The Production Control app helps users quickly detect and address bottlenecks. Within the Production Control app you will find 5 different pages.
Work Order Book:
The Work Order book is an exhaustive list of all the work orders in your scope, sorted by planned start date (soonest on top). Each row gives you a high-level understanding on the status and key information about each work order. In addition, you can also take quick-actions to address current or future disruptions (such as creating an escalation ticket) or simulate alternative production scenarios involving one or multiple work orders.
The following information or actions are available for each work order:
Work Order Book - List view
Under the list view of the Work-order books you will see all of the work orders that are managed by your plant. You can also apply the group-by filter to have a overall view of the orders displayed by equipments, MRP codes, buyer codes and Prod version.
The Selection tool: Allows you to select one or more work orders in order to add a comment, enter or reset simulation values, or create a new filter.
Event status icon, hover over tooltip, signaling the status of an event
Material coverage status: color-coded icon signaling the material coverage (covered, blocked or cond. covered
Work Order number: hyperlinks to the Work Order 360 view, to have a comprehensive view of all information related to a work order
Part Name: hyperlinks to the Part 360 view, to have a comprehensive view of all information related to a part
Make or Buy indicator Equipment type (in house or out sourced )
Planned Start Date the date on which production is initially scheduled to begin for a specific work order, based on the original plan or MRP output.
Actual Start Date the date when production actually started for the work order. This may differ from the planned date due to delays, early starts, or rescheduling
Suggested Start Date date automatically calculated by Pelico suggesting the optimal start date for a work order, considering material availability and schedule constraints
Simulation Start Date start date resulting from a simulation analysis. It shows when production would start if all simulated conditions and adjustments (like changes in supply events) are applied
Planned End Date The projected completion date for a work order, calculated from the planned start date and expected duration. This reflects when the order should finish if the plan is followed without disruption
Open Quantity: Represents the remaining quantity of items that still need to be produced or processed to fulfill the work order.
Simulation Quantity:The quantity generated by running a simulation (what-if scenario) of the production plan
Escalation Ticket/Comment icon:indicates the escalation ticket tier (if a ticket exists), a tooltip with the latest comment (if a comment has been made, and no ticket exists)
Escalation button:button to create a new escalation ticket for a specific work order.
There are also several hidden columns ( that are specific to your routines and plants available, you click on the columns panel right hand to choose which ones you need to see.
Work Order Book - Graph view
The graph view in the Work-Order Book presents a comprehensive visual representation of the status of various work orders over a specified time period. In this view, the work orders are categorized by their status—Covered, Conditionally Covered, and Blocked—indicated by green, yellow, and red bars respectively. The horizontal axis displays different time frames or weeks, providing a chronological perspective of the work order statuses. The vertical axis measures the number of work orders. The graph prominently a visual representation of how many work orders are launched, conditionally covered or delayed. This tool allows users to quickly identify critical issues in the workflow, monitor progress, and manage priorities effectively. The ability to sort, group, and filter the data further enhances the utility of this view, enabling a detailed and tailored analysis of work order statuses.
The filters at the top of the graph view in the Work-Order Book provide a powerful way to customize and refine the displayed data, allowing for a more focused and relevant analysis of work orders. These filters include:
Date Projection: This filter allows you to select a specific date for which you want to see the work order data. By setting this date, you can project the work orders' status as of that specific day, giving you insights into future or past trends.
Dropdown Filter (All, Equipments, Sub-equipments): This filter provides options to narrow down the data to specific to equipments or Sub-equipments
Sort by and group by filter: You can sort or group the graph by filtering on the work order, coverage, revenue in a Ascending or Descending order
By Launch Date/Storage date filter: These filters let you choose whether to view the data based on the launch date or the storage date of the work orders
Time Frame Filter (Week): This filter enables you to select the time frame for the data visualization, such as daily, weekly, or monthly. Choosing a week allows you to see a weekly summary of work order statuses, helping in short-term planning and immediate issue resolution.
Line of Balance
The Line of Balance is one of the most used pages within the Production Control app.
It helps users analyze work order coverage, easily pinpoint any missing parts in order of priority and time period, and quickly address any current or future bottleneck to mitigate its impact.
This view is very powerful because it provides a large amount of information at-a-glance:
Line of balance view
The Line of Balance columns indicate the time period, which can be defined in View Settings > "Time unit" and "Work order sorting"
The Line of Balance rows indicate each missing part, and are sorted in descending order, with the most critical missing part(s) shown first. Each missing part row also has quick access to the following information:
The Escalation ticket tier (if a ticket exists. If multiple tickets exist, the highest tier is shown), or an "Escalate" button to create an escalation ticket.
