It can support both the “f-MRP” function, which is strong in repetitive production, and the “mfg. no. control”, which is suitable for individual build-to-order manufacturing. It is also suitable for mixed management where, in custom production where the standard configuration is partially changed, the “f-MRP” function is used for versatile intermediate products and parts materials, and the “mfg. no. control” function is used for processes and parts configurations that differ for each sales order.
It is suitable for single item production. It supports different processes and parts configurations for each sales order. It is easy to understand the relationship with sales orders by planning to link products, intermediate processes, and raw materials with mfg. nos.
・TPiCS’s unique f-MRP function realizes “fast, cheap, responsive, but stable production”.
・Starting from the sales schedule and the production schedule of the product, everything from the production schedule of the intermediate unit to the arrangement schedule of the end parts is automatically created according to the Bill Of Materials, mfg. lead-time, lot size, etc.
When using the Customer Order and Sales Management option, you can seamlessly create a production schedule according to the sales order and forecasting information, automatically create a production schedule at the timing when production is in time starting from the shipping date, and from there, also make intermediate processes and parts arrangement schedules. Even if there is no clear information such as sales orders and forecasting orders, by entering into the Prospect line of the production schedule table based on the sales forecast and the annual shipment volume, you can do the lot-sizing according to the parameters and and make a production schedule tailored to the production capacity, and when an sales order comes in, it will be automatically allocated. The Prospect line can also be used at the unit and component level, and can also be used to adjust the neck process.
・When calculating the required amount, the production schedule is made by adding the quauntities of purchase orders, supplier delivery delay, and work delay to the current inventory. You can register multiple storage locations, and you can add up the inventory of multiple storage locations for allocation, or set them to storage locations that are not included in the calculation.
・You can register multiple operating calendars, create a production schedule for the first process according to the calendar of the outsourced processing destination, and make a shipping and production schedule according to the operating calendar of the customer when using the Customer Order and Sales Management option.
In the MRP calculations, the journal shows the plan changes that people should pay attention to, such as “being late for the purchase order lead-time”, etc. due to various situation changes such as new orders, changes in delivery dates, changes / cancellations in order quantity, and defects in intermediate processes.
The production schedule table can be displayed in conjunction with the matching item code in the [Production Schedule Table (MRP Calculations)] form, and you can adjust the production schedule, check the supplier information, and check the structure and master status.
By simply registering the old and new part codes in the Engineering Change Master, the current inventory and the consumption time of the arranged parts are calculated, and the purchase order is automatically switched to the new parts.
Even if the production schedule changes or the inventory quantity changes, it will automatically respond. When the parent’s actual results are entered, the withdrawal of the used child parts is automatically switched. You can also directly specify the component switching date. (Bill Of Materials)
・Gantt Chart By Mfg. Sector option
You can check the workload of the manufacturing department and adjust the plan on the Gantt Chart By Mfg. Sector from the production schedule created as a result of the MRP calculations.
・Automatic Leveling option
It is possible to perform automatic allocation based on the production capacity, the mfg. lead-time, the standard working hours, the quantity, and the priority of allocation of the work center.
You can make the following plans:
- Production schedule that automatically divides products and units by ratio into multiple manufacturing locations
- Normally, it is produced in-house, but if the production limit is exceeded, a part of it will be outsourced to a partner company.
- Production schedule with arbitrarily assigned manufacturing locations
- Arrangement plan according to the post-process
- Plan considering each calculated inventory of the supply-to
・Alternative Production option
When there is a shortage of constituent parts, you can make a production schedule using the future calculated stock for the specified substitute.
You can create MRP calculations that take into account the expiration date for each lot of parts and materials, and the expiration date for the units and products produced.
・There are three possible methods for the mfg. no. control of TPiCS
B-Seiban Basic mfg. no. control. An arrangement plan, in which products, intermediate units, materials, and parts are connected by the mfg. no., is created from the Mfg. No. Schedule according to the product structure by the mfg. no. explosion. You can change the product structure for each Mfg. No. Schedule.
S-Seiban Mfg. no. control by mfg. no. of preceding arrangements. The intermediate unit can be arranged and produced by the mfg. no. of preceding arrangements, and a finalized mfg. no. can allocate this for production of the product.
F-Seiban Mfg. no. control by f-MRP. A control method in which the required amount is calculated by f-MRP, which is flexible to demand fluctuations, and the created Schedule Detail is linked by the mfg. no.
TPiCS provides a very advanced function also in the mfg. no. control.
・Lot-sizing is possible by the quantity of the Mfg. No. Detail.
・It is possible to allocate all of the lot-sized quantity to the mfg. no., to allocate only the required quantity by the mfg. no., or for another mfg. no. to automatically and manually allocate the lot balance at the time of explosion.
・You can allocate the mfg. no. to the purchase order data that is being arranged as well.
・It is possible to arrange a large amount depending on the yield rate, etc., and release the surplus parts from the mfg. no. due to the completion of the product or unit, and allocate it to another mfg. no.
・Insufficient parts due to defects can be re-arranged and parts that have not been allocated to mfg. nos. can be allocated.
・You can manage revisions and select the inventory to allocate.
・You can take inventory by mfg. no.
