invalid

ProcessReceive Tools &

Material

Report Job

Complete

Calculate

RateOfFlow

Record Piece

Completion

For automatic

machine tools

Direct Processing

Record new

Setup Start

Record Invalid

Tools

Display Job

Instructions

Record

Selected Job

Record Invalid

Material

Record Special

Charge

Record Job Start

Report Tools

Transfer

Record Tear-

down

Record Job

Assignment

Log-on Operator

Log-off Operator

Page 221: Fcs - Encyclopedia

Machine Control

Setup

Machine Control

(split request)

Lot In-process

Capacity Plan

Machine Rollup Data

Job Step

Resources

Machine to WorkCenter

Work Center toMachineDynamic Machine

Data

readscreatescrud

updates

crud

updates

updates

updates

updates

Page 222: Fcs - Encyclopedia

Machine Rollup Data

Job Step Completion

Equipment Usage

Manpower Usage

Part Scrapped Count

Process Plan StepDeviation

Raw Material Usage

Machine Idle Time

(at job completion)

Machine Rollup Data

Page 223: Fcs - Encyclopedia

Shop Floor Control

Shop FloorControl

MaintenanceControl

InspectionControl

ProductionControl

Job ShopServices

TransportControl

MaintenanceControl

Component

JobShop

Control

WorkCenterControl

BufferControl

MachineControl

JobControl

FactoryControl

WorkCenter

StoresControl

ToolCrib

Control

FactoryControl

Application

Job ShopControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

WorkCenterControl

Component

Buf ferControl

Component

Page 224: Fcs - Encyclopedia

Job Control

Job Control

Equipment In-use

Process Plan

Material

Job Schedule

Job Deviations

updates

updates

updates

updates

crud

Page 225: Fcs - Encyclopedia

Job Data Structure

Job

Job Accounting DataJob Assignment

Job Step

Job Type

Job Schedule

Operator

Machine

Job Deviations

Scrap Tear DownProcess Rework SetupDirectProcessing

Page 226: Fcs - Encyclopedia

Batch Manufacturing

ManufacturingAutomation

ManufacturingTools

BatchManufacturing

Shop FloorControl System

MfgEngineering

Shop FloorControl

Page 227: Fcs - Encyclopedia

Manufacturing Tools

Production Solutions

FlexibleManufacturing

Methodologies

ManufacturingTools

QualityAssurance

DemandForecasting

ProductConfigurator

ProductionCosts

Accounting

LaborAccounting

FactoryAutomation

EngineeringData Mgt

Facility &Equipment

Planning

Bill ofMaterial

ItemControl

ProductClassif icatio

n

LeanManufacturing

ProductionBudget

JIT

Page 228: Fcs - Encyclopedia

Batch Manufacturing

ManufacturingAutomation

ManufacturingTools

BatchManufacturing

Shop FloorControl System

MfgEngineering

Shop FloorControl

Page 229: Fcs - Encyclopedia

Shop Floor Control System

Job ShopControl

Application

FactoryControl

Application

WorkCenter

Application

Job ShopServices

Application

Shop FloorControlSystem

BufferControl

Component

WorkCenterControl

Component

MachineControl

Component

Job ControlComponent

Tool CribControl

Component

TransportControl

Component

StoresControl

Component

Maintenance Control

Component

InspectionControl

Component

Page 230: Fcs - Encyclopedia

Tool Crib Control Component

Tool Crib ControlComponent

Log-on ToolCribOperator

Record SpecialToolCrib Charge

Log-off ToolCribOperator

Record OutgoingTools

Report InvalidToolCrib Items

Record ToolsReceived

Report ToolsPickUp / Delivery

Display ToolAssignment Status

Display ToolCribOrders

Page 231: Fcs - Encyclopedia

Batch Manufacturing

ManufacturingAutomation

ManufacturingTools

BatchManufacturing

Shop FloorControl System

MfgEngineering

Shop FloorControl

Warehousing

Page 232: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

WarehouseReceipt

AllocationControlling

Inbound Control

WarehouseDelivery

Page 233: Fcs - Encyclopedia

Inbound Control

Inbound Control

Stock Movements /Adjustments

Stock ControlStock Movements /Adjustments

Stock Flow

Page 234: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 235: Fcs - Encyclopedia

Warehouse Replenishment

Stock Flow

Warehouse Replenishment

Material

Material

Requirement /ConstraintPlanning

Replacement Order

ControlInboundMaterial

Control Stock/ Location

(Repl.)

