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Production scheduling software for joiners and carpenters.

Production scheduling software for joiners and carpenters.

REGISTRATION OF WORK TIME (RWT)
AND HOURS CALCULATION 

No more lateness and wasting time at production! Use this joinery software to manage work smoothly.

2 in 1 – together with production software you receive a tool to register employees check-ins and check-outs, without a necessity of buying additional equipment.

Why is it worth using  RWT function (Registration of Work Time), even though you already have card /fingerprint system:

You can  see an updated status, with information about who is present at work, what time they checked-in and whether they just “hanging around”.

If an employee checked-in but failed to start work, you can see that straight away in your panel (even when you are working at home).

Check, how much time % at work is really spend on working.

Very often it turnes out, that for 200 hours spent at the production hall, only 140 hours are effectively spent on working operations.

The check-out function is locked, until all tasks are closed, so you can monitor things better and stay organized. 

 

Thanks to bar coded production orders employees easily navigate among tens of daily projects

 

Thanks to the orders print outs which “travel” as the product is moved from place to place, all employees know what’s what – and registration of progress can be done with bar code readers.

This solution ensures registration process is really fast and takes no longer then a few seconds, and you have active progress view.

 

Thanks to product templates you save time, standardize work procedures and minimize mistakes.

The rule is simple – instead of creating each time a product for the same Client, use earlier defined template adding only data specific for that order.  

This is possible thanks to any number of extra boxes, which you can add to your orders and products, and a possibility of attaching graphic files. How to add additional parameters? – click to see.

 

In your branch trusted us and helped to  develop software with their know-how:

Mainly carpentry manufacturers and joiners employing groups of several people:

  • door and door panels,
  • furniture panel producers / furniture fronts,
  • manufacturers of finishing elements, such as skirting.

 

Tips and tricks, how to adjust your new production management software

Prepare product templates; all what is left to do later – fill out customized for your Client boxes 

If we look at the example of custom-made door order, creating a new product each time for different measurements and combination would be a madness and a total waste of time.

It proves a better solution to prepare templates for main groups / types of products yuo have, add to them production technology and everything what is constant and repetitive and simply drag it to your current order. Using Prodio’s joinery software it is pretty straighforward. 

When a Client places an order you can complete information directly in the created template and fill out boxes for type of finish, size, door handle type – in this way, clear information will get to the production,

Give the production hall clear, one “click” orders 

When you move very fast from order to order it is very important to make the whole process as easy as possible.

Print manuals with bar codes, which you put at the production hall – see how?

and use bar codes for registration – link.

Use tags to mark particular priming or sanding – to see clearly the stages of the whole process

Within this technology (as long as it happens at the same working station) separate priming and sanding by marking them as different processes – in the tag box type, write which time this is.

Thanks to this step you and your employees would see exactly which stage you are at and if you are stuck, where the problem is.

 

To produce multiple element products use tagging to mark their parts 

Technology of the product allows you to set up a path both for door, as well as door frame, by tagging “door” and “frame” and clarifying that division. 

 

Short-list with other suggested settings and useful tricks in production management:

What is the best to write down and set as “product” in Prodio:

The main type of products which you are going to personalize for the order.

Production plan – what can you set as machines / operations?

We recommend dividing into procedures ex. sanding, priming, varnishing, asembly, as well as for particular machines such as saw, file, etc.

Make sure to devide your view into separate production halls, to make it clear.

Production plan – tips regarding displaying  and planning

It is necessary for you to turn on previous operations tagging, so your employees know where to start and which procedure is still incomplete or queuing. How does it work? 

Additional boxes, worth adding for your branch:

All features personalized in the product:
– parameters,
– RAL colour (we recommend to divide it into white / others),
– finishing, etc.

Additional TAG-s at the production hall and in the product categories

– types of processing, ex. Sanding 1, Sanding 2,
– components ex. frame / door wing,
– colours: white / colour (plus the RAL number in the product description).

Frequently asked questions by door, windows, furniture fronts and other construction woodwork manufacturers.