There are two ways to change the product structure for each mfg. no.:
・Method to use the option code
You can change the structure by master-registering different parts to be used by the Option Code in the Bill Of Materials, specifying the Option Code in the Mfg. No. Schedule, and executing the mfg. no. explosion.
・Method to change the structure after the mfg. no. explosion
After creating the Mfg. No. Detail according to the product structure registered in the master by mfg. no. explosion, you can easily change the structure for each mfg. no., such as adding units and deleting or changing parts.
・Unfinished work can be calculated as predetermined cost even during manufacturing and can be included in the budget control in comparison with standard cost.
・Parts calculated by f-MRP can also be included in the cost by mfg. no.
・You can display the child parts associated with the mfg. no. and the progress status of each process.
・You can tell at a glance whether the previous process has been completed, or if f-MRP parts are in stock, and as a result, it is possible to start now.
・You can change the planned date by dragging and dropping.
・It is possible to specify the work start time, and plan the production order on the same day in more detail. You can change the planned date.
・By combining with the Shop Floor Control option, it will be displayed as ○, ×, and △ whether the work can be started with all the parts prepared and whether it can be partially started.
・You can issue a change slip for what has been changed, and when linked with the SCM option, changed contents can be automatically sent by e-mail to parts vendors and subcontractors.
In TPiCS, f-MRP and mfg. no. control can be set for each item, and by doing so, parts that cannot be arranged in time after receiving an order and exploding for mfg. nos. can be arranged by f-MRP, which is resistant to changes, based on forecasting orders, and production instructions can be issued for intermediate units and products by finalized mfg. nos.
Work Instructions, Purchase Orders, Outsourced Orders, Transfer (Supply) Instructions
You will perform the MRP calculations, perform the mfg. no. explosion, or issue a slip of the plan made manually.
Automatically setting the least expensive supplier
You register different unit prices in the Unit Cost Master depending on the supplier, season, quantity, urgency, and when creating a Schedule Detail, TPiCS looks at the season, quantity, etc. and searches for the least expensive supplier that meets the conditions, and sets it in the Schedule Detail so that you can issue a purchase order.
Ordering by supplier part code
You can place an order with the supplier’s part code (catalog number, etc.).
You can place an order divided by ratio to multiple vendors, or place an order for a quantity that exceeds the quantity limit to another vendor.
You can send the purchase order by e-mail.
Form Design Change
A form design created in Excel is prepared, the Excel form is displayed by clicking the print button, the data exported from TPiCS is read, and it is automatically printed.
Form design includes one-item-per-page format suitable for work instructions, multiple-items-per-page format suitable for work instructions with child parts used and and purchase orders, etc. You can easily adjust the design in Excel, and change or add a design according to the paper.
Specify the lot of raw materials used (Mfg. Traceability option)
You can specify the lot number of the raw material to be used in the work order.
At the same time as work instructions, outsourced processing request forms, etc., you can print the required number of identification tags obtained by dividing the planned quantity by the quantity of contents set elsewhere. It is also possible to register the expiration date and lot name of the actual article in the Actual Acceptance Result Entry for parts, and print the identification tag with the expiration date and the lot name from the Actual Results data.
Issuing a delay list
It is possible to issue a purchase order list or work list that is delayed in delivery, but instead of responding after a delay in delivery, to prevent delivery delays, you can issue something for each supplier, for example, as a list of acceptance schedules for next week.
For parts for which the unit price has not been set, a Quotation Request Form can be issued. It is also possible to issue competitive quotes to multiple vendors
The following Excel desktop application versions are supported:
・Microsoft Excel 2016
・Microsoft Excel 2019
・Microsoft Excel 2022
・Microsoft 365(Compatible with the above Excel versions)
Actual Production Result Entry
If you enter the actual results of an intermediate unit manufactured using materials and parts, the inventory of the intermediate unit will increase, and the inventory of the material will be automatically deducted and decreased. The appropriate method for withdrawal depends on the production method of parts and materials.
For example, when the completed quantity is smaller than the planned quantity in the actual assembly results, if the parts are loaded according to the planned quantity and discarded due to defective products, the input quantity will be deducted, but if it is partially completed due to production delay, it is sufficient to withdraw only the quantity required for it. Also, in the case of liquid production, there are some you want to adjust the withdrawal amount each time the actual result is entered. Such a withdrawal method can be set for each management point such as parts, intermediate units, and products.
In addition, you can enter the actual result time for each worker, work group, machine, and process, and aggregate it for each.
Actual Result Working Hours Entry
The actual result entry of the quantity is for the next step, so it is performed in real time, the actual result working hours can be entered later from the dedicated Actual Result Working Hours Entry form. It is also possible to allocate the total working hours of the work team to multiple work results and automatically set as each actual result time.
Actual Receiving / Acceptance Results
It is also possible to perform two levels of Actual Result Entry, one is the actual receiving results for receipt confirmation and the other is the actual acceptance results for which inspection is completed and payment is to be made.
It will be displayed on the Accounts Payable Detail depending on the actual acceptance results.
Actual Result Cost
You can carry over the purchase unit price of the purchase order data to the actual result, or change the purchase unit price of actual result when entering the actual result. In addition, in the Actual Work Result Entry, the result of (Actual Result Working Hours x Processing Cost Rate) is reflected in the actual cost.
