Japanese　Chinese　 Vietnam

　It supports both "f-MRP", which is strong in repetitive production, and "mfg. no. control", which is strong in individual made-to-order production, and creates production schedules using management methods suitable for each product, intermediate process, and common parts and materials.

Examples of industries where the system is used: 

Industrial machinery, measuring instruments, medical equipment, rubber products, ceramic and stone products, electronic circuits, etc.

Common Functions for Each System

Running change function

　By simply registering the old and new part codes in the Engineering Change Master, the system will calculate the time to consume the current stock and parts already ordered, and automatically switch to ordering the new parts.

　It automatically responds to changes in production schedules or in inventory quantity. When entering the parent's actual results, the negative (withdrawal) figures for the child parts used will also be automatically changed. You can also directly specify the part changeover date. (Bill Of  Materials)

Options related to production schedule and requirement calculation

※See the section of Options for more details.

 ・Gantt Chart By Mfg. Sector option

　From the production schedule created as a result of the requirement calculation, you can check the workload of the manufacturing department and adjust the plan on the Gantt Chart By Mfg. Sector.

・Auto Leveling option

　When calculating the required quantity, the system performs automatic leveling based on the production capacity of each work center, manufacturing lead-time, standard work hours, quantity, and allocation priority.

・Multiple Locations option

　It is possible to create production schedules that automatically divide products and units by ratio among multiple manufacturing locations, plans that normally produce in-house but outsource some production to partner companies when production limits are exceeded, production schedules that arbitrarily allocate manufacturing locations, plans for arrangements according to post-processes, and plans that take into account the calculated inventory of each supply destination.

・Alternative Production option

　When constituting parts and materials are in short supply, production schedules can be made using future calculated inventory for designated substitutes.

・Manufacturing Traceability option

　It is possible to calculate required quantities taking into account traceability from shipped products to raw materials, as well as the expiration dates of each lot of finished products, semi-finished products, and materials

・TPiCS allows for three different methods of mfg. no. control:
B-Seiban：Basic manufacturing number control. Mfg. no. explosion creates a procurement plan that links products, intermediate units, materials, and parts by mfg. no. according to the product structure from the Mfg. No. Schedule. The product structure can be changed for each Mfg. No. Schedule.
S-Seiban： Mfg. no. control of preceding arrangements. Intermediate units are ordered and produced using mfg. nos. of preceding arrangements, and the final mfg. no. is allocated to produce the product. If there is a shortage when mfg. nos. are exploded, a production schedule is automatically created.
F-Seiban：f-MRP mfg. no. control. The required amount is calculated using f-MRP, which is flexible to demand fluctuations, and the created Schedule Details are linked by mfg. nos.

　TPiCS offers highly advanced mfg. no. control functions even in mfg. no. control:

・Lot accumulation is possible for the quantity of Mfg. No. Detail.

・You can allocate the entire quantity accumulated to lot, allocate only the required quantity by mfg. no., and automatically or manually allocate the lot balance when other mfg. nos. are exploded.

・You can also allocate mfg. nos. to Purchase Order data as well that is currently being arranged.

・If excess parts and materials are procured based on yield rate, etc., and there surplus parts and materials when the product or are unit is completed, they can be released from the mfg. no. and allocated to other mfg. nos.

・Shortage due to defects can be re-ordered, and parts and materials that have been unallocated to mfg. nos. can be allocated.
・You can manage revisions and select the inventory to be allocated

・You can take inventory by mfg. no.

Structure change function

　There are two methods available for changing the product structure for each mfg. no.:
・Metgod of using option codes
　You can change the structure by registering the different parts used depending on the Option Code in the Bill Of Maerials, specifying the Option Code in the Mfg. No. Schedule, and exploding the mfg. no.
・Method of changing the structure after mfg. no. explosion
　After creating Mfg. No. Detail according to the registered product structure by exploding the mfg. no., you can easily change the structure for each mfg. no., such as adding units and deleting or changing parts and materials.