Is it possible for the one operator to operate multiple machines at the same time?

Yes, it is. Otherwise it wouldn’t be possible to register production effectively in your branch.

Is it possible to include additional procedures such as form assembly or packaging?

Yes, it is. It is possible to create different technological sequences as product’s technology part, which can be clearly displayed at the production hall.

While working od different projects Clients trust us with their documentation which is often confidential - is Prodio a safe solution?

We do our best safeguard your secrets – it is clear that the future of our business depends on it.
In 90-95% of case, data in Prodio is more secure than saved locally:
– connections to web browser are encrypted,
– the server is located in one of the leading and best secured data centre in Europe,
– 
in our company only two people have access to full data and they have financial liability,

–  together with security expets we request a paid simulations of hacking and breaking in to assess and update the level of security,

– separate server archives data few times a day.

We are ready to sign NDA agreement upon request of our regular Clients.

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Production planning in a small manufacture – MANUAL (examples, schedule, production plan, software for production management and Excel).

Production planning in a small manufacture – MANUAL (examples, schedule, production plan, software for production management and Excel).

Production planning for small manufacturers

Practical guide, which helps you to learn how to organize production planning simply and effectively. Additionally you will get ready to use tools plus simple software to manage your production better.
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Production planning in a small manufacturing company is very different from the big factories’ advanced working plans (and varies from methods learned during university education). It’s often much more difficult, and it also requires a different approach!

Despite all the bluster about semi-automatic planning, hundreds of detailed tables and charts and other hokum, which you find on the websites of providers of advanced software for production management, they can give you more troubles than it’s worth. At the end of the day, you will be the one left with paper orders and chaos at the production hall.

Many companies are still using old fashioned production planning methods: they might have worked, but in the past, when there were mainly big factories, with lots of workers and machines. The production structure is much more varied: there are numerous small manufacturing companies, and the old style does not apply to them. It will do more harm than good.

There is good news: if you tackle production planning using suitable tools, making it clear and understandable for everybody, streamlining the manufacturing process is within reach. Especially at the time of accessible Internet tools! 🙂

Instead of having tons of handwritten orders which need coping into Excel, you can have an online, neat dashboard and enjoy a paperless production planning process.

 

 

Would you like to discuss Prodio's offer for your manufacturing business?

What is production planning?

Production planning is the planning of production and manufacturing modules in a company or industry. In other words, this is your strategy for the whole manufacturing process. The plan works as a guide: it shows step by step what should be done, in which order, and how quickly to achieve the desired result. Production planning can help in efficient manufacturing or setting up a production site by facilitating the required needs.

There are, of course, different production methods, such as single item manufacturing, batch production, mass production, continuous production etc. Each of them has its own type of production planning. From clever production planning and scheduling comes good production control. These processes are naturally combined. When you have great production control, you are sure that all the necessary raw materials, tools, knowledge and people are there, so you know how much you can produce at any given time.

In this article the following topics are discussed: 

Other articles that might be useful if you are interested in production planning:

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What should be your main objective regarding production planning?

 

Objective 1: The employees should know what to do, and in which order. Even in your absence.

Imagine a situation: you can go home without worrying or take a short holiday because you know that production will continue, even though you aren’t present. How does it feel? Paradoxically it is straightforward to achieve.

You need a clear schedule, which shows what has to be done step by step — instead of a complicated vision when an employee doesn’t know what they should do. The idea is to create a simple solution. Even somebody, who isn’t really familiar with computers or technology, can intuitively use.

Illustration: the view of production plan from getprodio.com/pl system – try it for free HERE) 

Remember that even when you produce very sophisticated products (which consist of thousands of parts), each person at the production hall has to make a particular element, using that particular machine, accordingly to set parameters, and they have to do it well.

Considering the efficiency of work at the production hall, it turns out that the comment handwritten on the order form by an employee, for example, about changes in technical drawing, is much more important than giving a precise time of starting work.

 

Objective 2: You have to know how much you can produce at any given time, whether you will keep deadlines, and what is your machinery capacity?  

