■ Visualizing load and identifying bottlenecks

The system compares the capability of each production resource (capability registered to the Work Center Master) and the scheduled load quantity (scheduled quantity x standard time + setup time) on a daily basis and shows the result. If the set maximum load factor is exceeded for a particular day, the graph shows a warning color for the day so that you can identify operations with insufficient capability. You can implement measures based on numerical evidence, such as considering overtime and holiday work, as well as transferring scheduled work to other available equipment and outsourcing partners.

■ Intuitive operations by drag and drop

You can drag and drop schedule boxes on a chart to change the scheduled start date, scheduled completion date, and responsible location. Moreover, all related processes can be grouped and moved together. Two modes are available: all aggregate for adjustment and aggregation of person in charge for reference. The system allows for display with the aggregation speed prioritized according to the use.

■ Flexible schedule adjustment【5.1】

Schedule splitting and totaling functions have been enhanced. You can split a schedule by any quantity or number of records to finely adjust the load, or combine fragmented schedules into one, achieving an efficient production arrangement with less setups. Even if some portions of actual results have already been recorded, a schedule can be divided within the remaining quantity, allowing for flexible responses to sudden troubles or changes in priority. In addition, the system supports the "Set as temporary" function, which executes all of these adjustments in memory. The actual data is not updated until the "Reflect" button is clicked after repeated trial and error on the screen, so it can be used for a simulation to derive the optimal schedule.

■ Masterless start-up

You can enter unit structures and part information directly on the project screen to start arrangement without the need to register the Item Master or bill of materials beforehand. This responds to the operation of vertical start-up, where parts are arranged sequentially upon completion of their drawings.

・Creation from templates：By registering previous standard structures or units as "fixed pattern masters," you can complete the structure data simply by calling them and deleting unnecessary parts or adding new parts.

・Creation from CAD data：Linked with the Structure Information Conversion option, the system can directly import a bill of materials (CSV file) created by the design department as a project structure. This prevents errors that may be caused by manual copying.

・Copying similar projects：You can specify a previously created project and copy its structure tree to start up a new project.

■ Flexible tree-based structure editing

You can add, delete, and move (drag and drop) items on a tree-based graphical representation of the hierarchical structure. It allows for managing a mix of unregistered new parts and general-purpose parts registered in the master. Using the Add Child Item and Master Search panels, you can allocate parts to a specified structure hierarchy.

■ Setting of multiple location class

"Multiple-location Class" in the Item Basic Master can be set to Single, Multiple, Production Schedule Split, Withdrawal Schedule Split, By post-Process, or Supply according to the purpose, allowing for controlling the calculation logic for each site.

■ Schedule development according to the capabilities of each site

Different manufacturing lead-times, lot sizes, and operating calendars can be set for each site, and production schedules can be created according to the actual situation of each site.

■ Flexible schedule transfer and load distribution

When the load is high at the site in the original schedule, you can manually transfer the schedule to other factories or outsourcing partners. In addition, "Production Schedule Split" and "Withdrawal Schedule Split" automatically split production schedules (production schedule split and withdrawal schedule split) by a specified ratio or upper limit according to the registration details of the Split Schedule Master, distributing load and risks.

■ Strict supply management and control by post-process

The system handles the inventory of each site separately, preventing the mistake of allocating materials intended for a specific site to the wrong site. This function strictly separates inventory linked to sites by f-MRP calculations and demand. In supply management, the difference between paid and free supplies can be set. The system develops a detailed material supply schedule according to the start date of the next process through MRP calculations, considering the number of days required for transportation between sites.

■ Settings of load factor subject to leveling and allocation priority

You can set a "Load Factor Subject To Leveling" to the Work Center Master for calculations with a specified upper limit of load factor, such as 100% or 110%. Besides, by specifying an "allocation priority for leveling" in the Item Master, etc., you can prioritize particular, important items in the schedule.

■ Automatic schedule shifting

This function compares daily production capability and load, automatically moving exceeded load to available schedules. You can select either front-loading, which prioritizes delivery dates by moving the start date earlier, or back-loading, which reduces inventory stagnation by moving it closer to the completion date, achieving optimal adjustments for each item.

■ Consideration of manufacturing lead-time【5.0】

instead of determining the load from a single completion date only, the load is aggregated on a prorated basis over the entire lead time from start to completion. This prevents an unreasonable schedule from interrupting a time-consuming process, improving the accuracy of leveling calculations.

■ Equally-allocated (Ratio-based) production

This function automatically creates a daily detailed production schedule by evenly distributing weekly total production quantities based on the ratio specified for the working days. This helps stabilize takt time and level the load on the production site.