Inventory can be evaluated by the real-time moving average method,monthly moving average method (monthly gross average method), final unit price method, gross average method, and
lower-of-cost-or-market value method.
If you can produce as planned, you will want to reduce the daily input effort. In such a case, you can automatically set the provisional actual result quantity from the plan scheduled to be completed today, change and enter only some of the Schedule Detail that could not be produced as planned, and enter the actual results in a batch.
Entering lot name (Mfg. Traceability option)
If you have to enter the lot number at the time of receipt for important raw materials, you can do the setting of Lot Name Required.
When entering the actual production results, you can enter which raw material (lot number) was used. The data can be viewed retroactively at any time. If necessary, the manufacturing history can be recorded from the time of acceptance to the time of completion of production (time of shipment).
Inventory can be managed by automatic withdrawal based on actual acceptance results, actual production results, actual results of the initial process, inventory movement, and transfer between warehouses by issues. Furthermore, it is possible to grasp the inventory amount, the quantity of goods received and issued for the current month, the last withdrawal date, the date of last goods received, the date of last goods issued, etc. for each item such as raw materials, intermediate units, supply-tos, and products.
specifying the goods receipt location at the time of the goods receipt and the goods issue location at the time of goods issue.
You can use the Mfg. Traceability option to manage the remaining lot quantity for each lot of actual results that have been received and completed.
The last goods receipt date, the last goods issue date, and the last withdrawal date are recorded, and it is also possible to specify the narrowing conditions and check the stagnant inventory.
Inventory processing is carried out at the end of the period or the end of the month, and the Current Inventory for each storage location is adjusted to the inventory quantity of the actual stuff. Not only simultaneous inventory, but also partial circulation inventory and temporary inventory are supported.
If there is an inventory difference, Actual Inventory Result data for the inventory difference is created, so it is easy to aggregate how much the inventory difference was.
The reflection of the physical inventory is retained as the stock before inventory at the start of the inventory, the inventory difference is reflected in the current inventory that moves daily due to the input of the physical inventory value and the end of the inventory, and actual results can be entered during the period of inventory aggregation work.
For the planned quantity of production schedule table, you can convert the planned quantity according to the unit displayed in the instruction sheet, convert the display of Inventory List, convert the structure table, and change and display the unit for each product, intermediate unit, and member.
For example, the purchase order quantity of liquid raw materials can be calculated as 200 liters or 400 liters, and when ordering, the purchase order form can be converted into 1 can or 2 cans per drum can (200 liters). The conversion can be returned at the time of actual goods receipt results of 2 cans and 400 liters can be reflected in the inventory.
Cost Accumulation Table By Product
How much each item was produced this month is aggregated and displayed based on the Actual Result data.
Cost By Department,Profit & Loss Summary Sheet
Considering the amount used by the next process as sales, the profit and loss for each department is aggregated and displayed.
Cost Accumulation Table By Mfg. No. (f-MRP Mfg. No., Mfg. No. Control System)
You can compare the actual result forecast including the unfinished predetermined cost with the standard cost.
Actual Result Unit Cost Recalculation Function
When calculating the actual result unit cost by the moving average method, the actual result unit cost can be recalculated by reprocessing all the Actual Result data in chronological order, starting from the value at the beginning of the month.
Supply Management (Multiple-location option)
You can also manage paid supplies with the Multiple-location option. You can also manage the supply-to inventory supplied for a fee.
Group Aggregation, Item Aggregation, Total Aggregation
Analysis of the current situation is important for production control.
It is possible to display the displayed data in group aggregation with any item, or to aggregate and display child and grandchild groups in multiple items.
You can display the totals for each item and the total aggregation for any item. The aggregation method can be set for each item such as maximum value, minimum value, average, and total, and you can easily switch between saving and recalling by giving a name to the aggregation setting.
You can export each aggregated value to an Excel file.
Role Management (Authority Management)
You can set the operable range for each business person like “The person in charge of planning operations can update all Item Masters and Bill Of Materials, and perform the MRP calculations,” and “The person in charge of entering the actual acceptance results can only enter the actual acceptance results of the material.”
You can set roles for users. You can also set the dual-role settings for planning and purchasing operations, or set multiple users together as a group.
Management using a Windows login user is also possible.
There are many masters in TPiCS, such as the Item Master to register parts, raw materials, products, intermediate units, processing consignment to cooperating companies (plating, heat treatment,
painting, assembly, etc.), the Bill Of Materials that builds the parent-child relationship of items, the Unit Cost Master, the Working Hours Master, and so on, and master maintenance is essential
to create a production schedule that is suitable for production that changes daily.
The Integration Master is provided as a standard function so that these masters can be examined and edited at a production meeting that gathers related departments while checking the overall picture together.
When registering a new product, you can create a product structure with the Integration Master from the parts list of the design, and registered items can be added to the structure as a common item. By using the Integration Master in this way, it is possible to assemble a master with a parts list image for each product and reflect it in eachmaster. It can be changed by registering either from each master or from the Integration Master, and the general master registration can be done from the Integration Master, and the details can be done from each master for each department in charge.
You can add your own management items to most forms such as masters, Schedule Details, and actual results.
