This article builds upon previous blog posts „From Model to Product“, „Product Development“ and „Technical Production Preparation“ to dive deeper into the PEO (Production Engineering and Operations) module, focusing on its Operations component.
The PEO Operations module is designed to:
- Transfer production information to workers (replacing printed production documentation).
- Collect real-time production status data (e.g., work progress, measured values, and serial number tracking).
- Enable immediate problem notification to supervisors or foremen when issues arise.
With PEO Operations, production managers and planners gain up-to-date insights that allow them to respond quickly to shop floor events.
Streamlined Assignment of Work to Workers
The PEO Operations process begins when the planner releases a production order. The production manager can then assign specific activities (linked to production operations) to workers at the designated workstations.
Workers receive their assignments electronically on devices such as PCs, laptops, tablets, or mobile phones. From these devices, they can access all necessary instructions and record their progress.
There’s no need for printed documentation, as workers can view detailed drawings directly on their devices, with the option to zoom in for clarity. For complex or oversized drawings that require printing, the drawings are attached to the workflow as production aids. Workers can access these printed drawings through the designated tool custodian, while reusable drawings may be stored in the shop floor tool room.
Clear and Organized Work Queues
At the start of their shift, workers view their work queue, which is sorted by the scheduled start time for each task. The queue also reflects task prioritization.
Work queues can be:
- Shared: Visible to all workers on the same job.
- Individualized: Customized for each worker.
The production manager determines which option is best suited to the specific production scenario.
In the queue, workers see essential information for each task, including:
- Activity number and name.
- Operation number and name.
- Production order number.
- Material to be produced.
- Scheduled start time.
- Assigned worker (if applicable).
- Task status and required action.
User-Friendly Interface for Workers
Workers interact with their assigned tasks through a straightforward interface:
- Start Task: Clicking the “Execute” icon for an activity opens a task window. Workers click “Start” to begin work, changing the activity’s status to In Progress and starting the time tracking.
- Instructions and Resources: Workers access detailed work instructions, attached documents (e.g., diagrams), and even hyperlinks to specifications or instructional videos.
- Pause and Resume: If work is interrupted (e.g., for lunch or shift change), workers can click “Suspend” and provide a reason for the pause. When resuming, they click “Resume Work.”
- Production Tracking: Workers record completed products and defects directly in SAP. If serial numbers are involved, the worker specifies the serial numbers completed. Barcode and QR code scanners can be integrated for efficiency.
- Material Management: Input materials can be released automatically upon completion of a product or recorded manually by the worker. Serialized input and output materials allow precise genealogy tracking, linking finished products to specific input components.
- Completion: Workers click “Finish” to confirm task completion, stopping time tracking and updating the system.
Real-Time Problem Notification and Quality Control
In case of production issues, workers can pause the process by clicking the “Pause” icon. They can specify the scope of the suspension:
- Entire production order.
- Specific operation or activity.
- Specific material, serial number, or workstation.
The system provides a graphical overview of production orders, alerting production managers to issues such as delays, material shortages, or quality concerns. Managers can address these problems immediately to minimize downtime.
If control attributes are defined in the workflow, workers record measured values or qualitative assessments as part of quality control. For example:
- Quantitative Attribute: Workers input measured values, which are checked against specified limits.
- Qualitative Attribute: Workers assess materials for issues, such as surface damage, and log their findings.
For tasks requiring inspection, the workflow can automatically notify the designated inspector. Only after the inspector approves the product can the worker mark the activity as complete. Multi-level approvals can also be implemented.
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