In small manufacture it isn’t really possible (well, maybe it is, but it would involve the astronomic amount of work) to set precisely a production plan, and determine minute by minute when each product would leave  production hall — in a way that all these projections are accurate — there are too many variables, which would cause the original production plan to change very often.

Luckily you have a super processor — your brain, which has terabytes of experience in production, and it knows how to manage things optimally.  All it needs to make a decision is a clear view of individual operations, to adjust things accordingly 🙂

 

(Illustration: the view of production plan from getprodio.com/pl system – try it for free HERE)

The second element, which enables the supercomputer in your head work, is a simple overview, which forecasts ahead of your machinery’s capacity as well as its operational capacity in months, days, hours.

It gives you full control over your manufacturing process. You will feel confident in front of a client and will be able to quickly make accurate estimates, confirm the dates, negotiate with sales reps;

The system will prompt you that something is overdue and it requires you to follow up, or your quick reaction is an excellent advantage and undisputed facilitation.

Objective 3: You and your staff need to know whether the part has been already made during the previous operation.

That’s it — no more running and asking! The bigger the production hall, especially if it has a few floors, the more time is wasted. Countless questions are whether it is possible to start work on the said element or it is still waiting for completion at the previous working station.

A good production plan should show an employee what they can do and what actually can be done from the list of operations.

(Illustration: the view of production plan from getprodio.com/pl system – try it for free HERE)

Let’s say that the paint shop has run out of a particular colour. It doesn’t mean that the whole company stopped working — simply the further elements are being made instead. If one part of the metal-cutting machine has worn down, nobody will wait for it to be fixed; a different one replaces it. The employee can see it on the production plan, and it is clear that some things have to be skipped for the time being, and the job available at the moment can be done. These are the principles of production planning.

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3 ways of simple production planning in small manufacture — tools and software

1. Tables in lean methodology or your own methodology 

This is a typical old school, which doesn’t mean it’s a useless solution, because even today it is used by big factories to visualize a factual situation. All you need is a whiteboard, a roll of duct tape to separate lines, and a bit of imagination to divide things reasonably.

It works in this way: each order is a note self-adhesive or magnetic, on which the guidelines on how to produce something are given. A production manager sets the queue for particular machines, and next employees move the notes — if it is a job still in progress, they move the note to the first row, and when the job is completed, it is the last position at the machine.

There are alternatives: you can place boxes by the machines and put inside orders as they arrive; consequently, employees move the orders between each work station. It is possible to freely modify the above solutions or buy a dedicated one.

There is an example of whiteboard production planning below; instead of using notes employees write down pieces made with the marker, orders are horizontal (own materials).

There is a question of why use such a solution instead of using free Trello software or a low-cost monthly subscription at kanbantool.com, which both give much more possibilities.

Trello is in fact an easy and free table, which can be shared with production. Although it is a free program it has some disadvantages such as lack of work streamlining or analyses of pieces made (only progress), etc.

 

2. Production planning in Excel (or even better in Google Docs) 

Why plan production in Google Docs spreadsheets, not in Microsoft Excel?

  • it is straight away online, and it can be projected at the production hall,
    • it is more comfortable and easier to use: although many years I was working in Excel, after switching to the Google version, I have no intention to go back, mainly because I value comfort the most,
    • the online version is better at handling a lot of production data (where MS Excel online showed mistakes, Google had no problems whatsoever),
    • easier and more intuitive file sharing,
    • better surveys offer a possibility to collect production data.

 Different types of production planning in MS Excel  and examples: 

 Production planning as Gant’s graph – Excel’s example (here Google Spreadsheet)

Production plan Excel (Google Docs) with each employee included

 Above – simple production planning, example production plan in Excel (here Google Docs)

3. An easy to use production planning and work registration online software for small manufactures 

It is 2021, and displaying a work plan at the production hall is very easy, fast, and most important, practically free. The principles are easy — you decide to leave your tested invoice and inventory management system, to implement a new external tool – Prodio and continue production comfortably without any complications. 