The added user items can be displayed in the grid section and detail section, and can be searched, narrowed down, and entered in the same way as the existing items of TPiCS, and data can be entered by selecting from the registered pull-down list. Detailed settings such as font size, back color setting, IME setting, display, non-display, tab cursor order, display order, etc. are possible. You can also change the grit title name of the existing item, and you can make the form according to the user only by setting
In addition, by registering SQL statements, user items registered as masters can be referred and displayed in plan data, values can be carried about and written in the Actual Result data, and fields from other companies’ sales management systems can also be referred if they can be referred from the database server.
You can manage the actual payment results by aggregating the data to be paid from the Actual Acceptance Results data, creating a payment schedule according to the closing date.
Since you can specify a payee different from the send-to of purchase order, you can make the supplier of parts to a branch and the payee to the head office of the supplier. It is possible to export payment journal data for the accounting system.
Accounts Payable Management(Accounts Payable Detail)
When entering the actual acceptance results, you can enter the amount purchased, supplier, etc., which will be reflected in the Accounts Payable Detail.
You can write out the journal data of the Accounts Payable Detail and the Accounts Receivable Detail according to the “journal data import format” of the general accounting system for personal computer.
Accounts Receivable Management(Accounts Receivable Detail) Customer Order & Sales Management option
Text Export and Import
Data of all tables such as master, transaction data such as Schedule Detail and purchase-ordered data, and aggregated data such as Inventory List, cost accumulation by item, cost accumulation by product, etc. can be written and read as a text file.
Transaction Data Text Import
The related tables are updated at the same time as importing the text file, as when operating on the form, such as sales order entry, Schedule Details, actual work results, actual shipping results, actual issue results, and inventory movements. When reading the Sales Order data, it will be reflected in the production schedule table at the same time as the Sales Order data is registered.
Automatic Transaction Import / Export (Transaction Interface option)
With a text file base, if frequent data reading is assumed,it will be difficult to deal with reading errors due to data inconsistency. With the Transaction Interface option, when a read error occurs, the contents are written on the table and status management is performed, which makes it easier to link. In addition, transaction data operated on the TPiCS form can be automatically written to the writing table, which enables bidirectional linkage with other companies’ systems.
You can register calendars with different holidays and working hours.
There is no limit to the number of calendars, and you can specify the calendar to be used in detail for each supplier, each partner company of the processing request destination, each customer at the time of shipment, each in-house manufacturing department, each process, and so on. You can manage up to 24 shifts for day and night shifts. It is possible to set operations with different granularity in one calendar, such as a day shift and night shift calendar for the current month, a daily unit calendar for the next month, and a weekly unit calendar for the months after that, and it is possible to create a production schedule according to these.
You can set the capability for each production location, which changes from day to day, in the capability calendar. You can check the load factor from the production volume for the daily capability on the Gantt Chart By Mfg. Sector, and it is possible to level the workload by combining it with the Automatic Leveling option. The capability for every Wednesday is reduced for planned maintenance of production equipment. It can be used to check the number of part-timers and workload that change daily.
The contents operated by macro recording are created as a script file, and the same operations as manual operations such as importing transaction data and monthly processing can be performed automatically.
For example, you can import Sales Order data every day during lunch break, and automatically calculate requirements, create Schedule Details, and create slips.
You can perform equal search, first match search, last match search, partial match search, equal to or more than, more than, equal to or less than, less than, and negative search on almost all forms and items. In addition, there is a quick search function that searches each time you type in the search value with the keyboard, you can display the necessary data while checking at any time. You can narrow down by AND or OR condition with multiple narrowing conditions, and if there are multiple conditions, you can sort by giving priority to either condition, or by double-clicking on the grid title row.
・You can also create a TPiCS shipping plan from the Sales Order data and calculate the required quantity as it is.
・Parts and materials can be arranged based on the forecasting plan by linking with the f-MRP function. Even if the forecasting plan changes, it can be directly connected to the next MRP calculations because it is based on the function of f-MRP.
・When receiving a sales order for a mfg. no. control product, a Mfg. No. Schedule is created at the same time as input, and the sales order is allocated to the preceding Mfg. No. Schedule. When the number of Mfg. No. Schedules to be allocated is insufficient, it is possible to automatically create a new Mfg. No. Schedule with the insufficient quantity.
・Sales Order data and Delivery Instruction data coming from the Internet etc. can be imported in CSV text file format.
・You can import sales orders from systems such as EDI and ERP via Transaction Interface option.
・It will fully respond to daily delivery instructions.
・You can reconcile the forecasting data while importing the firm Sales Order data.
・You can also leave it as a backorder without reflecting it in your production schedule.
・You can respond to sales orders for full-choice option production.
・Sales Order data can be entered at any level of the product structure. This makes it possible to ship intermediate products and parts at the OEM stage and manage them as repair parts. This makes it possible to ship OEM shipment at the intermediate product and parts stage and manage them as repair parts. You can calculate the required quantity by adding those required quantities.
・When firm delivery instruction data is sent daily, as in the automobile industry, you can import the data while reconciling the forexasting data in the order of the unofficial delivery date for
the same item and the same delivery location.
・Processing for firm and forecasting orders can be performed.
・You can periodically delete the forecasting data and reload the new data.
・Based on the shipment planned date of the Sales Order data, you can issue shipping instructions from today to the set number of days ahead.