Cost accumulation by lot function

・Even if production is in progress, incomplete work can be calculated as a planned cost and compared with the standard cost, allowing for budget-to-actual management.

・Parts calculated using f-MRP can also be included in the cost by mfg. no.

Form issuing function

Work instructions, purchase orders, outsourced processing requests, supply instructions
　It calculates required quantities, explodes mfg. nos., or issues purchase orders, work instructions, and outsourced processing requests of plans made manually.

Response to the Electronic Books Maintenance Act

　It saves a PDF file where the date and time and any file name are given to the print contents.
Automatically set the cheapest supplier
　Different unit prices depending on supplier, season, quantity, and urgency can be registered in the Unit Cost Master, and when creating a Schedule Detail, TPiCS will be able to look at the season, quantity, etc., search for the cheapest supplier that meets the conditions, set it in the Schedule Detail, and issue a purchase order.
Order by supplier part code
　You can place orders using a supplier's part code (catalog code, etc.) that is different from your company's management code.
Parallel orders
　You can place orders with multiple suppliers by dividing the order proportionately, or order quantities exceeding the upper limit from other suppliers.

Specify raw material lot used (Mfg. Traceability option)

　You can specify the lot number of the raw materials to be used in the work instructions.

Idetification tag
　You can print the required number of identification tags according to the setting of Quantity Of Contents as the planned number at the same time as work instructions, outsourced processing requests, etc. In the Actual Acceptance Result Entry for parts and materials, you can also register the expiration date and lot name of the actual article, and print identification tags with the expiration date and lot name from that Actual Results data.

Issuance of delayed event list
　You can issue lists of purchase orders and work that are delayed for delivery dates, but rather than dealing with delays after they occur, you can prevent delays by printing or emailing them to each supplier as a list of expected receipts for next week, for example.

Quotation request
　You can issue a Quotation Request for not to mention new parts with no unit price set, as well as a quote when its deadline has expired or is approaching each time a plan is created. You can also obtain competitive quotations from multiple suppliers and automatically adopt the one with the lowest replied unit price and shortest delivery date.
Sending e-mail
　Purchase orders and quotation requests can be sent by email.

Actual result working hours entry
　You can enter the actual results for the quantity in real time, and for the actual result working hours, you can enter them later using a dedicated “Actual Result Working Hours Entry” form. You can also allocate the total working hours of a work crew to multiple actual work results and automatically set them as the actual result time for each.
Actual receipt/acceptance inspection results
　You can also enter actual results in two stages: the actual receipt results for receipt confirmation and the actual acceptance inspection results for payment after inspection is completed. A record of the liabilities will be displayed on the Accounts Payable Detail based on the actual acceptance inspection results.

Bulk entry
　Once you are able to produce as planned, you will want to reduce the hassle of typing every day. You can automatically set tentative actual result quantity from the plan to be completed today, change and enter only some Schedule Details that could not be produced as planned, and enter the actual results in a lump.

Lot name entry
　You can make it mandatory to enter a lot number (lot name) when registering the receipt of critical raw materials. You can also automatically assign any lot name by combining sequential numbers, dates and times, fixed characters, SQL statements, etc.

　By entering actual production results, Inventory you can record the use of raw materials and lot numbers for previous processes, and you can specify lots manually, automatically allocate lots on a first-in, first-out basis, and allocate multiple lots and lot balances. You can give work instructions specifying the lot to be used before the work begins depending on the setting.

　In the Manufacturing History option, by linking the lots used, the process from receiving parts and materials to production and shipping is recorded, and part and material lots can be extracted from shipments, and shipping lots can be extracted from part and material lots.

