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Daily Production

Daily Production

Daily Production Module - User Guide

1. Introduction 📝

The Daily Production module is the execution heartbeat of the manufacturing floor. It bridges the high-level Production Plan with the granular daily reality of the factory. It allows plant managers to set daily shift targets, record real-time output, track labor efficiency, and monitor production downtime.

ℹī¸

In the overall business flow:

  1. References the active Production Plan to set daily item targets.
  2. Captures Actual Output (Good Qty) vs. Time-Out Qty (Loss/Delayed Qty).
  3. Provides data for Labor Productivity and Financial Performance analysis.

Typically, this module is used by Shift Supervisors, Floor Managers, and Production Clerks.

2. Getting Started with Daily Production 🚀

Accessing the Module

Navigate to Daily Production via the Manufacturing menu. The index is partitioned into Targets (Set by Supervisors) and Actuals (Recorded by Line Operators).

Daily Production Index Page

Key Workflows

  1. Setting Daily Targets: Define which products will run on which Plan/Date, including the specific time slot and targeted worker count.
  2. Updating Actuals: Line operators or supervisors update the “Actual Qty” achieved against the set target.
  3. Worker Management: Track the number of workers assigned to a specific floor plan for a given date to calculate “Output per Man-Hour”.

3. Features & Benefits ✨

đŸŽ¯ Targeted Shift Planning

  • Time Slot Management: Define production windows (Shift starts/ends). The system enforces a mandatory duration between 1 to 12 hours per entry.
  • Live Target Tracking: View real-time progress of “Target vs. Actual” throughout the shift.

👷 Labor Efficiency Tracking

  • Worker Allocation: Record the total number of workers assigned to a specific floor plan. This data is critical for calculating labor cost per unit produced.
  • Automatic Worker Record: Creating a production target automatically initializes a worker record for that date to ensure no data is missed.

⚡ Performance & Value Analysis

  • Financial Visibility: Reports automatically calculate the Actual Value (Actual Qty × Rate) and Target Value (Target Qty × Rate) to evaluate floor performance in monetary terms.
  • Percentage Completion: Instant visibility into the completion percentage (Actual Qty / Target Qty %) for every item.

4. Complete Flow 🔄

Set Daily Target

  • Select the Floor Plan and Date.
  • Choose the Product (must be active for that target date).
  • Define the From/To Time.
  • Set the Target Qty and optional Notes.

Allocate Labor

  • Navigate to the Worker Index.
  • Update the No. of Workers for the respective Plan and Date.

Record Actual Production

  • Locate the active target in the Actual Production Index.
  • Update the Actual Qty (for units produced) or Time Out Qty (for units delayed/lost).
  • The system supports both Manual Entry (typing a fixed qty) and Incremental Entry (adding to previous count).

Daily Production Monitor Details

5. Validations and Logic ⚠ī¸

Main-Level (Header/Target) Validations

  • No Prior Dating: Targets cannot be set for dates prior to today’s date.
  • Shift Duration: The interval between ‘From Time’ and ‘To Time’ must be between 60 minutes and 720 minutes (1–12 hours).
  • Unique Daily Targets: The same exact Item ID cannot be specified twice for the same Plan and Date.

Recording Validations

  • Target Existence: You cannot record “Actual” production for an item that was not first defined in the “Daily Target”.
  • Manual vs. Auto: If an entry is marked as IsManual = N, the system defaults to incrementing the count by 1 (ideal for QR/Scanner-based recording). If Y, the user must explicitly type a quantity > 0.

6. Master Data Dependencies 📚

  1. Production Plan: Provides the “Plan Codes” and overall item targets that the daily entries reference.
  2. Item Master: All products produced must be valid, active items.
  3. MFG Log: Tracks every deletion and update for audit trails.

7. Related Reports 📊

  • 📊 Daily Production Report: The primary summary report. It includes:
    • Actual Qty vs. Target Qty vs. Time Out Qty.
    • Calculated Percentage (%) of achievement.
    • Actual Value vs. Target Value (Monetary performance).
    • Total Qty (Actual + Time Out) across specific date ranges.
  • 👷 Labor Analysis: Integrated within the production report to show “No. of Workers” alongside output metrics.

8. Best Practices / Tips 💡

  • Use ‘Time Out Qty’ for Blockages: If production was halted due to machine failure or power cut, record the potential units lost in “Time Out Qty” to maintain a true record of floor capacity.
  • Real-time Worker Updates: Ensure worker counts are updated at the start of the shift. Accurate labor data is the only way to calculate “Throughput per Worker”.
  • Notes for Deviations: If a target wasn’t met (percentage < 80%), use the Update Notes feature to explain the cause (e.g., “Shortage of Raw Material”).
Production PlanIIRS (Internal Issue Return Slip)