・You can issue shipping slips by narrowing down to only the products that are in stock at the time of issuing the shipping instruction.
・A warning is displayed when the product's current inventory is below 0 when you enter the actual shipping results.
・For the shipping plan, you can enter the actual shipping results and the actual results of acceptance completion separately by status after arrival at the customer, and the Inventory List can be
confirmed as the unaccepted quantity at the customer after the product inventory has been deducted. At the time of shipment, it can be reflected in the Accounts Receivable Detail, or it can be
reflected in the Accounts Receivable Detail at the customer’s acceptance inspection.
・When combined with the Mfg. Traceability option, the lot number of the used raw material can be linked to the intermediate process and actual shipping results, and the used lot can be searched from the actual shipping results and the ship-to can be searched from the lot number.
・You can issue shipping slips, packing slips, invoices, and accounts receivable book.
・You can output a sales order list, a shipping schedule for a specified date, and a shipment delay list.
・It is also possible to operate with the selling price changing depending on the order quantity and order timing.
・You can manage cash receipts by issuing invoices based on sales details.
・It is possible to register and display overseas customer information in the language of that country.
・You can export the Accounts Receivable Detail for the accounting system.
・There is a delay in delivery even though you have received an forecasting order. You are having trouble with having a surplus of material even though you are arranging the materials based on the forecasting order. In these causes, there may be a difference that cannot be covered within the range of error between the forecasting and firm orders. By analyzing the cause, in order to make a proposal to improve the accuracy of the forecasting orders or to make a production schedule including errors, you can check the number of increase / decrease and the rate of increase / decrease of the forecasting and firm orders.
Based on the production schedule established by the MRP calculations and the mfg. no., you can display a Gantt chart that aggregates the details of machinery and equipment, manufacturing groups,
individuals, outsourced processing destinations, etc. as departments.
In the Gantt chart, the schedule that exceeds the production capacity of the department is displayed in red and you can grasp the plan with high load, move the plan to other departments by drag and drop, adjust the plan back and forth, split the plan, and adjust the quantity. In addition, it is possible to make drag adjustments in conjunction with intermediate processes and materials that have a parent-child relationship with the product
In the latest plan, it can be aggregated from the Schedule Details with the detailed production location set. and if you register a machine at the production location, you can assign work to the machine and adjust the schedule
The Multiple-location option allows you to make a production schedule of an item at multiple production locations according to parameters such as manufacturing lead-time, purchase order
lead-time, and lot size.
As a result, it is possible to make a production schedule where normally it is produced in-house, but it is outsourced depending on the load of the manufacturing department, or that divides the production volume into two manufacturing departments at a ratio.
You can create a plan that suits a more complex situation, such as making separate supply plans for multiple subcontractors. You can also by change by drag and drop in combination with the Gantt Chart By Mfg. Sector, and adjust and simulate the neck process from the journal displayed by receiving ordesr with a short delivery time.
Some functions can be used also in the Mfg. No. Control.
Based on the Schedule Detail created from the production schedule created by the MRP calculations and the mfg. no. explosion, the quantity and the start date of the created Schedule Detail are
expanded to the detailed process, and detailed work process instructions and actual result management can be performed.
The detailed process that was expanded when creating a Schedule Detail according to the master can be re-expanded at any time by changing the routing code. For example, you can register the routing when using an old machine in advance, change the routing code of the process source when the load is high, and issue a process slip with a setup added to the normal work sequence.
The process can be used for the operation that only instructs the work contents to the site and the operation that requires entry of actual results for work time and progress management. You can also check and adjust the load by using the Gantt Chart By Mfg. Sector together.
This is an option that allows you to instruct (picking) the parts, units, etc. to be issued from the storage location to the production site in advance so that the production site can start work according to the instructions, manage the actual results, and manage the issue inventory.
Issue Instructions, Actual Results
In the issue aggregation, the issue quantity is calculated based on the quantity of parts required in the work order, the stock quantity of the issue-to, and the current stock quantity of the parts, and the stock of the issue-to can be managed by entering the actual results. If it is an f-MRP item, they can be aggregated only by the required quantity or for each work order. If it is a mfg. no control item, they can be aggregated for each mfg. no. it is possible to specify a issue lot size that applies only at the time of issue, or in combination with the Manufacturing Traceability option, perform issues considering the goods receipt lot balance on the parts side.
By combining with the Multiple-location option, it is possible to manage the issue of each production line, and manage the inventory of the materials to be issued from the site and the materials to be supplied in production where in-house production and material supply by consignment production are mixed.
Product Issue Instructions, Actual Results
When used in combination with the Customer Order and Sales Management option, it is possible to issue product issue instructions from the product warehouse to the shipping workshop so that shipping instructions can be given. If you are using the Mfg. Traceability option, you can also give goods issue instructions by specifying lots based on the actual production results, manage the actual results, and manage the lot balance.
In the MRP calculations, the in-house process also considers the manufacturing lead-time to make a product schedule, but in the MRP calculations, the required amount of material parts is arranged, and regarding the instruction of the in-house process, work instructions can be given to the previous step at the timing of the site team leader who produces the product.
The post-process brings the required quantity from the stock of the previous process. The previous process makes the shortage that occurs due to use. It is possible to realize a behaviour like a so-called “kanban”.