ControlMaterialPicking

(Repl.)

ControlReceipts

Material Receipt

Page 236: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 237: Fcs - Encyclopedia

Warehouse Receipt

Goods Flow

Suppliers

Warehouse Receipt

Carriers DeliverGoods

Allocate Goods

Purchasing

Goods -ToBeAllocated

(purchased)

Receive Goods

NegotiatedAgreemeent

Receipt Note

Goods -ToBeReceived

Invoice

Page 238: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 239: Fcs - Encyclopedia

Warehouse Production Materials

Warehouse Production Materials

Production

Stock Flow

Material

Material

(Prod.)

ControlReceipts

(Prod.)

ControlMaterialPicking

Work OrderControl

Work OrderProductionOperation

Control

Page 240: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 241: Fcs - Encyclopedia

Cutomer Returns

Customer Returns

Customer Return Order

Sales Order ChangeRequest

Credit Note

Carriers ReturnGoods

Sales InvoiceHandling

Inbound Control

Goods

Orders Issuing

(Cust. Returns)

AllocationControl

Customers

CustomerOrderlines

(Cust. Returns)

Receipt Control

Stock Data

Stock FlowGoods

acceptsallocatesissues

maintains

Page 242: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 243: Fcs - Encyclopedia

Warehouse Delivery

Warehouse Delivery

Goods

Sales Orderlines

Goods

Carriers

Customers

Finished ProductsFlow

Packing Flow Shipping Flow

AssemblyScheduling

CarriersDeliverGoods

PackingControl

(Sales)

ControlMateerialPicking

ShippingControl

CustomersReceiveGoods

Page 244: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 245: Fcs - Encyclopedia

Storage Inspection

Stock Flow

Stock ControlStorageInspection

Storage Inspection Order

Page 246: Fcs - Encyclopedia

Warehousing Services

Warehousing

StatisticalInventory Control

Supplier Returns

CutomerReturns

WarehouseReplenishment

Stock Control

WarehouseProductionMaterials

StorageInspection

Cycle Counting

Inbound Control WarehouseReceipt

AllocationControlling

WarehouseDelivery

Page 247: Fcs - Encyclopedia

Supplier Returns

Warehouse Receipt

Supplier Return Orde

Picking Flow

InboundControl

Suppliers

Shipping Flow

Carriers

SupplierReturns

Packing Flow

Return OrderIssuing

CarriersDeliverReturns

Stock Data

Supplier ReturnOrderReturn Orderl

Lines

updates

manages

maintains

Page 248: Fcs - Encyclopedia

INFRASTRUCTURE LAYER

Page 249: Fcs - Encyclopedia

Shop Floor Nodes

Work CenterServer

Work CenterControl

Component

MaintenanceControl

Component

MaintenanceServer

StoresServer

TransportServer

FactoryServer

Job ShopServer

Job ShopControl

Application

FactoryControl

Application

InspectionControl

Component

StoresControl

Component

TransportControl

Component

Tool CribControl

Component

Job ControlComponent

MachineControl

Component

BufferControl

Component

InspectionServer

Tool CribServer

Page 250: Fcs - Encyclopedia

Shop Floor Network

LAN

Work CenterIntranet

Work CenterServer

Job ShopIntranet

Work CenterPC

FactoryIntranet

FactoryPC

MaintenancePC

Job ShopPC

MaintenanceServer

MacjineController

Inspection PC

ProductionHost

InspectionServer

FactoryServer

TransportPC

Tool CribPC

StoresServer

TransportServer

Tool CribServer

Job ShopServer

StoresPC

MaintenanceHub

Inspection Hub

FactoryHub

Job ShopHub

Tool CribHub

Stores Hub

TransportHub

MachineHub

WorkCenter Hub