Production Control

Track, Analyze, Be Efficient

Tracking, analyzing, and understanding product costs, material flow and employee efficiency are significant challenges for manufacturers today. Production control tracks your materials, operation activity, labor and outside services for all sub-assembly components and finished goods produced.

The work order is the document used to track all production activity within the system. Work order types include the following:

  • Stock (for inventoried items existing in the item master file)
  • Non-Stock (items do not exist in the item master file, but can be manufactured and linked to sales order or parent work order)
  • Service (tracks materials and labor for processes such as preventative maintenance, training, cleanup, idle time, and waiting for materials or machinery)
  • Teardown (allowing an item to be disassembled and component parts returned to inventory)

Typically, a stock item, its bill of materials (BOM) and routing operations (both primary and alternate) are established in the inventory master file for that item. Upon creation of the work order, the BOM and primary routing are defaulted into the work order, and standard quantities and units are extended for the quantity of items being produced. For non-stock and service, work orders, the BOM and routing are established at the time of work order creation.

After the work order is created, several transactions are used to track the flow of activity. A material pick ticket can be created which reserves material in an inventory bin for a work order. The pick ticket directs the material handler to the bin for pickup and to the work center for delivery. The material transaction moves material or sub-assembly inventory to the work order in the system. A labor transaction can be entered to track actual labor time for an employee to a specific work center, while work in process move transactions enable work center and employee efficiencies to be calculated as well as indicate to planners the progress of the work order. Finally, the work order close transaction partially or fully moves product from work in process to finished goods, or rejects product for quality purposes. All of the above transactions may also be entered through the MasterTools Shop Floor/Warehouse Control Module.

Additional Features

  • Track work order completions, cancellations, and rejections
  • Create work orders from MRP, sales orders, quotes or estimates
  • Backflush materials at the work order operation, or work order close
  • Associate images (i.e., drawings, specifications, schematics) to a work order for viewing
  • Track machine and tool activity
  • Analyze picker, work center and/or employee efficiency
  • Create material pick tickets per work order, location, work order or sales order
  • Link outside service purchase orders to work order operations for cost tracking
  • Handle floor stock inventory

Reports Include

  • Open Work Orders
  • Open Material Allocation
  • Open Operations
  • Material and Labor Variance
  • Work Center and Employee Efficiency
  • Work Center Schedule
  • Work Order Valuation
  • Open Work Order Cost
  • Payroll/Labor Variance