6. Production/Digital Polca
The production process consists of two phases. Both phases are performed using the Digital Polca module. In the first phase, Job Tickets are put into production. In the second phase, the Job Tickets are reported as finished or can be interrupted in order to register the actual production time. Material consumption and the quantity ready can also be reported.
Execute the Jobs, including a subcontract and a rush order.
After the work preparation has been completed and the availability of the various materials has been checked, production can be started.
According to the Polca principle, the Jobs are indicated in the correct order of execution and started as late as possible in order to still meet the desired delivery date. They can only be started if a number of criteria are met. After the job has been processed, it can be reported as ready or interrupted.
The progress of the Jobs can be monitored via a dashboard and issues and warnings can be made known, so that they can be reacted to, sometimes as proactively. An outsourcing is a Job, for which a purchase order must be created in the ERP system. These orders only have a lead time and are followed up via the Polca system. Any rush orders will always be at the top of the list.
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This section contains 3 steps, in which you will learn the following:
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1. Editing a job
2. Pause a job
3. Report a Job Complete
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You will also learn why certain jobs cannot (yet) be taken into production and what you can do about it and how to deal with the production dashboard.
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The chapters have a fixed layout. First we show how Polca works in a video, so that you also get an insight into the process. In a demonstration we will then show how this works in FlowOpt. Finally, you can get started on an assignment that you can perform in the test environment
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Polca (Paired-cell Overlapping Loops of Cards with Authorization)
Polca is a production control system for companies that produce a high mix of variation and small runs, whereby the production of larger series can of course also be supported. Usually production is done on customer order or project, but production in stock is of course also possible.
The system ensures that the jobs are executed as efficiently as possible and in one continuous flow with as little waiting time as possible and Work in Process.
The system works with Polca cards that indicate whether there is sufficient capacity available in the next cell/work center to immediately perform the next job in the process. Polca works with loops between 2 cells/work centers. The cell/work center combination is assigned Polca cards, which represent the available capacity in the next cell/work center. The video shows how this works.
Digital Polca does not work with physical cards, but with digital cards assigned to a cell/work center combination.
As soon as a job is put into production, the Polca cards are assigned to the job, which means that the capacity in the next cell/work center is reserved. The cards are released once the Job in the next cell is completed.
Digital Polca thus supports a paperless shop floor, as we can also link drawings and work instructions in any form to the Jobs and make them visible in the workplace.
6.1 Activating a Job, putting it into Production
As soon as the required material for the Job is fully available and the work preparation has provided the Job with the correct digital documents (drawings/work instructions) (may of course also be physical documents) and the previous Job has been reported as ready and/or the right time has come, the Job can be put into production.
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To activate a job you will have to start Digital Polca via the menu and possibly select the correct cell/workcenter to see the Queue.
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In the Queue, the jobs currently to be activated are displayed and it is indicated whether there are any problems that require action. The full list is displayed and you can view the details of each Job by clicking on the line. Now the details of any exceptions are shown and action can be taken. If there are no problems, select the job to activate and press Start. The job is now moved to the 'In Production' list and disappears from the Queue.
How does this work in FlowOpt ?
In the explanation below we show how Digital Polca can be set up for your environment, how you can put a Job into production, which exceptions can occur, which actions are possible and how you can register time, material consumption and quantities produced.
What is Digital Polca
Digital Polca is the method with which the production follow-up can be monitored in the most effective way. Through the slides below we explain what digital polca is and how it behaves in the execution of the jobs. The method shown is the strictest form of Polca. The system supports less strict forms, which can be set up together with the implementer.
Setting up the Digital Polca Screens
The Digital Polca screens can contain very limited information or almost all information for the preparation and execution of the job. The job related data such as documents and drawings, tools, sales order reference, problems and warnings, links to previous and next jobs and notes can be turned on and off. It can also be determined whether two screens are shown next to each other or only one screen and the line spacing can be increased and decreased.The slides below explain how the layout can be created and saved per Cell and user.
Show the job queue and start a Job
All jobs to be prepared and executed are put in a queue, from which they can be released for production. The data such as drawings and documents can also be set up or supplemented and resources can be assigned. If necessary, jobs can be moved in the schedule or designated as rush jobs via the rescheduling function.The slides below explain how this function works and what can be adjusted.
Why can't I start a job
Depending on the settings, there can be different reasons why a job cannot yet be started or released to production.The slides below explain why a job cannot be released/started yet and what you can do to solve this.
Show a Drawing or work instructions
You can view or add drawings or documents in any form to the job. The drawing is displayed in a separate window so that it can be viewed in full screen.VIn the slides below we explain how you can view drawings or instructions and add them to the job.
Production execution
FlowOpt supports a full digital follow-up of production activities. You can start a job via a start button or via a QR code, you can temporarily interrupt the job and start it up again and close the job, whereby you can record the numbers produced. VIn the slides below we explain how you can carry out the follow-up.
Extended functionality
The application supports additional functionalities such as reporting activities after start/stop and unplanned activities and reporting material consumption. Through the slides below we explain how you can use this functionality.
6.1.1 Putting a job into production
Now we will show you how to put a job into production in FlowOpt. The demonstration consists of a step-by-step plan and a video.
Step-by-step plan 'Putting into production'
Production can start. In FlowOpt you need to perform the action 'Take into production'. The Job ticket contains all relevant information for the workplace.
1. Open the Production module and choose the function 'Digital Polca'
2. If necessary, select the Cell/Workcenter for which you want to activate the Jobs
3. You can also choose the Focus Target Market via the Filter .
4. The jobs to be activated are shown in the Queue and you can activate them by clicking on 'Start' . The job now disappears from the Queue and becomes In Processing.
Demonstration Putting Job into Production
In the demonstration we show how you can put a Job into production and which exceptions can occur. Skip the demonstration >> Go directly to the command.
As soon as a job has been fully provided with material, work preparation has provided the job with the correct digital documents (drawings/work instructions) (which may of course also be physical documents) and any previous job has been reported ready and/or the right time has come When the job has arrived, the job can be put into production.
Putting a job into production is a process step. Now watch the video in which you can see how to select and start a job in FlowOpt. You can also see where in the process the job is and what the status is of the following or parallel jobs.