In this article, you will learn...

  • The capabilities of the Factory Bundle
  • How the apps apps interact with Tables and create data for analytics

The "Factory Bundle" is a set of apps and tables that are automatically included in your Tulip account.

They demonstrate how a company that manufactures furniture might manage their shop floor within Tulip.

Rather than using some combination of paper, Excel and a manufacturing execution system (MES), this furniture manufacturer can manage all production data within Tulip.

The Factory Bundle eliminates the need to fill in paper forms and copy/paste between multiple systems. No code is required- the app design, logic and data can be modified via a drag and drop interface.

And, if you want to replace one app with an external system like NetSuite or Quickbooks, you can set up a connector function to integrate a 3rd party system and the rest of the bundle will continue to function.

Some common reasons that Tulip customers create their own version of the Factory Bundle include:

  • Automatic inventory management
  • Statistics for each work order
  • Cycle time by operator
  • Report on common defects
  • Enforced certifications for individual operators

Here are the 4 apps:

  • Inventory Management app
  • Work Order Creation app
  • Work Instructions app
  • 5S Audit app

And here are the 4 tables:

  • Bill of Materials (BOM)
  • Inventory
  • Skills Matrix
  • Work Orders

Here's a quick overview of how the apps and tables work together:

Scenario

This fake company makes three products: cabinets, wine cabinets and conference tables. With these 4 apps, they are able to track inventory for these 3 products, as well as production data for every operator and work order. They also see common types of defects in the production process.

Editing The Factory Bundle

Although you can certainly edit the apps and tables in the bundle, we recommend that you build your own bundle rather than attempting to edit the bundle until you are able to achieve your goals.

Before building your own bundle, you should: 

  1. Learn app building with Tulip Basics
  2. Understand the Tulip Terminal
  3. Build your first Table

After using those resources, you will be able to understand all the concepts within the Factory Bundle.

However, if you want to test out the Bundle, you can run each app in the Tulip Player. After using an app, you can check out the "Tables" tab to see each table updates after an app is used.

Here's a full guide to each app in the Bundle.

Inventory Addition App

Purpose

This app is meant to be used by an associate who restocks inventory. When they receive new materials, they can use the "Add To Inventory Form Step" to update inventory in Tulip.

It updates the Table called "factorybundle_inventory", which has 5 items: two types of screws, two types of lumber and maple stain.

How To Use It

The first step gives an overview of all items in inventory. Here is what it looks like in the Player:

When the operator pressed the "Add To Inventory" button, they are able to add new inventory and update the table.

Here's what that Table looks like:

How It Works

  1. When the app is opened, all 5 records are loaded from the inventory table.
  2. The first step uses the "Table Record" widget to display the latest values to the associate
  3. When an associate presses the "Submit" button after adding inventory, all values are added to the inventory table.

Further Reading

Work Order Creation App

Purpose

This app allows an operator to add a new work order to the production process. Since this factory makes three products, the operator must choose from one of three options. This means that the record in the work orders table will be easily connected to a product in the BOM table.

Then, the operator can also view all recently added work orders in the following step via an embedded Analysis.

How To Use It

On the first step, you can choose whether you would like to view all recently added work orders, or add a new work order.

If you choose to create a work order, you will be sent to a Form Step to create a work order with 6 fields:

  1. Work Order ID
  2. Create Date
  3. Product
  4. Customer
  5. Intended Ship Date
  6. Quantity

After creating a work order, you will be able to see all recently added work orders on the final step.

How It Works

  1. The first step allows an operator to go to the second or third step, depending on which button they press.
  2. If the operator goes to the second step, they are asked to create a new work order. After pressing "Submit", a new record is created in the "factorybundle_workorders" table and all associated fields are updated via "Data Manipulation" "Store" actions.
  3. On the third step, the analysis populates the latest work orders that have been created.

Further Reading

Cabinet Making Work Instructions App

Purpose

This app gives instructions on how to build one of the cabinet products. When the app is completed, the appropriate materials are deducted from inventory based on the values in the BOM table. And, the work order status is updated in the work orders table.

This app also incorporates the "Skills Matrix" table. When the app is loaded, it checks the credentials of the operator who is logged into the Tulip Player. If the operator has the correct credential, they will be allowed to proceed through the app. If not, they will not be able to advance past the first step.

How To Use It

The first step allows the operator to choose whether to manually input their work order number or use a barcode scanner.

However, before they can successfully advance, they must have the "band saw certification" in the Skills Matrix table.

Here is what that table looks like:

After the operator chooses an option, they will add a work order number. This should already exist in the "factorybundle_workorders" table. This will also load the correct list of materials from the BOM table.

Then, when they reach the next step "Picklist", the list of materials that they need to grab will be populated based on the BOM table.

Here's what that step looks like. Both work order info and the pick list are included.

After that, there are 4 work instructions steps, followed by a quality inspection step, and then one final work instruction step. Each one follows the same pattern:

Finally, when the operator presses the complete button, on the last step, a few things happen:

  1. The status of the work order in the work order table is updated
  2. Inventory is deducted based on the BOM
  3. A warning email is sent if inventory levels are too low for any part
  4. The app is completed and all data is saved.

How It Works

When the first step opens, three triggers fire:

  1. An operator's certifications are loaded from the skills matrix table based on their badge ID.
  2. Then, the second trigger checks whether they should be allowed to proceed
  3. The third trigger loads all 5 inventory records so they can be modified at the end of the app

When the operator presses either button, the app will first check their band saw credential before allowing them to proceed.

Regardless of whether the number is entered manually or via barcode scanner, after a work order number is entered, two things happen:

  1. That work order is loaded from the work orders table
  2. Based on the product in the work order, the correct record will be loaded from the BOM table.

Here's an example of the trigger from the barcode scanning step:

Each work instruction and visual inspection step is very straightforward, since each button either goes to another app or step.  

Finally, when an operator presses the complete button on the final step, 4 triggers fire:

  1. The "status" field of the appropriate record in the work orders table is updated
  2. All material quantities are deducted from the inventory table based on the BOM
  3. A warning message is sent if any quantities go below the threshold
  4. The app is completed and all data is saved.

Further Reading

Basic 5S Audit App

Purpose

This app allows you to run a typical 5S Audit. Then, it will automatically calculate a "Health Score" at the end, both for each of the 5 "s"'s and an overall score. It does not connect to any tables.

How To Use It

The app can be accessed independently, or from any step in the "Cabinet Making Work Instructions" via a button at the bottom of each step.

At the beginning of the app, the operator selects one of 4 lines via a Form Step.

Then, they are presented with a series of steps where they can indicate yes/no via 2 large buttons.

Finally, on the last step, they see a score for each category.

How It Works

  1. The initial Form Step ties all responses to a single area.
  2. Each step creates a new variable and saves a yes/no value based on the button that is pressed.
  3. At the end of each section, the app calculates whether the area has passed the test based on the number of "Yes" responses. If it has, the overall 5S score increases.

Further Reading

How To Create Your Own Bundle

This bundle demonstrates the capabilities of a series of apps and tables that are connected. However, that we do not recommend that you edit each part to suit your needs.

Instead, you should first determine if the bundle is an appropriate solution to your problems. If you just need work instructions, or defect reporting, you can solve your problem with single app or a single type of app.

However, if you need a universal system to track shop floor data, then you should consider building your own Factory Bundle.

To do this, you should plan each app individually. Use this guide to learn how to plan a manufacturing app, and then begin drawing a diagram between the different apps and tables you will need. Like this one:

After that, please reach out to a Tulip representative via the chat button in the bottom right of the screen. We would be happy to help you start building out the bundle for free.

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