No more burning the midnight oil and working the second shift to make sure things are running smoothly. Spend the evening with your family or on your preferred pastime. No more cutting holidays, because the production won’t be functioning without you, no more such dilemmas!

 production planning plan

Objective:  

Controlled and better-organized production at the production hall; your employees must know what order should be produced (they always have an updated production schedule at the production hall). You know the real-time of when the product is ready, can estimate progress and efficiency.

 

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It is recommended for:
  • industries with simple products: metalworking, CNC, injection molding machine industry, elastomers, carpentry, cardboard boxes, printing houses, tool shops and other similar production-support services (ex. galvanizing industry),
  • producers of equipment/ machinery/ steel structures, where it is necessary to manage separately individual elements of the construction (or group of products),
  • the number of employees starting from 2-3 people at the production hall up to about 40.
Typical cost (based on Prodio software):
  • Monthly subscription:  from 97 USD net per company
  • Implementation/setting up costs: 0 USD, the clients start by themselves.
  • Update costs:  0 USD (always up-to-date)
  • Necessary equipment at the production hall: simple laptop/computer with Internet access, RFID readers + key-fobs 
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What should the production plan contain to be effective in the management of work at the production hall? 

 

1. Necessary data regarding production planning, so an employee would know what to do and how:

1. The list of machines/ manufacturing operations depending on how you plan to work;

2. The queue of orders for individual machines/ manufacturing operations;

3. Important comments, usually given as spoken remarks, not connected directly with product’s technology, ex. that at 2 p.m. the courier comes to collect a particular product;

4. Parameters regarding how something should be made — with a reference number to documentation or external order;

5. Deadline – when is the particular operation due.

2.Data necessary for simple production and machinery capacity planning:

  1. Working time of particular manufacturing operations and how they are ordered,
  2. Total working times for individual machines,
  3. Indication, what is overdue or at risk of being overdue,
  4. The connection between orders — the order of manufacturing operations.

What you DON’T need for production planning in small manufacture:

  1. Giving a PRECISE calendar with an estimated time of starting each manufacturing operation is based on scheduling in big facilities. Flexibility is a priority for you, so one phone call from your client would prove it wrong.
  2. System of production planning with Gannt’s charts, etc. Charts are great but to set them up in a way that facilitates production planning would require a great amount of time and precise technologies for each product — otherwise, they would be unnecessary.

 

Online production planning — why is sit so important to have Internet access?

Experience shows that a production hall is where the most common production mistakes happen due to which the company makes losses. Incorrect interpretation of guidelines given over the phone, obsolete drawing, incorrect communication between shifts, mistakes caused by confusion, and resulting from changes of the plan — these are the grounds for the majority of complaints.

The lack of an online working plan and monitoring of progress results in:

  • Much higher risk of using bad parameters/ unsuitable products;
  • The wrong sequence of works, unnecessary changeovers;
  • Hold-ups, during which employees don’t know what to do;
  • Long hours which you spend on controlling the production hall instead of developing your business;
  • Incorrect exchange of information between shifts.

The fact that you don’t have a computer in the production hall is a single reason why you lose a lot of money:

The arguments I CAN’T AFFORD IT/ I DON’T HAVE TIME/ EMPLOYEES WON’T BE ABLE TO HANDLE IT lost their validity. All you need to have an online production plan is:

  • one of the 3 programs mentioned at the beginning of this article,
  • second-hand laptop or cheap tablet,
  • Internet access (Wi-Fi / 3G).

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When each employee knows what to do – your simple online production plan

When each employee knows what to do – your simple online production plan

Your magic board with always updated production plan

First steps in Prodio - how to use production planning

That’s it! You will not waste your money!

Have you recently experienced any of below problems which cut your profits: 

  1. The employees on stand by waiting for you to assign tasks to them personally.
  2. Chaos at the production, which even if you put in extra hours, is not changing into increased productivity.
  3. The employees wandering aimlessly, asking about progress or whether the element is ready at the machine.
  4. Stressful situations caused by lack of control and inability to pinpoint your orders status.
  5. Incomplete information, which stops you from accepting extra work or slowing you down, as you don’t know what’s the capacity of individual machines.