Missing Part name, with a hyperlink to the Part 360 view
Parent Equipments related to this part (tooltip shown as a tree icon).
All events which will increase the stock of this missing part, such as Purchase or Work Orders (tooltip shown as a truck icon)
Suggested solutions to address the missing part bottleneck (tooltip shown as a lightbulb icon)
Make or Buy indicator (shown as an icon)
Name of supplier(s)
Number of delayed days
BoM (bill of materials) level of the missing part
Current stock
The data shown in the Line of Balance cells can vary, depending on what view setting you choose (in Pelico, there is a color-coding legend for each view):
Projected stock at the end of the period: Stock of a given Part at the end of a given time window (day, week, month). This is the value used to calculate the material coverage status based on projected stock.
Need quantity:Quantity needed of a given Part by one or multiple consuming orders during a given time window (day, week, month)
Pegging Availability dates:Date when the required quantity of a specific PlantPart, by a consuming order, is fully covered to meet the order's needs. Today based on the current 'optimistic' Pegging algorithm, i.e. based on Master Plan
Equipments:
The Equipment page gives you a top-level overview of all of the parts that are produced by work orders (in Pelico, these are called Equipments), in the scope of your choice. Within this page, you have two different views.
Table view
Equipment name: name provided to each part being produced.
Equipment number:reference number for each part being produced.
Sourcing:lets you know if you Make, Buy, or Make&Buy a specific equipment.
Covered WOs:number of work orders that are covered for a specific equipment.
Covered Quantity:number of parts that will be produced (are covered) for a specific equipment.
Late WOs:number of work orders that will NOT be produced (not covered) due to unsolved disruptions.
Production Stop Date:first date at which the production of a specific equipment will stop due to a lack of material coverage.
Projected CoverageThis percentage value represents the projected coverage based on the following parameters, which can be defined in the top right-hand corner of Equipments table:
Score Projection: defined end date of a time period (start date is "today")
Score:
by WO percentage based on the work orders planned during a time period (defined above)
by Quantity percentage based on the total quantity of equipments to be produced during a time period
Planning view
This view provides a comprehensive overview of the current status and future projections for various production elements related to specific equipment. The key components and filters of this view include:
Each row represents data for a specific piece of equipment or assembly,
Late Indicates the number of work orders that are late.
Current and Future Weeks Shows the status of work orders for the current week and future weeks.
MPS (Master Production Schedule) WO based on Master Plan that you plan to released this week.
Input row that you can use to simulate a new value as MPS, ex. You planned to produce 40 qtys, but you simule you'll produce 30 instead
Current Simulation based on the above example,When you simulate, the 30 will appear in Current simulation.
Delay MPS/Simulation You see the cumulated delta between MPS and Simulation.
Stock level optimistic projected stock of the plantpart, based on optimistic algorithm.
Conditinal projection projected stocl of the plantpart, based on standard projected stock.
The escalation ticket tier (if a ticket exists), or an "Escalate" button to create an escalation ticket.
Forecase Demandneeds in planning
Missing Parts:
The Missing Parts page is the second most important page with the Production Control app. It allows users to quickly identify missing parts that are affecting or will affect work orders in your scope, as well as have full context of the events and information regarding this part. In addition, Pelico provides users with multiple ways to quickly address missing parts, such as suggested corrective actions and the ability to create and collaborate on escalation tickets.
Missing Part view
The view provides you with a list of all the missing parts affecting work orders in your scope, ordered in a timeline format from oldest to most recent delays. The information that can be found for each missing part is the following:
Name of the missing part (with a hyperlink that leads you to the 360 view of that specific part).
Number of days since the part has not been covered, as well as the date when it stop being covered.
Color indicator signaling if a part is not covered (red) or conditionally covered (yellow).
Parent Equipments number of work orders that are covered for a specific equipment.
All events which will increase the stock of this missing part, such as Purchase or Work Orders (tooltip shown as a truck icon).
Suggested corrective actions to address the missing part bottleneck (tooltip shown as a lightbulb icon)
Make or Buy indicator(shown as an icon)
The affected Plant number
The escalation ticket tier (if a ticket exists), or an "Escalate" button to create an escalation ticket.
Opportunities:
The Opportunities page provides users with a quick-view list of alerts regarding current or future bottlenecks affecting your manufacturing workflows. Each alert gives you some context on the type of disruption and a recommended corrective action. When expanding/maximizing the list, you have hyperlinks to each related work order, as well as the quantifiable impact of solving each disruption.
At the top right-hand side of every page/section within the Production Control app, we have added a WO Coverage indicator so you can keep track of one of your most important KPIs.