Process Director

Traditional Manufacturing Systems

Start with a simplified process model to reduce implementation time.  Modeled process complexity can evolve at a pace operations can absorb and implement.

Complex to set up and maintain.  Large effort required before it can be utilized.

No separately maintained routing file is required.  At the time of order creation, a “dynamic” routing based on a process model is established including only those tasks needed for the selected options.

Individual routing for each component or assembly built in-house.  Process change impacts all routings in this process.

No separately maintained Bill of Material file is required.  Single level Material kits are assigned at the task level in the process model.  At the time of order creation, a “dynamic” multilevel Bill of Material (BOM) is created based on scheduled tasks and linked material kits.  A traditional multilevel bill of material representation is available on line or as a printout.

Multi-level Bill of Materials must be created and maintained for each manufactured item prior to using in an order regardless of how minor a difference from existing items.

Tasks are scheduled through predetermined rules and links in the Process Model automatically at order time.  Online priority lists are available throughout facility.  PD includes configurable master scheduling functions which automate the creation of work orders and purchase orders based on sales and/or build to stock demand.

Master scheduling function is often un-flexible and complex.  Outputs are often in the form of large, hard to read printouts.

Since tasks are updated in each reporting area as they are completed, everyone in facility has access to real time status of orders.

Production reporting is often a “batch” process; i.e. updates are not real time.  Status outside of production areas is not available.

Material transactions “flow” based on the process model and linked material kits.  For example, when task with a linked assembly kit is clicked complete, all components of assembly are automatically relieved from inventory and assembly is added to inventory in a “WIP” location at the next scheduled task work area.   

A separate inventory adjustment menu(s) has to be accessed and inventory transactions created.

Inventory is organized by inventory “groups” that have common characteristics.  This speeds creation of new inventory masters and allows “on the fly” inventory number creation at order entry time.

Each inventory master is separately input.  Inventory masters have to exist prior to order entry time.

Includes office process control as well as the shop floor, leading to reduction of paperwork and faster order processing.

Provides only shop floor production control.

Reporting areas have the ability to quickly input shop labor, production numbers, scrap, rework, etc. against each scheduled task in their priority list.  While barcode interface is available, it often is not any faster than just reporting against tasks.

Shop floor job costing and labor reporting is often a costly 3^rd party system that needs to be interfaced to the main system and/or requires more key punching input to obtain information.

Each reporting area has their own on line priority list of tasks and, at a right click of mouse, a menu of functions specific to their job function.  This includes built in PD functions and input screens as well as access to any Information Director report or stored document.  PD can also launch 3^rd party programs that are part of the users required functions.

No equivalent function in traditional system.  User has to go to separate area of menu tree, launch another application, or look for a printed report.

System function and process flow is highly configurable using built in setup function.  This setup requires no code modification and associated debug cycle.  Only a few people within a customer’s organization need to be trained on this module.  Once trained they can configure system without the expense of outside help.

System is rigid requiring adherence to program structure.  Variations involve costly custom programming.

Can be used also to model major projects that may use the same resources assigned to production processes.  PD has a full function project tracking capability including real time project updates.

No equivalent function in traditional systems.

Reporting directly available from reporting area menu can be in the form of a built in “Quick Report” function, automatically filled in Excel templates and charts, or 3^rd party report generator.  Includes automatic email notifications and ability to update databases for special requirements.

Standard set of reports provided in some kind of report generator.  Optional reports require navigating menu tree or launching separate application. 

Accounting tasks can be included that interface directly to 3^rd party accounting system.  For example, invoice task will have an Excel template of the customer invoice automatically filled in with information based on order info and input at the shipping task.  Once verified and invoice task clicked complete, the appropriate AR transactions will automatically be created in the accounting database.

Often include proprietary accounting module that replaces existing accounting system or requires separate operation to update accounting system.

Process Director installation is done by implementers that are also manufacturing operations efficiency experts.  The setup process done at the beginning of PD installation is an excellent time to streamline both office and production processes to eliminate inefficiencies, better define employee job functions, and better organize material flow.

Often done by implementers that are experts on the software but not necessarily manufacturing operations.  Because of the upfront requirement for routings and bill of material databases more time is required for data transfer and data input.