Instructions for the previous process are given from the Schedule Detail Manual Entry form or the Shop Floor Control option.
In the case of individual production, you make different products for each customer’s order, so it is not a business like repetitive production where masters are prepared in advance and uniform processing is performed. Therefore, the production control system, in which masters had to be prepared in advance, was very difficult to use. In order to solve these problems, TPiCS has strengthened the functions so that it can be used in various operation methods. In TPiCS, we have considered and enhanced functions that can support various operation methods. Even if it is individual production, instead of designing all products individually, common products and repair parts are arranged by the repetitive production function and incorporated into the configuration of one-item production, or the repetitive production function and the mfg. no. control function are used depending on the product, and it can respond to mixed fine management.
This function assumes the case of operating the system without registering the master because the specifications change each time a sales order is received and it is a “one-time
・Due to the extremely high operability, it is possible to make arrangements while registering the work contents and parts used each time.
・You can copy a similar mfg. no. from the past, modify it, and use it.
・The drawings are presented in a sami-dare style, and you can make arrangements from something “necessary” and “possible” among them.
・Once you have some patterning, you can use it with modifications based on it.
・By linking with the Structure Information Conversion option, “addition”, “improvement”, and “discarding” due to design changes can be processed seamlessly and can be quickly reflected in the arrangement.
・It is possible to use general-purpose units and general-purpose parts that have repeatability.
・You can issue an Quotation to your customers.
・You can issue an “quotation request slip” to the supplier and make transactions in accordance with the Subcontract Act (competitive quotes are also possible.)
・Parts that are no longer needed due to design changes can be managed and can be diverted to other projects.
・This option requires that you purchase the “Mfg. No. Control system.”
The “product structure information” and “change information” of the design are imported as structure information in a CSV file from the parts list managed by CAD or Microsoft Excel, and
reflected in the production information of TPiCS. Since linked processing can be performed with a single piece of data, design changes can be reflected in production without omission and
・You can register work that is not in the design BOM, such as supply and outsourced processing, in the manufacturing BOM.
・It is also possible to take in information that is not in TPiCS, such as implementation information and supplier information described in the parts list, and print it on the purchase order or
・Even design changes after modifying the design BOM to the manufacturing BOM can be quickly reflected in the arrangement.
・The design-changed part is displayed in status and color to prevent processing omissions.
・When used in combination with the One-item Production option, design changes can be seamlessly reflected in the arrangement data.
Use of CAD Data
Customer needs have become more diverse, product life cycles have become shorter, and it has become increasingly important to shorten the cycle of ordering, designing, and production even for individual production.
Therefore, in order to make things in a fast cycle, you will consider using design information to arrange for production. However, the product structure information (E-BOM) considered by the designer and the structure information (M-BOM) considered by the person in the manufacturing department are often different, and it is common to add human judgment and recreate it as structure information for production. Then, when there is a design change, it cannot be directly changed to the system and reflected in the arrangement. Therefore, the reflection of the design change have been done by human beings comparing E-BOM and M-BOM one by one.
However, by using the Structure Information Conversion option of TPiCS, even if there is a difference between the two structure information, if there is a design change, with just a few button clicks, you can find out what you no longer need or need additional arrangements from the data you have already arranged (ordered), create a cancellation slip, or create an additional arrangement slip. This feature should greatly ease the production control work of individual production.
The plans for multiple parts or products specified by the group are adjusted so that they are always worked out at the same time.
・For example, when processing different parts on the left and right with one mold, the same quantity must always be produced at the same time regardless of the quantity ordered. In such cases, you can make a plan for the same quantity at the same time in the MRP calculations.
・You can make multiple product plans at the same time at a specified ratio, such as when by-products are produced.
・When changing the schedule by dragging and dropping the production schedule table, the schedule of the items specified in the set production group can always be changed together, and the result can be reflected in the Gantt Chart By Mfg. Sector at the same time.
It is possible to produce it by advancing the sales order for shipment at the end of the month and make a production schedule that takes into account the load on the capability of the neck
You can perform leveling processing of “equally-allocated production” that evenly allocates daily production for the total quantity for one week.
・In the MRP calculations, the workload and the load factor are aggregated for each hierarchy level of the structure based on the calculation result of the parent hierarchy, and if there is something in which the load factor exceeds the set value, the corresponding plan is moved back and forth.
Moves target only yet-to-be-determined plans.
The MRP calculations will be continued based on the plan after leveling for the child parts below it.
・You can perform “front-justified” and “rear-justified” processing.
・You can set the necessity of leveling and the standard load factor for each production line.
・The target item is set in the Leveling Priority of the Item Master.
・The processing of equally-allocated production is also calculated for each parent-child level. After stock allocation and catch-up calculation of lead-time, a plan is made for equal production for each week and item. Low-volume items are calculated to be planned at the beginning of the week as much as possible.
This is an option that allows you to trace the actual results in manufacturing assembly and processing from the shipped product lot name and track the lot name of the procured raw materials and
parts. Not only can you track the raw materials from the product, but you can also track the ship-to from the lot name of the raw material where the problem was found.
We can support lot traceability required by ISO9000, IATF16949, PL Law, Pharmaceutical Affairs Law, etc.
