Production Order and Material Progress Visualization#

Overview#

Production Order and Material Progress Visualization provides real-time visibility into Production Order execution and Material Flow across process Steps and Process Activities, enabling comprehensive monitoring of shop floor execution throughout the manufacturing process.

Business Context#

In today's manufacturing environment, monitoring production progress is essential for operational control and production planning, ensuring alignment with the planned schedule and enabling proactive decisions to address deviations and meet delivery commitments.

Production Order and Material Visualization extends the core Production Order progress indicator by providing a more granular view of execution progress. This feature introduces a progress indicator at Material level based on Steps and Process Activities, reflecting the actual advancement of each Material through its production Flow.

This capability is particularly relevant when a Production Order represents a single unit of a Material, as is often the case for large or complex equipment, enabling a clear view of work completed versus remaining work. The progress indicator is presented in simple and intuitive formats, such as Steps or Process Activities completed out of the total, or percentage of production Flow completion. When a Production Order contains multiple Materials, progress is aggregated as an average of Material-level progress, ensuring a consistent view of overall execution status for production planning.

Progress is calculated based on the main production Flow of the Material, excluding temporary activities such as rework or Off-Flow operations, in order to reflect true production progress.

The progress data is stored as a property of both Material and Production Order entities, enabling reuse across reporting, dashboards, and future production control capabilities.

Concept#

The progress calculation supports multiple configurable modes, enabling production teams to select and apply the most appropriate method based on their specific production process and operational needs.

The supported calculation modes are as follows:

• Steps of the Flow (ProgressByNumSteps) - Number of Steps completed / Total number of Steps in the Flow
• Example: If a Flow has 10 Steps, when tracking out or moving to the next Step on the 2nd Step, the Material progress value is calculated as (2/10) * 100 = 20, representing 20% of the Steps in the Flow completed.

• Process Activities Completed (ProgressByNumPAs) - Number of Process Activities completed / Total number of Material Process Activities
• Example: If a Material has 4 Process Activities. Upon completion of the 3rd Process Activity, the Material progress value is calculated as (3/4) * 100 = 75, representing 75% of Process Activities completed.

• Hybrid (ProgressByNumStepsAndPAs) - Number of Steps completed + Number of Process Activities completed / Total number of Steps in Flow + Total number of Material Process Activities
• Example: Assuming we have a Flow with 4 Steps and 3 Process Activities, the Material is at the 3rd Step, and has 1 Process Activity completed.
  • Upon Track-Out within the 3rd Step: (3 Steps are completed + 1 Process Activity is completed) / (4 Steps + 3 Process Activities) * 100 = 0.5714 * 100 = 57.14%
  • Upon Move Next to the last Step: (3 Steps are completed + 1 Process Activity is completed) / (4 Steps + 3 Process Activities) * 100 = 0.5714 * 100 = 57.14%
  • Upon completion of a Process Activity: (3 Steps are completed + 1 Process Activity is completed) / (4 Steps + 3 Process Activities) * 100 = 0.5714 * 100 = 57.14%

The progress is updated upon the following action:

- Material MoveNext
- Material ChangeFlowAndStep
- Material TemporaryOffFlow
- Material Rework
- Material Receive
- Material Create
- Material TrackOut
- ProcessActivity.Complete
- ProcessActivity.Skip
- ProcessActivity.Cancel

Administration#

Configuration Entries#

The following table describes all configuration entries related to the Process Activities.

IndEq_ProductionOrder_Page_Production_Orders Dashboard#

A new column Flow Progress has been added to the custom dashboard, showing the completion status of Materials across Flow Steps and Process Activities.

The Flow Progress column remains empty if none of the associated Materials have started any Process Activities.

The Flow Progress column displays a progress bar reflecting the completion progress status of the associated Materials.

The Flow Progress column displays a green progress bar reflecting the completion of all Materials' Steps and Process Activities.

A new property IndEqTotalProgress has been added to the Production Order entity. The property reflects the average progress of all associated Materials.

A new property IndEqTotalProgress has been added to the Material entity. The property reflects the individual progress of the Material.

Access points and Extensibility#

To check the progress of the Material and Production Order, you may access the custom page IndEq_ProductionOrder_Page_Production_Orders (go to Administration > UIPages > IndEq_ProductionOrder_Page_Production_Orders).

Assumptions and Restrictions#

• Progress is not tracked if the Material has no associated Production Order.
• Progress is not tracked if the Material's Product does not match the Production Order's Product.
• For ProgressByNumPAs mode, progress is set to 100% if no Process Activities are found.
• When a Flow is updated, the associated Materials' progress will not reflect the change until the next action (e.g., Track-Out or Move Next) is executed.
• When a Production Order is updated, the associated Materials' progress will not reflect the change until the next action (e.g., Track-Out or Move Next) is executed.
• Rework and Temporary Off-Flow Materials are excluded from the progress calculation.