Production Execution Models

A distinguishing feature of a highly functional system is its ability to support multiple production models simultaneously and on the same data, rather than just a single model. The main models and their system requirements are summarized below.

1. Production according to order.

Production begins when a customer order is received; the product is often customized for the customer.

• Establishing a direct link between sales orders and work orders; tracking which batch belongs to which customer.
• The ability to define customer-specific product trees and routes; if a configurator is used, the tree can be derived at the time of ordering.
• Order-based inventory allocation: the inability to transfer manufactured goods to another order.
• Order-based cost collection and customer-based profitability analysis.
• Engineering time should be included in the delivery time (if the order is in design status).

2. Repeated production

Producing the same product in high volume over a long period of time on the same production line.

• Instead of work orders, use a periodic production plan ; do not create separate orders for each batch.
• Line-based planning table and determination of daily production quantities.
• Automatic reduction of material consumption through backwashing method, along with production notification.
• Costs are collected on a period and product basis, not per work order.
• Feeding lineside stock with pick lists

3. Flow generation

A model that operates based on takt time, where the product moves continuously along the line.

• Track balancing based on takt time and workload distribution by station.
• Mixed model sequencing: different products progressing in a specific order.
• Sequential feeding: parts are brought to the edge of the line according to the product sequence on the line.
• Station-based quality control and Andon mechanism.
• Bulk notification and automatic serial number assignment at line exit.

4. Workshop production

Varying routes, small parties, and high variety.

• Each work order progresses along its own route in the machine queues.
• Detailed operation-based tracking: start, end, duration, amount produced, and amount of waste.
• The critical importance of finite capacity scheduling and setup optimization.
• Monitoring intermediate stock and holding times; most of the flow time is holding time.
• Detailed cost calculation on an order basis.

5. Lean manufacturing

Waste reduction and a pull-based workflow.

• Defining Kanban cycles in the system: card count, capacity, replenishment point, and trigger rule.
• Electronic Kanban: cards circulate systemically rather than physically.
• Production without orders: notification made by referencing a defined production method without opening a work order.
• Modeling of supermarkets and line-side stock points.
• Monitoring value stream indicators: flow time, work-in-process inventory, first-time correct rate.
• Recording of Andon calls and measurement of response times.

6. Process production

Production in measurable quantities and according to a recipe through processes such as mixing, reaction, and distillation.

• Recipe management: A combined product tree and route; including process parameters (temperature, time, mixing speed, pressure).
• Scaling transformation: Adapting the recipe proportionally to different batch sizes.
• Productivity management: Comparing theoretical and actual productivity; a key indicator of process output.
• By-products and co-products: Recording and allocating costs for other outputs from the same process.
• Process instructions: Step-by-step guidance for the operator and recording of critical parameters.
• Equipment and tank management: Capacity, cleanliness status, and product transit compliance.
• Quality integration: Embedding intermediate checks into the process flow; preventing progress to the next step until the result is approved.

7. Party leadership

It is the carrier of traceability in process and regulated production.

• Batch creation rules: Automatic numbering, batch separation based on date and shift.
• Batch specifications: Production date, expiration date, analysis results, quality class, and source lots.
• Batch selection rules: Which batch is used first: first in, first out, by expiration date, customer-specific batch requirements.
• Batch release: The batch cannot be used or shipped without quality approval.
• Forward and backward traceability: Answering the question "Which products did this raw material lot go into and which customers did it go to?" with a single query.
• Party merging and splitting: Recording physical processes without compromising traceability.
• Quarantine and blockage: Systemic closure of the suspected batch.