Production Control empowers manufacturing teams to quickly identify, analyze, and resolve production issues, minimizing downtime and optimizing output. With real-time monitoring and advanced diagnostic capabilities, Pelico's Production Control transforms complex troubleshooting into a streamlined process, ensuring that you can maintain high levels of productivity and meet your operational goals effectively.
How to identify planned and materially covered WO and release them to optimize production capacities?
As a Production Controller, you can easily identify and manage work orders that are materially covered but delayed using Pelico's PC app. Here’s a step-by-step guide,
Steps to follow
Navigate to the Production Control section in Pelico. This is where you can monitor and control various aspects of production.
Slide over to the Work-order Book View to access a detailed list of work orders.
Apply filters for the equipment to narrow down the list based on specific equipment or criteria relevant to your needs.
Add the filter Status → Released and Material Coverage → Covered to filter work orders that are ready for production but have not yet started.
Include a filter for the Planned Start Date and set it to later than today. This will highlight work orders that are not launched but have all the necessary materials
Click on the Graph View in the top right corner to visualize how many orders are not launched. This will give you a quick overview of the situation.
Click on the bar representing delayed orders to get a detailed list of all materially covered work orders.
Select the checkbox at the top left corner to choose the work orders you need to escalate. Forward them to the person in charge to take the necessary actions.
Watch the video tutorial for a step-by-step walkthrough.
How to make sure that sub-assembly orders are planned and covered on time with respect to final assembly?
As a Production Controller you can easily make sure that sub-assembly ordered can be planned and covered on time with respect to final assembly, here's a step by step guide
Steps to follow
Navigate to the Production Control section in Pelico. This is where you can monitor and control various aspects of production.
Slide over to the Work-order Book View to access a detailed list of work orders.
Under the Workorder view, apply the equipment filter. This will display all the Work Orders related to that specific equipment.
To narrow down the orders that are blocked, apply the material coverage filter and select the "blocked" option.
Slide over to the Line of Balance view to see details about the events blocking the Work Orders.
Additionally, you can apply the sourcing filter to narrow it down to "make" and "make and buy" parts.
Open the 360 view of the references where the Work Orders are blocked to investigate further .
Watch the video tutorial for a step-by-step walkthrough.
How to asses whether there is enough lead time to avoid shortage?
To prioritize shortages based on whether there is still enough supplier lead time to avoid them, follow these steps,
Steps to follow
Go to the work order book view and select the equipment you need to track.
Select Material coverage as blocked and status as planned.
Set the planned start date as strictly later than today.
Identify work orders that are not covered and click on them to see the missing parts and related upstream and downstream events.
Under missing parts, select which ones need more attention and click on them.
You will be redirected to the 360 view of the missing part, where you can see events, projected stock, the supplier, and their lead time.
Go to the line of balance view and select filters: coverage status as blocking and sourcing as buy.
Add the column for delivery lead time to see which parts have more or less lead time and plan accordingly.
Watch the video tutorial for a step-by-step walkthrough.
How to identify STOs from other plants?
With the help of Pelico, we can identify missing parts and stock transfer opportunities from other sites and request stock transfer orders (STOs) as a remediation strategy. This approach leverages existing inventory within the organization to quickly mitigate shortages and ensure continuity in production processes.
Here's how you do it,
Steps to follow
Go to the work order book view and select the equipment you need to track.
Slide over to the line of balance view to see all the missing parts related to that equipment.
Click on view settings on the right corner and set the filter to Projected stock at the end of period.
Click on the pitchfork icon under the part column to view the parent equipment of that part. You can also see the part's stock projection in the coming weeks.
Look for a bulb icon in the cell where there is a need, indicating stock transfer opportunities within your factory.
Add filters forelivery and stock opportunities, and select any stock opportunity and then stock transfer opportunities.
You will be redirected to the 360 view of the missing part, where you can see events, projected stock, the supplier, and their lead time.
Go to the line of balance view and select filters: coverage status as blocking and sourcing as buy.
Review which plant has how much stock and leverage them accordingly.
Escalate the part and contact the relevant person about the opportunity.
Watch the video tutorial for a step-by-step walkthrough.
How to identify shortages based on a simulated production plan?
As a Production Controller, you can identify shortages based on a simulated production plan to recover from production delays. This proactive approach allows you to foresee potential issues and implement corrective actions to ensure continuous and efficient production.
Here's how you do it,
Steps to follow
Go to the work order book view and select the equipment you need to track.
Add filter status as planned and set the date comparison filter to planned start date earlier than a fixed date. This will list the work orders that are overdue (i.e., those with a start date prior to the selected date).
Reschedule some covered work orders by clicking on the check box and the new simulation input at the bottom of the page. Select a new date in the near future and fix the quantity.
