Real-time Shop Floor Control System for the Sewn Products Industry
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- Low cost network of barcode, data collection terminals
- Clocking in and out at employee work station
- Clocking off and on standard at employee workstation
- Extensive operation backlog analysis by epartment/cut
- Production status by cut/bundle/subassembly with dates and employees performing operations
- Team production support
- Multi-language support with user defined dictionary
- Control of scrolling signs for display of team or department production statistics
- Control of buzzers/bells for shift, lunch, break start/stop
- Comprehensive mechanics/repair subsystem
- Comprehensive quality/inspection subsystem
- Motivational feedback (e.g. efficiency, earnings, bundles/pieces done) to sewing operators
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- Data collection terminals may be configured as:
- Time clocks
- Individual data collection devices
- Shared devices (each user presses a key prior to use)
- Multiple user devices (each identifies himself with an ID card prior to use)
- Team devices (shared by any number of users for clocking and production)
- Pacing for operator selected efficiency
- Support for either bar-coded or Radio Frequency Identification (RFID) technologies for employee or production bundle tracking
- Shares data with NGC’s TPM™ system for employees, cuts, bundles, attendance, time and production reporting for incentive payroll
- Runs on any Windows 32-bit LAN server commonly found in most offices (e.g. Windows 98/NT/2000/XP)
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Real-Time Shop Floor Control is a Combination of the following subsystems:
(Time & Attendance) (WIP tracking)
(Machine Repairs) (Quality Control)
Partial List of Data Collection Transactions (Employee, Supervisor, Mechanic, Inspector):
- Employee clock-in
- Employee clock-out
- Work ticket start
- Change operation
- Split bundle
- Start pacing at specified percent efficiency
- Quality reporting by operation/type
- Display employee efficiency
- Display units/hour for 100%
- Display earnings
- Display current earned hourly rate
- Display current operation & pay code
- Assign multiple operations to terminal
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- Display employee who performed operation
- Change employee/dept to off-standard pay code
- Change employee shift (authorize overtime)
- Change bundle quantity
- Change number done at an operation
- Divide bundle into sub-bundles
- Change employee department
- Call mechanic
- Mechanic start repairs
- Mechanic finish repairs
- Retroactive clock-in/clock-out
- Authorize terminal operations
- Configure terminal as time clock, shared, etc.
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Partial List of Real-time PC Screens:
- Attendance showing on time/late/absent employees by dept/pay code/efficiency
- Operation backlog bar chart showing dozens of units waiting before each operation in each department
- Operation backlog bar chart showing dozens of units waiting before each operation in each cut
- Cut status showing bar charts of percent completed by cut/bundle/subassembly
- Electronic employee gumsheet showing each clock-in/clock-out/pay code change/bundle completed for any date
- Production monitor bar charts showing production goals and progress toward goals throughout day
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- Bi-hourly display showing quantity completed during each two hour period and cumulative totals by department/operation/employee
- Mechanics repair log display showing pending, on-hold and completed machine problems, time waiting, repair time, mechanic, priority, etc.
- Machine problem reports showing efficiency of mechanics, machine failure frequency, type failure, etc.
- Quality bar charts showing quality problems by department, employee, inspector and problem
- Bundle status showing operations not yet done and operations done by employee and date
- Numerous setup screens for terminals, time clocks, user authorization, log analysis, shift definitions, language translations, etc.
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