■ Di-directional production linkage

Based on the production characteristics of the equipment, the system comprehensively checks inventory status within a group. The system automatically replenishes any missing items at a preset ratio to prevent a shortage in the set schedule. This optimizes the inventory balance of the entire group while leveraging the benefits of production from the same mold for the same number of parts and co-production.

■ Batch adjustment and management【5.1】

When a schedule is moved on the Gantt chart, the schedules for all related set products automatically follow it. Additionally, the system automatically assigns a common order number (with different branch numbers) to set products, allowing for issuing a single work instruction for multiple items or registering actual production results in batch. This reduces the man-hours for slip management and data entry at the site.

■ Wide scope of application due to synchronized production

This option is applicable not only to material processing and intermediate units but also to final products.

■ Separation of advanced arrangement and replenishment instructions

For long-lead items or materials purchased from outside, the future required quantity is projected by f-MRP calculations, and advanced arrangement is performed based on the difference between the schedule detail creation period and order issue period, preventing stockout. On the other hand, start instructions for internal processes do not unconditionally follow the planned schedule calculated by the system; instead, the "inventory (consumption) actually pulled" from the preceding process from the post-process triggers a real-time insurance of manufacturing instructions as "pull production requests" to replenish the exact quantity consumed.

■ Suppression of work-in-process inventory and message function

This function controls the behaviors of push-type production, where preceding processes produce too many products at unnecessary timings based on calculated schedules. This achieves just-in-time production. From the Shop Floor Control option screen, requests for replenishment from post-processes to preceding processes can be made directly. Moreover, texts indicating priority or designations of express order can be entered as "messages," supporting coordination between sites.

■ Direct link to production and arrangement schedules

When sales order data is registered, it is written to the shipping schedule (shipping schedule line) in the Production Schedule table and acts as an independent demand for f-MRP. Performing the subsequent MRP calculations consistently explodes the arrangement schedule of parts and materials at the end of the configuration.

■ Reconciliation management of forecasts and firm sales orders

While importing long-term forecasts in advance and proceeding with arrangement, the system automatically offsets (reconciles) old forecast quantities when firm sales order data is registered. By adjusting the "reflection level" of forecast data, you can control the risk of arranging items for uncertain demand (unnecessary parts stockpiling).

■ Actual shipping results and sales recording

In addition to the function to automatically record sales at the same time as actual results registration, you can select a method to keep actual shipping results in the status of "Temporary Shipping (uninspected at customer's site and in transit)" and officially recordsales when you enter "Acceptance" at a later date. 

■ Accounts receivable details and billing management

The system creates accounts receivable details for each customer from the sales data. It issues invoices according to the closing date and performs reconciliation upon cash receipt consistently. Multiple designs of forms, including invoices, are available, and you can issue invoices with multiple tax rates.

■ Product issue instructions

Using this function in conjunction with the Issue Management option automates instructions to pick items from product warehouses to shipping locations. When this function is used in conjunction with the Manufacturing Traceability option, you can specify in the system the lot to be allocated for shipment beforehand.

■ Management of sales order trends 【5.0】

The system records the change history of how forecast order quantities and sales order delivery dates have changed since they were registered. The data can be used for analyzing customer order characteristics and demand fluctuation.

■ Accurate delivery date simulation calculations

Based on the desired delivery dates and quantities, the system identifies shortages across the hierarchy, from product to material at the end of the structure. In the case of a parts shortage, it develops an arrangement schedule while observing the purchase order lead-time (order issue period) set for the item, adds the manufacturing lead-time for each process based on the goods receipt availability date, and back-calculates the final product-completion date. This allows you to provide the soonest possible delivery date. You can change the simulation conditions by selecting from "after the confirmed period," "after the confirmed period for outside the company only (interruption is allowed inside the company)," or "express (interruption is allowed both inside and outside the company)."

■ "Ship Today" at the time of inventory allocation supported 【5.0】

In the calculation for replying delivery dates, when the product inventory is allocated, this function automatically sets the replied shipping date to today (calculation date). It acts as an instant delivery reply logic for stock items.

■ Saving and reusing quotation history【5.1】

When a quotation (hard copy, PDF, etc.) is issued, the data is stored in two history tables: Product quotation History table and Quotation Calculation History table. Based on the data, you can quickly create a new quotation using similar past quotations or "re-quote (count the number of quotations)" to control versions according to the progress of sales negotiations.

■ Seamless linkage between quotations and sales orders【5.1】

This function automatically explodes a quotation breakdown from the project structure of the One-item Production option or the product structure of the Standard Master. Simply clicking the [Create Sales Order] button directly creates and inherits sales order data based on the settings (scheduled delivery date, quoted quantity, amount, etc.) of a quotation.

