ERPlite Pro :: Shop Floor TravelerTracker Version 3

1.0 Overview

Shop Travelers are an integral part of the production, incoming inspection and repair processes. Shop Travelers are the documents created from orders ( SO, RMA, PO) that keep track of what products need to be created/repaired and what steps are needed using specific procedures and materials.

ERPlite Pro TravelerTracker creates a schedule for each traveler from the Itemmaster routing list (including setup and run times), and keeps track of the traveler status as operations are completed. If conditions change, the schedule can be manually updated. (note…routing lists can be created for manufactured assemblies and for purchased parts).

Travelers can be printed out and passed from workstation to workstation as each production step is taken care of, or internally created in the computer and signed off electronically at each step in the process.

2.0 Setup Instructions

TravelerTracker v3 is included in ERPlite version 9575 and later.

Travelers are tracked via an autonumbered TOxxxxx (like the PO). To setup the TO and initial starting number, open the ERPlite backend in the database window (Click F11 key on your keyboard), and add TO to the SN table, along with your desired starting number xxxxx.

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3.0 Example Usage

Following shows workflows for Travelers generated from SO, RMA, PO

3.1 SO Example

The example following creates the traveler from the SO form

Shop Traveler Management Form

After creating the SO, click the “Generate Travelers” button….

A popup window shows the Traveler number…..

The first two letters are for Traveler Order are TO…to be consistent with ERPlite nomenclature :: SO, WO, PO.

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The next xxxx digits are the autonumbered TO number.

The SO number is concatenated on the end, so that the TO can also be traced back to the originating order (ie see examples of RMA, PO later).

Traveler Manager Form

Open the Traveler Manager form via the switchboard :: Mfg Orders >> TravelerTracker . The following shows the form on which all of the shop travelers are displayed. …

Usee the following buttons for creating, editing, revising, or deleting a Shop Traveler:

Edit  - Opens an existing Shop Traveler for Traveler scheduling and editing.

Delete  – Deletes the shop traveler from the system. Lot Split  - Lot split lets you easily split a Shop Traveler into multiple

Shop Travelers. This is very useful if you have a customer that wants a large order split into several deliveries over a span of time. When clicked it opens up the "Lot Splitter" screen where you enter in how many lots you would like the Shop Traveler split into, and the size of each. (Note: this feature is not yet operational but will be added soon).

Click the “Edit/Print” button to see the autogenerated schedule for the operations, or to edit the existing schedule.

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Traveler Operations Edit Form

The following screen is the Edit/Print Traveler Tracker screen.

This Traveler Tracker gets its operations (routing list) data from the Itemmaster….

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Note :: see Appendix A for how to create routing steps/lists

From this Operations Tracker screen you can see things such as job number, order numbers part numbers and so forth. These entry fields are automatically pulled from the Sales Order and the Itemmaster Routing tab. Descriptions of each part and notes to go along with the production of each part can be added to the Shop Traveler and will be printed when the Shop Traveler is printed.

The initial schedule is computed from todays date and the Itemmaster setup and runtimes ( assumed to be in minutes). The schedule is based on Equipment setup/runtimes if the operation step Equipment Runtime is positive (ie > 0), and Labor Setup/Runtimes otherwise (ie if equpement runtime is blank or 0)

The schedule date calculator assumes

1. setup and runtimes are in minutes.

2. Uses Equipment setup/runtimes if Equipment Runtime > 0.

3. Production days are 8 hours

4. Production is not scheduled on weekends.

If you change the start date for for any operation ( say Reflow Solder to 1/2/2013 from 9/3/2012), then the schedule for the operations start and end dates from that operation on will be recalculated using the Itemmaster setup/runtimes…… as shown below

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You can then edit any other start/end dates to modify the schedule from the default values.

Clicking the “Completed box” shows the status of the project, and prevents the start/end dates for that operation from being edited.

Note that the default notes from the Itemmaster can be edited before printing the Traveler.

There are the following buttons for printing the Shop Traveler and changing inventory counts…

Print Traveler opens the Traveler for preview and printing

Manage Inventory autopopulates and opens the selected inventory management form :: Materials Management, Inventory Transfer, Work

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Order :: so that the individual operations can create/consume assemblies/materials using the ERPlite form designed for that purpose. (this feature will be implemented soon).

Traveler Status In addition to creating and printing the Traveler, status changes are entered on this form by checking operations “Completed” and if necessary, changing start/end dates. Thus, any time need, the Traveler can be viewed in ERPlite to see the operations completed, and the expected Operation and Project completion date.

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3.2 RMA Example

Customer Service >> RMA

Click the “Create Traveler” Button.

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3.3 PO Example

Mfg Orders >> PO Receive >> Receive 10 units of CMP1111

Click on History Tab.

Click on “Create Traveler” button

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Note that the PO receipt was for 10 feet of Ethernet Cable, and 120 inches of Ethernet cable were transferred into inventory based on the Units of Measure in the Itemmaster.

Note that CMP1111 has a different routing list versus the ASY0005 used in the previous examples. Also, ASY0008

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Appendix A: Creating a Routing List

The manufacturing steps for a CMP9777 Mouse Pad are:

1. Cut to size from roll stock

2. Print logo.

Itemmaster/BOMs >> Itemmaster >> CMP9777

Click on the pulldown button for the “From Operation” to see the current list of operations available for Rounting Lists.

The first routing step must set “From Operation” = START.

Note that the “To Operation is automatically set to FINISH.

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Note: The % Following field is for future functionality use and not currently used. Eventually, it will be use for providing loops in the routing (ie test failure requires repeating earlier or alternate steps).

Clicking the “To Operation” pull down menu, shows that the needed routing steps are not in the current list, and need to be added.

Adding Routing Steps

Itemmaster/BOMs >> Routing Lists >> Edit Operations

Click the * to create a new Operation

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Enter the data for the CUT operation

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And the PRINT operation

Note that adding Equipment and Labout Groups etc is done a similar way via the appropriate button at

Itemmaster/BOMs >> Routing Lists

The completed Itemmaster Routing …..

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