Overview
In the third method of the Operator Portal, we turn on the Production Planning features. This uses the Product Order functionality which enables the use of the Operator Console instead of the Operator Portal as you see fit.
- Actual Product
- Pitch Demand
- Target Quantity
- Pitch Actual
- Scrap
- Operator Count
- Downtime (taken from Dispatches)
- Operator Comments
- eKanban features/Product Orders
- Production details via API
- Scrap Collection
Operator Portal
Operator Console
Setup
For this method, you'll need to setup several things. The following will need to be setup before you can create Product Orders.
- Product Categories can be used to group products together that use the same or similar inspection limits. If you want to use product categories, you can see how to set them up here: https://support.leading2lean.com/hc/en-us/articles/360048365671--Production-Product-Categories
- To see how to set up Products, use this article: https://support.leading2lean.com/hc/en-us/articles/360035528751--Production-Products-Components
- For scrap set up: https://support.leading2lean.com/hc/en-us/articles/360016195152-Defect-Scrap-Categories-Types-Classification
- There are several different methods of assigning scrap in L2L; the default method, by category, by product, or by machine. For more information on those methods, see this article: https://support.leading2lean.com/hc/en-us/articles/360061405831-Methods-of-Documenting-Scrap
- You'll also need to set up Line Cycle Times: https://support.leading2lean.com/hc/en-us/articles/360016406471--Production-Line-Cycle-Times
Once you've completed the setup items, you can create Product Orders. This article will walk you through that: https://support.leading2lean.com/hc/en-us/articles/18758552177549-Product-Orders-Creating-Status-Changes-Build-Sequences-Importing-and-More
Settings (production and line)
In a previous lesson you should have reviewed the pitch start of day and the pitch length. In addition, you'll also need to enable 'Show Pitch Demand column' in the Production Settings.
Optional Production Settings include: Require Comment if Actual is less than Demand or Target, Setting individual pitches red if actual exceeds max quantity', Launch metrics if red threshold is crossed.
Line Settings to enable include: 'Enable Product Orders', 'Order Based Line' (if using Operator Console), 'Number of Product Orders visible on the Op Portal'.
Optional Line Settings include: 'Enable the Setting of Production Demand on Changeover', 'Enable Auto Setting of Production Demand'.
*If you are using the Operator Console, you'll need to assign users to the line.
How to (ekanban)
Once you've gone through the Preparation Lesson and the Setup of the Method of Production you intend to use, you can finally start planning and scheduling your orders.
Remember that Pitch Schedule Template we built? Well now we need to put it in place. You'll go to the Pitch Schedule; choose your Area and Line, and be sure to select the correct template. Now hit load. A pop up box will ask if you want to load for that line or multiple lines. You can choose to load for the day or a timeframe. You'll want to review the schedule for accuracy. (1 Option to set Pitch Demand).
Now let's go to the eKanban Planner. Use the filters to choose the Area and Line where your Product Orders are going to be built. The default status is 'View Schedule', which will show you all product orders. If you didn't import the orders as 'Scheduled' you'll want to set that status here. The Scheduled Status allows them to appear in the eKanban Queue of the Operator Portal. Beneath the Product Orders, you'll see methods of scheduling: Redistribute, Minimal Changeovers, Once per Day, Once per Shift, or Heijunka Ideal. To read more about what each of those buttons does please read this article: eKanban Scheduling: Minimal Changeovers vs. Heijunka Ideal (1 Option to set Pitch Demand).
Once the eKanban Planner Calendar looks good with your orders scheduled, you'll see them appear on the eKanban Queue of the Operator Portal. Now they can be selected to start the build process. To do so, you'll simply select the order you want to start and hit 'Changeover'. Once the Changeover has been completed, you'll hit 'Finish Changeover' and that will put the order to a 'Work in Progress'. If you need to put the order 'On hold' for any reason, that status is available, as well as Pause. To complete the order, you'll select 'Complete Order'.
Integration
If your facility has an ERP or any sensors it can be integrated with our Production Module for creating Product Orders, Submitting Actuals, and Scrap.