Confirm and launch the simulation, then close the date comparison filter.
Observe the impact of your simulation on the work orders directly in the Work Order book.
Go to the simulation basket by clicking the arrow at the top. Review the coverage status before and after the simulation for the selected work orders and the impacted events.
Finally, go to the Line of Balance (LOB) view to identify shortages for the rescheduled work orders and any other work orders.
Watch the video tutorial for a step-by-step walkthrough.
How to identify covered planned work orders and release them into production to meet the daily load target of the assembly line?
As a Production Controller, you can identify and launch covered planned work orders in production to meet the daily load target of the assembly line using Pelico's PC app. Here’s a step-by-step guide:
Steps to follow
Navigate to the Production Control section in Pelico. This is where you can monitor and control various aspects of production
Slide over to the Work-order Book view to access a detailed list of work orders.
Add the filter Status → Planned and Material Coverage → Covered to filter work orders that are ready for production but have not yet started.
Filter covered and planned Work Orders within next month.
Include a filter for the Planned Start Date
Go to the WOB, Graph View (daily, by launch date) in Pelico's Production Control.
Review the daily overview of covered and planned WOs for the upcoming month.
Identify days where the number of planned WOs is below the daily capacity (e.g., 4 WOs per day).
Select WOs that can be advanced to optimize assembly line capacity.
Adjust Work Order dates to align with the daily load target by advancing them as needed.
Select your work orders, click on "New Simulation Input," and choose your new dates
Validate the new simulation plan to launch WOs in production with the new simulated dates.
Watch the video tutorial for a step-by-step walkthrough.
How to identify mid-range (6-12 weeks) shortages caused by subassembly make parts and escalate them to inform subassembly planners about load changes and rescheduling the production line?
As a Production Controller, you can identify mid-range (6-12 weeks) shortages caused by subassembly make parts and escalate them to inform subassembly planners about load changes and rescheduling the production line using Pelico's PC app. Here’s a step-by-step guide:
Steps to follow
Navigate to the Production Control section in Pelico. This is where you can monitor and control various aspects of production
Slide over to the line of balance view to see all the missing parts related to that equipment
Filter the LOB on Make sub-assembly parts :Sourcing -> make, make&buy
Identify sub-assembly make parts shortages within the next 6-12 weeks
Check need date and escalate missing sub-assembly parts to ask for replanification
Watch the video tutorial for a step-by-step walkthrough.
How to identify shortages with approaching delivery dates and collaborate to align reception and production priorities?
As a production controller one of the common problems you may is identifying material shortages ahead of key production deadlines. This requires real-time visibility into inventory and proactive communication between departments.
If reception teams aren’t aligned with production schedules, incoming deliveries may be mismanaged, further delaying critical production processes. This below section explores how to effectively collaborate with reception and production teams to prioritize the right deliveries, streamline workflows, and mitigate the impact of shortages before they derail your production timeline using Pelico,
Steps to follow
Open the PCR app in Pelico and start by filtering the work orders within your scope (such as specific equipment or departments). You can do this in either the Work Order Board (WOB) or directly in the Line of Business (LOB).
Once in the LOB, switch to the Need Quantity view. Set the time unit to either daily or weekly, depending on your needs. This will generate a list of upcoming work orders based on your selected scope.
Apply the Sourcing: BUY filter to narrow the view to only the parts that are missing and expected from suppliers.
For each row that contains orange cells, hover over the truck icon to see upcoming delivery events related to that part.
Leave a comment for the Supply Manager to ensure they are managing the delivery process effectively and that the required parts will arrive on time for production.
Watch the video tutorial for a step-by-step walkthrough.
How to push out sub-assembly work orders based on estimations/context from supply chain team?
In dynamic manufacturing environments, the ability to adapt sub-assembly work orders to real-time changes in the supply chain is crucial for maintaining smooth production flows. As supply chain teams provide updated estimates and contextual data, it’s essential to adjust work orders accordingly to avoid bottlenecks and delays.
In this section, we will walk through the process of pushing out sub-assembly work orders based on the latest information from the supply chain team. We’ll also cover how to effectively share these changes with internal customers to keep everyone aligned and ensure production continues without disruptions.
Steps to follow
In the Work Order Book (WOB), filter for planned but uncovered Work Orders specific to sub-assembly equipment.
Identify that these sub-assembly Work Orders have downstream Work Orders as connected events.
Simulate new planning dates for the sub-assembly Work Orders based on the availability date of the last upstream event.
In the Simulation Basket, check the coverage status of the sub-assembly Work Orders with the newly simulated dates.
Share the updated planification and coverage status with the internal customer to keep them informed of the changes.
Watch the video tutorial for a step-by-step walkthrough.