Inventory
　Inventory processing is carried out at the end of the fiscal year or month to adjust the Current Inventory at each storage location to the actual inventory quantity. In addition to simultaneous inventory counts, we also support partial cycle inventory counts and temporary inventory counts.
　If there is an inventory discrepancy, Actual Inventory Results data for the difference will be created, making it easy to aggregate the amount of the inventory difference.
　The physical inventory is reflected by holding the inventory as pre-inventory at the start of the inventory, entering the physical inventory value, and reflecting the inventory difference in the current inventory that changes daily when the inventory is completed. It is also possible to enter actual results during the period in which the inventory count work is being carried out.

Quantity conversion function

　You can convert the planned quantities to match the units displayed on the instructions for the planned quantity in the production schedule table, convert the Inventory List display, and convert the structure table, and display different units for each product, intermediate unit, and part and material.

　For example, you can calculate the purchase order amount of liquid raw materials as 200 liters or 400 liters, and when placing the order, convert it to 1 can or 2 cans in drum cans (200 liters) on the order form. When 2 cans are actually received, the conversion is reversed and 400 liters can be reflected in the inventory.

Payment management

　You can aggregate data eligible for payment from the Actual Acceptance Inspection Results data, create a payment schedule according to the closing date, and manage actual payment results.

Accounts payable & receivable management

Accounts payable management (accounts payable detail)
　When entering actual acceptance inspection results, you can enter the amount purchased, supplier, etc., and this will be reflected in the Accounts Payable Detail.

　You can write out journal data for accounts payable and accounts receivable details in accordance with the "journal data import format" of general PC-based accounting systems.

Accounts receivable management (accounts receivable detail), Customer Order and Sales Management option
　The sales amount will be reflected in the Accounts Receivable Detail by entering the actual shipping results. Tax rates compatible with the invoice system, as well as the total sales amount and consumption tax amount for each tax rate will be output on the invoice. When printing or emailing invoices, PDF files are saved to comply with the Electronic Books Maintenance Act.

Group aggregation, item aggregation, total aggregation

　The displayed data can be aggregated and displayed in groups by any item.

　You can display the totals for each item or the grand totals for any item. The totaling method can be set for each item, such as maximum, minimum, average, or total, and you can name the total settings, save them, and easily call them up and switch between them.

　You can write them out, including each aggregated value, to an Excel file.

Linked Interface with Other Systems

Text export and import
　All table data, including transaction data such as master data, Schedule Details, and purchase-ordered data, and aggregate data such as Inventory Lists, cost accumulations by item, and cost accumulations by product, can be written to and read from text files.
Transaction Data Text Import
　 Just like when you operate on a form, such as entering sales orders, Schedule Details, actual operation results, actual shipping results, actual issue results, and inventory transfers, as soon as the text file is read, the associated tables are updated. In the case of importing Sales Order data, it is reflected in the production schedule table at the same time as the Sales Order data is registered.
Transaction automatic import and export (Transaction Interface option)
　 This is a table linking function of the Transaction Interface option. You can import data written from other systems into the import table and process it in the same way as TPiCS form registration. Also, TPiCS registered data can be automatically written to the export table, allowing two-way linkage with other systems.

WebAPI linked import (Eransaction Interface option)

　The Transaction Interface option operates as a built-in HTTPS server, and by sending commands to this web URL, you can import data such as sales orders, actual material results, actual work results, and actual shipping results in real time. The WebAPI response indicates whether the import was successful or not, so you can create a system that prompts the operator to re-enter data.

Calendar

Operating calendar

　You can register calendars with different holidays and operating hours.
　There is no limit to the number of calendars, and you can specify the calendars to be used in detail, such as by supplier, by cooperating company for processing, by customer at the time of shipping, by manufacturing department within the company, and by process.。You can manage up to 12 shifts, including day and night shifts.

　You can easily create daily, weekly, and monthly calendars from the "base calendar" where you register your annual business calendar. Also, you can set operating calendars with different granularities, such as a day shift and night shift calendar for the current month, a day-by-day calendar for next month, a week-by-week calendar for the month after next, and a monthly calendar beyond that, in one calendar, and you can also make production schedules and purchase orders with long delivery time items accordingly.