You can also manage the expiration date of raw materials and in-process inventory.
・You enter the lot number of the raw materials at the time of acceptance processing of the raw materials depending on the necessity (setting). (“Required” can be specified)
・When entering the actual results of in-house processing, you can register the in-house lot number and link it with the lot number of the raw material used.
If some of the raw materials used require traceability, TPiCS will automatically allocate them by “first in, first out”. After that, a window to confirm the contents of the allocation will automatically open, and you can make corrections and register as necessary.
・A product or process can use raw materials from multiple lots, and processing where one raw material is used in multiple products or processes is possible. That is, many-to-many relationships can be handled.
・After the raw materials arrive, you can manage all the movements in the factory, such as issuing some of them and returning them to the warehouse.
・Since you can see the purchase price of the raw materials used, and the workers and the working hours when working, the “Cost By Lot” form shows the net cost of each production lot.
・For raw materials and in-processes that require “expiration date management”, you can print a list of items whose expiration date is approaching and dispose of them all at once. For raw materials and goods in process that require “expiration date management”, you can print a list of items whose expiration date is approaching and dispose of them all at once.
・It is possible to calculate the required amount considering the expiration date after the product is completed and after the intermediate products and raw materials used are received.
・You can instruct “raw materials to use” in the work slip. The instructed raw materials will be provisionally allocated and will be automatically withdrawn at the Actual Completion Result Entry for the parent. You can also fix it on the way.
This is an option to approve high-value purchase orders and record all table changes to prevent fraudulent business processing.
・The correction history of all tables can be written to a dedicated table.
・Only the data approved by the “order approval authority” in the issuance of the purchase order can be targeted.
Approver, Approval Date and Approval Key (Encryption) are written in the approved data, and if the purchase order details are modified after approval, the approval will be invalidated.
・You can record operation logs for a long period of time.
This is a system for performing the process control at the site, and it is a system that we would like to use for those who think as follows:
“When I give instructions to the site, the site complains that the load cannot be managed, so I want to make a plan that supports the pile of load.”
“I don't have control because the site does it on their own. I want to be able to manage it somehow using the system.”
“The setup effort differs depending on the production order. I want to make a plan that requires as little effort as possible.”
“There are multiple machines in each process, andtheir capabilities are slightly different, and there are some that can be made and some that cannot be made depending on the product to be made. I want to make a plan that is as efficient as possible among them.”
“Whenever a customer inquires about the delivery date, I can't answer unless I go to the site each time. I want to be able to understand it in the system.”
"Parts are arranged using the MRP system, but we cannot improve the mess and respond to fluctuations in demand. In order for us to respond to the times of rapid change, we want a system that can quickly create an inter-process schedule backed by the parts.”
・The jobs for today and tomorrow are listed on the screen of the on-site work manager, group leader, or the person in charge at the shipping site. (It is important to limit the work to 2 to 3
・When the office changes the plan, it is instantly reflected on everyone’s screen, and the necessary parts are not available, the previous process has not been completed, and the ones that can be started at any time among them.
“Possible-to-start” yet, check the material and the support of the previous process with the Previous Process button and, by writing in the message, the worker knows which one should be prioritized.
If you press the Previous Process button with “Impossible-to-start”data, which process, what child parts are missing, and what’s going on with that plan will be displayed in the window.
・Apart from the result of the MRP calculations, the daily production level (quota) can be specified clearly. This makes it possible to suppress the required level of leveling of production
・From that screen, you decide what you want to do next and press the Start button.
When you are done, click the Register button to register the actual results.
・When you press the Start button, you can see what time the previous process has been started from the next process.
・When you register the actual results, it disappears from the plan instruction screen.
On the contrary, if you do not register the actual results, it will not disappear from the screen.
・When displaying the work that must be done, it can be color-coded according to the work content and work method, so you can think of an efficient work order in consideration of setup etc. by selecting work with similar color.
・When you register the actual results on the start signal screen, they will be reflected in the inventory quantity of TPiCS in the office at the same time.
・The actual results entered in the previous process will be reflected on the start signal screen of the next process immediately, and the red display on the screen will disappear.
・In the evening, you can output today’s daily report and the leftoverlist on your office computer without bothering anyone.
The Shop Floor Control option is a system that solves the problems behind the needs, rather than just meeting the needs that appear on the surface. Alternatively, it is a system that aims to perform true “management” in terms of “soil improvement” by removing the mess that leads to those problems, and enables the site to make the right decisions, rather than having the site put in the actual results to collect the actual results.
This is an option for bidirectional automatic linkage by importing data from other systems into TPiCS and writing the processing performed by TPiCS to the linkage table.
For example, by adding data to the Automatic Import table from the handy terminal side, the Actual Acceptance Results data, the Issue data, and the Actual Work Results data registered in the handy terminal are automatically imported by TPiCS and data can be processed in the same way as entered from the TPiCS form.
In addition, a table for transferring the Actual Shipping Results data entered to TPiCS is prepared for linking with ERP and sales management system, and data is automatically added to the Automatic Export table at the same time as data is entered, and you can grasp the updated data of TPiCS. When checking to prevent double data transfer, it may be necessary to update the TPiCS data. At this time, if the Actual Shipping Results table is updated directly, it is necessary to check the effect on the processing of TPiCS, but if it is an Automatic Export table, you can easily update the transferred check items because only data is added from TPiCS.