■ Explosion based on the Routing Master

 If you set a "Routing Code" in the Item Master, the system refers to the settings of the Work Master and the Routing Master (setup time, standard time, work sequence) when schedule details are created, automatically exploding schedule data of detailed processes. If a part of a process involves outsourced work, specifying an outsourcing partner as the production location automatically creates data for issuing an outsourced processing request.

■ Individual setting of withdrawal timing【5.0】

The timing of inventory consumption can be set in detail for each item, such as "at the start of the first process" or "at the completion of a specific intermediate process," instead of the completion of items only.

■ Material arrangement according to the start of the process 【New】

TPiCS-X Ver 5.2 allows you to specify in a master which detailed process of the parent product shall use a child part in the structure. Based on this information, the f-MRP performs calculations for arrangement and develops a goods receipt schedule according to the scheduled start date of the relevant process. This prevents unnecessary early delivery of parts.

■ Efficient issue instructions

The system can create instruction data according to conditions, such as batch issues with specified order numbers of parent products or issues to replenish items exactly to make up for shortages, with consideration to the on-site inventory level. When it is combined with the Manufacturing Traceability option, an inventory lot is automatically selected based on first-in, first-out logic and recorded as traceability tracking data.

■ Free location issue supported【New】

Ver 5.2 supports multiple-warehouse and free-location operations. Using pre-set "priorities" or "issue group settings" based on physical distance, the system automatically determines the optimal storage location and creates instruction data for picking work.

■ External linkage【5.1】

When an indication mark changes to ○ or when work is delayed, you can process the situation using linkage, such as by calling an external system program to illuminate a warning lamp or playing an announcement using a voice synthesis system.

■ Long-term storage with history records

Massive amounts of traced data are preserved for a long time as a "Manufacturing history record" separate from daily transaction data. This prevents data bloat while allowing you to search and track data when a defect is found, even after a few years.

■ Advanced linkage with production schedules【New】

In MRP calculations, TPiCS-X Ver 5.2 restricts the capability in a scheduled maintenance period and performs calculations to develop a production schedule, while automatically avoiding that period.

■ Automatic arrangement of maintenance materials【New】

When replacement parts and consumables required for maintenance are registered in a master, TPiCS-X Ver 5.2 creates a "Maintenance Withdrawal Schedule line" in the Production Schedule table. If a shortage of inventory is found by MRP calculations, a purchase order schedule for the part is automatically developed, and the inventory is withdrawn upon the registration of the actual maintenance results.

■ WebAPI as a service【New】

TPiCS-X Ver 5.2 features an architecture where the WebAPI processing function operates as an independent WebAPI Service.  There is no need to keep the TPiCS running: it begins to accept processing in the background when the OS starts up.

■ Addition of concurrent execution user licenses【New】

A dedicated license has been added to TPiCS-X Ver 5.2. In the event of asynchronous, simultaneous access from multiple terminals, it executes processing, such as data registration and updates (POST commands), in parallel without generating wait times. When actual results are registered by automatic import, it performs exclusive control by locking record to prevent data inconsistency.

■ Real-time reference by GET commands【New】

TPiCS-X Ver5.2 supports GET commands, which are used to inquire from outside about current inventory levels or the progress of a production schedule, allowing you to acquire real-time data and hand it over to another system.

■ Purchase order and quotation approval function【5.1】

You can prohibit the output of purchase orders/work instructions and the input of actual results until an authorized supervisor approves them. In addition, TPiCS Ver. 5.1 and later support the approval of product quotations. An "approvable upper limit amount" can be set for each user's role, allowing you to establish a correct ordering and quotation process in place according to the job authority of each person in charge.

 ■ Data encryption lock

The system assigns an encrypted approval key to approved data and locks it. This prevents illegal tampering through direct access to the database from outside.

■ CSV linkage with terminal programs

The client is configured as the "Supply chain host," and the supplier as the "Supply chain terminal." Suppliers can use the demo version of TPiCS-X (free of charge) as a terminal, building an EDI environment without system investment. The system receives data sent from the host, enters replies about delivery date changes or quantity splits on the terminal, and sends the data to the host.

■ Importing reply data and reflecting into schedules

The system receives replies (same reply, delivery date change, partial delivery, quantity reduction, etc.) sent from suppliers and imports them into the Production Schedule table on the host. By executing MRP calculations, it detects through journals how delays in parts delivery or partial deliveries will affect your company's product assembly schedule, allowing for rapid rescheduling.