Capability calendar

　The capacity of each production location and equipment, which changes from day to day, can be set in the capability calendar. The Gantt Chart By Mfg. Sector allows you to check the load factor based on production volume against daily capacity, and leveling is also possible by combining it with the Automatic Leveling option. For example, you can reduce capacity every Wednesday for planned maintenance of production equipment, or check the number of part-time workers and their workload, which changes from day to day.

From sales orders and forecast data to production schedules

・You can create a TPiCS shipping schedule from Sales Order data and perform the MRP calculations without any change.

・By linking with the f-MRP function, parts and materials can be arranged based on the forecast plan.Even if there are changes, because it is based on the f-MRP function, it can be connected to the next MRP calculations without any change.

・In receiving an order for a product with mfg. no. control, you can create a Mfg. No. Schedule at the same time as entering the order, or allocate the order to the Mfg. No. Schedule of preceding arrangements. If there are not enough Mfg. No. Schedules to allocate, a new Mfg. No. Schedule for the missing quantity can be automatically created.

Importing data

・Order data from the Internet, etc. and delivery instruction data can be imported in CSV file format.

・Sales orders can be imported from EDI, ERP and other systems via Transaction Interface option.

Various sales order registrations 

・We fully comply with daily delivery instructions.

・You can delete forecast data while importing firm Sales Order data.

・It is also possible to leave it as a backorder and not reflect it in the production schedule.

・We can accommodate full-choice option production orders.

・Sales Order data can be entered at any level of the product structure. This allows us to manage intermediate products and parts as OEM shipments or repair parts. You can perform the MRP calculations by taking these required quantities into account.

Forecast data

・In the case that confirmed delivery instruction data is sent daily like the automobile industry, data can be imported while deleting the forecast data in the order of the forecasting delivery date for the same item and delivery location.

・You can process firm sales orders and forecast data.

・You can periodically delete the forecast data and import new data again.

Selling price registration

・It is also possible to change the selling price depending on the order quantity and time of order.

Billing and cash receipt management

・Based on sales details, invoices can be issued under the Qualified Invoice Storage Method (invoice system), and cash receipt can also be managed.

・It is possible to register and display overseas customer information in the language of that country.

・Accounts Receivable Detail can be written out for accounting systems.

Sales order trend list

・Even though we have received a forecast order, there are delays in delivery. Although we are arranging materials based on forecast orders, we are having trouble with excess materials. These causes may result in differences between the forecast and firm sales orders that cannot be covered within the margin of error.原因を分析することで、By analyzing the causes, you can make proposals to improve the accuracy of unofficial forecasts. In order to create production schedules that include errors, you can check the increase or decrease in the number of forecasting and firm orders, the rate of increase or decrease, and the trends in changes to delivery dates.

　In the case of individual production, different products are made for each customer order, so it is not a process like repetitive production where master data is prepared in advance and uniform processing is carried out. Therefore, production control systems that require the preparation of master data in advance were very difficult to use. In order to solve these problems, TPiCS has been designed and enhanced with functions to be able to accommodate a variety of operational methods. Even with individual production, it is not necessary to individually design every product. Instead, common items and repair parts are arranged using the repetitive production function. It can also handle detailed management of a mixture of these, such as when it is incorporated into a one-item production configuration, or when the repetitive production function or mfg. no. control function is used depending on the product.

　This function assumes cases where the specifications change with each sales order and the system is operated without registering the master data, due to "one-off production."
 

・You can copy the structure of a similar mfg. no. from the past and modify it for use.

・The drawings are released in a piecemeal fashion, and you can make arrangements from "what is necessary" and "what is possible" among them.

・Once you have been able to create a pattern to a certain extent, you can use it as a base and make modifications to it.

・By linking it with the Structure Information Conversion option, "additions," "modifications," and "eliminations" due to design changes can be processed seamlessly and quickly reflected in arrangements.

・Repeatable general-purpose units and parts can be used.