It can also be used for the linkage of the following uses:
・Importing EDI data and forecasting data with customers
・Linkage with a production scheduler that adjusts machine production on an hourly basis
・Importing Actual Results data collected from machining centers
・Linkage with the actual acceptance results and the actual work results using POP terminals, handy terminals, smart devices, and RFID for collecting actual results
・Linkage with a cost control system that allocates and aggregates overhead costs
・Linkage with ERP, sales management system, and accounting system
・Coordination with a workflow system that approves purchase orders
The SCM option is an option that strongly cooperates with suppliers and cooperating companies that request production, and realizes production that quickly responds to fluctuations in the
percentage of forecasting orders becoming firm orders and unannounced orders from customers.
The supply chain host can send purchase ordering information and forecasting information to the business partner, and the partner company receives it using the supply chain terminal. In addition to simply sending and receiving order information, it is also possible for cooperating companies to respond if it is possible to meet the specified delivery date or to respond that they will deliver in installments if it is not possible. Sending and receiving is a mechanism of email, so you can use it if you have a dedicated email address.
In order to realize fast-cycle production, as internal improvements progress, it will be necessary for partner companies to shorten their purchase order lead-times in order to make further improvements. At this time, it is difficult to do one-way traffic, and when the production of the partner company is not really in time, by receiving this, you will make it the shortest purchase order lead-time that is built upon a relationship of trust. TPiCS has a buffer concept of basic stock, so if you can cover it with this, you can reply as partial delivery immediately, and if you can not cover it, it will be displayed in the journal and you can decide whether to request the customer to change the delivery date. It is easy to follow the exchange of one ordering data, but it can solve the problem in the large amount of data that changes every day such as the situation of partner companies like this, the situation in the company, the change of product plan using the same material, etc.
You can use the supply chain terminal for free, but if you upgrade to TPiCS, you will be able to seamlessly connect from the supply chain terminal to receiving orders andYou can use the supply chain terminal for free, but if you upgrade to TPiCS, you will be able to seamlessly connect from the supply chain terminal to receiving sales orders and calculating the required amount, andit will show its true value.
When a customer requests a delivery date reply, if the inventory and the on-site progress are checked and the reply is made several days later, the customer’s situation may change. With the
Delivery Date Reply option, it goes without saying that you can answer “can” or “cannot” according to the requested delivery date, but even if you can not, you can answer the schedule that can be
handled by partial delivery.
Order shipment plans and production schedules are made in order from the product level, the calculated inventory of the required date is figured out from the lot balance of the production schedule, and if there is a shortage, the calculated inventory is checked by pulling in the parts to be used and intermediate units, and eventually, up to the calculated inventory of the end parts is checked. When the calculated inventory of parts is insufficient, this time conversely the parent’s plan is adjusted from the plan that keeps the purchase order lead-time, and the schedule of the intermediate unit and the schedule of product production are figured out, and the delivery date that can correspond to the customer is calculated.
You can specify only the quantity and answer when the delivery date can be met.
After the calculation, you can create Sales Order data and the Schedule Detail data directly from the Reply Request data and the Reply Detail data, which can be reflected in the next delivery date reply calculation.
This is an option to temporarily change parts, materials, and intermediate units that are not included in the normal product structure to alternative items.
Changes to alternative items can be accommodated during the MRP calculations, before making an arrangement after schedule creation is confirmed, and when entering actual results after work.
When the parts, materials, and intermediate units registered in the structure in the MRP calculations are out of stock and the stock of alternative items is sufficient, the plan is automatically allocated to the alternative items. You can set multiple alternative items, set the order of the alternative items, and set the amount used of each alternative item.
In order to change the items used after the production schedule is finalized, it is necessary to maintain the Plan data and the Actual Results data. The Alternative Production option makes the process easier and allows you to be more flexible with temporary changes in the raw materials used.
For example, it is suitable for cases where parts that do not meet the specified delivery date may be replaced with available alternatives for production, raw materials that are about to expire and are wasted may be used up first instead of the raw materials that are normally used.
You can also do that with the Actual Result Entry after work. This makes it possible to handle both cases where changes to the items used are confirmed before production and cases where changes are decided during work based on on-site judgment.
You can also replace all quantities with replacements for the original scheduled quantity to be used, or replace some quantities.
This is an option to make a usage plan of finite “resources” such as dies, jigs, machine tools and presses required for production together with the production schedule, instruct the resources
to be used and manage the actual results together with the work instructions, and perform maintenance management by aggregating the degree of resource consumption based on the actual
At the same time as the work instructions of the Schedule Detail created from the production schedule table, the resource schedule to be used is created, and the molds, tools, machine tools, etc. used in the work can be described in the work instructions. By combining with the Gantt Chart By Mfg. Sector option, you can check the usage schedule of “resources” on the Gantt chart and adjust the production schedule considering the load of “resources”. In addition, “resources” are consumed with each production, and replacement and maintenance work are required. The amount of consumption and time during production are recorded, maintenance is performed when the amount of consumption exceeds a certain amount, and the molds, jigs, tools, etc. used for work instructions are output so that the person in charge of work can perform efficient work.