Manufacturing

Every Manufacturing topic of the Zyntra OS user guide, step by step: Manufacturing home, Work centres, Bills of materials, Routings and 22 more.

26 topics

Manufacturing homeManufacturing is a module of Zyntra for companies that make what they sell. It runs beside any edition, or on Zyntra OS alone. It starts with the bill of materials: what each product is made of, level by level, and the units each part is measured in. It uses Zyntra's own items, warehouses and stock costs.
Work centresA work centre is a place on the floor where work is done: Cutting, CNC machining, Assembly, Painting. Each one has its machines, its cost per hour and its calendar, so Zyntra knows how many hours it can give each day and what an hour of its work costs. Each operation of a routing is done at one.
Bills of materialsA bill of materials says what one run of a product makes and what it takes: its components with their quantity, unit and scrap, the parts that have bills of their own, and what else comes out of the run. Each product keeps its bills as versions; one is active at a time.
RoutingsA routing is how one product is made: its operations in order, each a stage done at a work centre, with its times and its instructions. From it Zyntra works out how long a batch takes and what its work costs, for the batch and for one unit.
Units of measureA conversion says how one unit turns into another: in general (1 kg = 1,000 g) or for one item (a box of this screw = 200 pieces). Every bill of materials reads them both ways, so a line asking 250 g of a glue kept in kg takes 0.25 kg.
Engineering changesAn engineering change is how a product's bill of materials or routing changes: why it changes, the proposal side by side with what it changes, its approval, and the day it takes effect. Until that day, the factory keeps making the product as before.
Production ordersA production order makes a quantity of one product by its bill of materials and its routing: it reserves the materials, takes them off the shelf by hand or as the units are reported, puts what it makes on the shelf in parts, and follows each operation on the floor. It is made for stock, for a sales order or for a project.
Disassembly ordersA disassembly order is a production order the other way round: it takes a product off the shelf and puts its parts back, by the lines of its bill of materials — a returned product with a damaged door, a kit taken apart, a set split into its pieces.
Formulas and batchesA formula is a recipe for paints, food, chemicals or medicines: each ingredient is a percent of the batch, so a batch of any size takes the same proportions. A batch is a production order of a formula: it says how much goes in, what it should give, the lots that went in and the yield it really gave. An active ingredient is taken by its strength: a weaker lot is taken in a larger quantity.
Kanban boardKanban refills what the line uses without anyone planning it. Each card stands for one bin of an item in one warehouse. When the bin runs out, its card is scanned empty and it makes one document to refill it: a draft production order for an item made here, or a purchase request for one bought. When the bin is refilled, the card is scanned refilled and is full again.
Production scheduleThe production schedule places every open production order's operations on its work centre's real capacity: the centre's shifts and working days, the company's holidays, its machines side by side and its efficiency, in the order of the routing. You see which order will be late and by how much before it happens, and you can move an operation by hand.
SubcontractingWork a subcontractor does for your production orders — one operation (painting, plating, heat treatment) or a whole product. It goes out on its own purchase order, your materials go to the subcontractor's warehouse and stay your stock, and what comes back completes the order and lands in its cost.
Material planningMaterial planning says what to buy, what to make, what to have made outside and what to move between warehouses, and by when. It reads the open sales orders, the master schedule and the forecasts, and nets them against the stock, what is on order and what is being made, through every level of the bills of materials.
Production costWhat each product should cost (its standard), what each production order really cost, and the difference between them. In a company that keeps its stock perpetually, every move of an order is posted to the books as it happens, and its variances are posted when it is closed.
Shop floor tabletA tablet at each work centre shows its queue of operations. The operator signs in with a PIN, starts the setup and the work, pauses with a reason, counts good and scrap, and finishes — and the production order shows it at once, with the minutes it was worked.
Manufacturing quotesPrice a product before it is ordered: its materials, labour, machine time and overhead for the quantity the customer asks, worked out the way a standard cost is, with a margin on top — then turned into a sales quote in one press.
Master scheduleThe master production schedule is what the factory commits to make: an item, how many and by which day. Material planning reads it as demand, suggests making it, and buys what it takes through every level of its bill of materials.
OEEOEE says how well each machine was used, day by day: Availability × Performance × Quality. It is read from what already happened — the machine's stops and the counts at the shop floor tablet — never typed.
Machine dataA machine can send its own counts, its run or stop state and its energy. Nobody types them: its counts become counts on the operation running on it, its stops become breakdowns on the asset, and its energy is kept per day.
ForecastsA forecast is the demand expected for an item in a week or a month, typed or made from past sales. Material planning plans what is left of it after the sales orders and the master schedule due inside its period have used it up.
TraceabilityTraceability follows one lot or one serial number through every level of production: backward to every component lot, receipt and supplier it came from, and forward to every product lot made from it and every customer it reached. Nothing is typed for it: it is read from what the receipts, the production orders and the deliveries already recorded.
ExpiryExpiry lists the lots on your shelves that have expired or expire soon, the soonest first. With Manufacturing on, the soonest lot leaves first and an expired lot does not leave for a customer.
Production reportsThe factory over a period, on one page: orders, lateness, work in progress, OEE, scrap, quality holds, planning and energy. Each figure opens the screen it was counted from. The same figures head the Manufacturing overview.
Quality inspectionsAn inspection plan says what is checked, where and how often. Its inspections are made by themselves at their point — goods received from a supplier, an operation of a production order finishing, a production order's output. A lot that fails is held in the quarantine warehouse, where nothing is delivered from it, until it is released, returned to its supplier or scrapped.
Non-conformanceA non-conformance report says what did not conform, how bad it is, its root cause, and the corrective and preventive actions that close it — each with its owner and its due day. It is approved, then each action is done by its owner, then it is closed.
Control chartsA control chart follows one measured check over time, so a process drifting is seen before it makes a lot that fails. Each finished inspection is one subgroup: its readings of that check.

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