If you answer yes at least once, there is good news – the solution is within your reach and it is production planning. 

Always updated lists of tasks for each operation or individual machine – Prodio’s production plan.

  • The data is always current as computers at the production hall are able to exchange information with your personal computer online and updated production plan is always displayed.
  • At any time you are able to change work order and add new tasks (from manager’s account). They are straight away displayed at your production hall.
  • The employees are able to see a simplified view only and don’t have access to all functions (ex. checking Clients, products), but they can check in / check out their working time. 
  • For better communication you  and your employees both can add to production plan comments (they can be displayed at the plan straight away).

Production plan as easily accessible list of tasks 

What’s the easiest form of assigning tasks that everybody understands? SIMPLE LIST OF TASKS, that’s why in Prodio employees see production plan in a form of list of task for each individual machine / operation and know exactly what to do and in which order. 

  1. The employee always chooses the first from the top task on the list.
  2. Once the task is completed it’s marked green or it dissappears (depending on settings) and the employee can move onto next task. 

You can change the order of tasks from your computer – just drag the particular task up or down to the required position on the production plan. All changes will be visible within a few seconds at the production. What’s important you can react quickly – because you see who is working a particular task and what’s the progress. When there is a problem with completion of order, employees can leave a comment, and you will see it as a pop-up cloud regarding last operations.

Production plan set for machines or operations?

In Prodio you decide how a production plan will be set, by ordering tasks – by simply naming particular lists (Settings -> Machines/Operations). Think how you see your production and try to replicate it in the software.

Tip: different manufacturers use categories such as “Preparing technology” or “Cooperation services” and mark them as operations on the production plan, which allows them to see production as an overall technological process.

The production plan can be divided into clear desktop panels, separate for each production hall or group of machines

  • You can have any number of computers / tablets at the production hall and you can display all machines on all computers or devide them into desktop panles. 
  • The devision of the production plan to different desktop panels makes it clearer for employees – one computer displays only thiese machines / operations, which are necessary. 
  • You, as a manager, have a full access to all data and desktop panels directly from your computer.

 

You can see machines occupancy and you know straight away whether you keep a deadline

In a small manufacture there isn’t time to waste it on setting a precise production schedule/ There are too many variables and there is too much work, so the constant corrections would make it pointless.

All you need is a clear view, how much time is left for particular operations, a forecast of machines occupancy – to make a decision whether you are able to accept further orders. This is a practical solution you get from preparing a production plan in Prodio.

Additionally the software will let you know which orders are overdue, marking them red – and you can receive an e-mail with this information if requested. 

You know exactly what is happening at the production hall and can react adequatly

Prodio gives you a complete array of tools, so at any time you know:

  • Who is working, what time they started, wheter they complete machine tasks.
  • Which machines / operations are now in motion and who is working and where.
  • Which stage are particular oreders at, and who is working them.
  • What and how efficiently has been produced and if there were any important comments during prodution.

Obviously, you can access getprodio.com not only on your computer, but also on your  smartphone – so you have always your production with you.

Your employees will not waste time to find out whether they can start the next procedure or is it still underway. 

That’s it! No more wandering and asking what to do! The bigger the production hall, the worse it usually is and the workers waste time checking whether they can work on the said item or if it’s still waiting for completion at the previous machine.

The good production plan should show employee visually not only what they have to do, but what from the list can be actually made.

Production plan objectives 3

Apart from marking with the dark color, the employee at the different production hall / different operation can see what stage is the product at, how much was already completed (ex. can they take the first pieces from the milling machine and start sanding).

 

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Do you have any questions?

We are glad to help ?

Let’s chat (the right-hand corner of the screen)  or talk on the phone, call us: +48 32 746 61 62

We are happy to hear from you from Monday to Saturday 9.00 am to 5 pm

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