・By using it in combination with the Quotation Management option, for example, you can issue a re-quotation using the quotation before the design change as reference material.

・You can issue a Quotation Request to the supplier and conduct business in accordance with the Subcontract Act. (Competitive quotes are also possible.)。

・It is possible to manage parts that are no longer needed due to design changes, etc., and reuse them in other projects.

・This option requires that you purchase the “Mfg. No. Control system.”

　“Product structure information” and “change information” for design are imported as structure information in CSV files from parts lists managed in CAD or Microsoft Excel, and reflected in TPiCS production information. Linked processing can be performed with one data, so design changes are reflected in production quickly and without omissions.
 
・Operations that are not included in the design BOM, such as supply and outsourced processing, can be registered in the manufacturing BOM.

・It is also possible to import information not included in TPiCS, such as implementation information and supplier information listed in the parts list, and print it on purchase order and work instruction forms.

・Even design changes made after modifying the design BOM to the manufacturing BOM can be quickly reflected in the arrangements.

・Design changes are displayed with status and color to prevent processing omissions.

・When used in combination with the One-item Production option, design changes can be seamlessly reflected in procurement data.

Use of CAD data 
　As customer needs become more diverse and product lifecycles become shorter, it has become increasingly important to shorten the order-design-production cycle, even for individual production.
　Therefore, in order to manufacture products in a fast cycle, we consider using design information to arrange production. However, the product structure information conceived by the designer (E-BOM) and the structure information conceived by the manufacturing department staff (M-BOM) often differ, so it is common for human judgment to be added to reconstruct the structure information for production. This means that when there are design changes, it will no longer be possible to directly change them in the system and reflect them in arrangements. For this reason, design changes have traditionally been reflected by humans comparing the 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, when there is a design change, you can simply click a few buttons to find out what is no longer needed or what needs to be ordered additionally from the data that has already been arranged (ordered), and create cancellation slips or order forms or work instructions for the additional arrangements. This function should make production control work for individual production much easier.

　This system makes the workplace "visible, understandable, and doable," thereby realizing more efficient production control and information sharing.

Recommended for those who have such concerns:

System Features

・A list of jobs for which work instructions have been issued is displayed on the screen of the site supervisor or team leader.

・Whether it is possible to start will be displayed with ○×△.

・When materials and previous processe are available, a ○will be displayed, and when the entire quantity is not available, a △ will be displayed along with the number that can be manufactured. Any tasks that cannot be completed are displayed with an ×, making it easy to see whether they can be started or not.

・By pressing the Previous Process button on data that cannot be started, marked with an × or △, you can check the production status and inventory quantity of the previous process, making it easy to understand.

・By writing in the message when the previous process will be completed, it will indicate at what point the work can start.

・ When you change plans in the office, it's instantly reflected on everyone's screens.

・Priorities can be rearranged by dragging, regardless of delivery date, and this is reflected on everyone's screen.

・Daily production levels (quotas) can be clearly stated.

・When you press the Start button, the start status of the previous process is sent to the next process and the start time is also set.

・Today's daily report and remaining list can be printed on the office computer.

　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 option allows you to import data from other systems into TPiCS and perform two-way linking between the processing performed in TPiCS and other systems via a link table.

Automatic Import: 

　If you add data from ERP, sales management, or actual result input devices such as handheld terminals to the Automatic Import table, TPiCS will import the data periodically and process it in the same way as if it had been registered in a TPiCS form.

Automatic Export: 

　This is used to transfer actual shipping results registered in TPiCS to an ERP or sales management system, and to automatically transfer purchase orders created in TPiCS to a purchasing system. Data is added to the Automatic Export table dedicated to linkage every time TPiCS processes it, so it can be converted in the linked system and transferred to other systems.

　Data can be imported into TPiCS by sending commands and JSON data to the URL of the web server (HTTPS) built into TPiCS. Table linkage is suitable for batch processing that is executed periodically, and WebAPI can display the registered results on the spot, such as actual results registration, and encourage re-registration.

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