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Purpose

It is a common need to understand the status and location of various work orders as they move through a valuestream. This helps in both execution and planning. The Work Order Tracking bundle enables you to track your orders from when they arrive at areas for processing throughout your value stream using a simple app for initiating, completing, or moving work. There is also a dashboard to give you an at-a-glance view into your operation.

The data gathered about actual status transitions gathered by the Terminal app can be used to guide continuous improvement initiatives, as well, and be a valuable source of key performance indicators such as lead time, OTD, or even help to create a real-time valuestream map.

General Process Overview

Work orders are created at the first station or process in a sequence of processes. Orders have one of three statuses at each station: Queue, In Progress, or Completed. All orders can be viewed in terms of their time spent at each location or status. Once the tasks for a WO at a station are completed, the WO can be passed to any other station or marked as fully complete. Please refer to the diagram below for a representation of the workflow within this application.

Main Components

Apps

  • Work Order Terminal - Operator Interface for tracking WOs at each station / process
  • Work Order Dashboard - Dashboard showing overall status of WOs in the system

Tables

  • Jobs - General information about each WO
  • Job History - Detailed process information for each WO
  • Stations - List of stations / process steps of the system

Installation

In order for this application to function you will need to create stations in the Tulip shop floor that represent the locations or processes where work orders could be processed. This doesn’t have to be a machine or workcenter, but could represent a body of work that needs to be completed. For example: you could choose to create a terminal for Quality or Manufacturing Engineers to keep track of work orders that need their attention.

You will also need to create the analytics so that you can view aggregations of orders by status or location. Refer to the analytics section of this document for more information regarding building the analytics.

Getting Started - Application Overview

This application has two parts: the Work Order Terminal and the Work Order Dashboard.

Work Order Terminal

The Work Order Terminal is the interface that each process or station of the operation will use to interact with and process the work orders.

There are two sections on the left side of the screen which allow you to select work orders that are in the queue or ones that are in progress at the current process / station. Clicking on the order will make it appear in the WO Detail area to the right. Once selected, you can choose to move the order back into the queue (if it currently is in progress), start the order (putting it “in progress”) or complete the order at this process / station. If the order is completed, you will be routed to another view to select the next process / station the order should be routed to or to complete the overall order if the current process / station is the last.

Each time the status of an order is changed, the amount of time spent in each stage will be added to the Job History table to maintain a record of lead time for your analysis. There are three analyses in the top right of the screen, representing the number of work orders in queue, in progress, and completed today.

The “create new WO” button on the bottom left will allow you to initiate new work orders by entering a WO ID, a due date, the part number and the required quantity. However, a work order can only be created once. After creation, the order must be passed from station to station.

Work Order Dashboard

The Work Order Dashboard provides a quick at-a-glance visualization of the work moving through your value stream. The initial step shows an overview of the queued and In Progress WOs of all stations on the shopfloor.

This provides supervisors and planners a very easy way to see which processes are bottlenecked or may have extra capacity and can aid in resource allocation or work order routing.

In addition, the Dashboard provides multiple detailed views on individual WOs as well as analytics on waiting and procedure times per station.

Application Design

This section describes some of the unique features used in this application beyond the basic Tulip features such as creating tables or variables. Trigger logic in this application is fairly straightforward, however the use of two tables in particular and their relationship to one another is worth describing in greater detail.

Table Structures

The Jobs table is a shared table used by a number of other applications, so some of the fields in this table are not used in this application but represent opportunities to expand into other related applications or expansions such as Dynamic Work Instructions or Part Routing. Fields not used in this application will be greyed out.

This is a color to represent its status and make management of orders more visual

The job history table creates a single record for each stage in the Work Order’s life. The unique identifiers in this table are a concatenation of [Job ID] and [Procedure Number]. For example: WO01-1, WO01-2, WO01-3, and so on. This is the table where a record is maintained regarding the duration of the work order in each status.

Analytics

When applications are copied over between instances, table analytics are not transferred. The following instructions explain how these can be easily rebuilt on your instance.

Work Order Terminal - Analytics for Work Order Totals (In Queue, In Progress)

These analyses display the total number of work orders in queue and in progress, and completed that day. They are fairly simple to construct.

  1. Click on the “select from existing” button on the empty analysis widgets
  2. Switch to the “Table” tab (top left)
  3. Select the *Jobs table
  4. Click on “Create New Analysis”
  5. Choose the “Single number” template
  6. Under the “number” selector to the left, create a “count where true” function where the “Procedure Status” equals “IN QUEUE”.
  7. Set the date range equal to “all time”
  8. Save the analysis and create another similar one where the “Procedure Status” equals “IN PROGRESS”
  9. After creating these two widgets, add filters to them from within the app editor (select the analysis widget and click edit filters on the right) that filter the station field based on the current station, as shown in the image below.

Work Order Terminal - Analytics for Work Order Totals (Completed)

This analysis displays the number of orders that have been completed through the station in the current day.

  1. Click on the “select from existing” on the empty analysis widgets
  2. Switch to the “Table” tab (top left)
  3. Select the *Job History table
  4. Click on “Create New Analysis”
  5. Choose the “Single number” template
  6. Under the “number” selector to the left, create a “count where true” function where “Total Duration (s)” is not blank.
  7. Set the date range equal to “Today” and save the analysis
  8. As for the other two widgets, after creating the widget, add a filter from within the app editor (select the analysis widget and click edit filters on the right) that filters the station field based on the current station.

Work Order Dashboard - Factory Overview

In the example setup of the app, we have three stations - Station 1, Station 2 and Station 3. For each station you have an “IN PROGRESS” analysis and an “IN QUEUE” analysis in the factory overview. Those are a reuse of the “In Queue” and “In Progress” analyses you already built for the Work Order Terminal. The only difference is that you need to add a static value for the station filter instead of the variable “Station Name”. The steps are:

  1. Click on the “select from existing” button on any of the empty analysis widgets.
  2. Choose “Table” on the top left.
  3. Select the appropriate widget you created earlier (IN PROGRESS or IN QUEUE) from the analyses shown on the right by clicking on the “+” next to the analysis.
  4. Click “Add Analysis” to add the analysis to the widget.
  5. Add a filter in the app filtering the station field based on a static value for the station this widget is for (see below Station 1 as an example).

You can of course use any other station name and/or add/remove stations to adapt the dashboard to your operation’s setup.

Work Order Dashboard - Analytics

The analytics page shows two filterable pareto analyses. These can be creating following a few steps:

  1. Click on the “select from existing” button on the empty analysis widget.
  2. Switch to the “Table” tab (top left)
  3. Select the *Job History table
  4. Click on “Create New Analysis”
  5. Choose the “One Operation” template
  6. Click on “Display” in the upper configuration bar and select “Pareto Chart” from the options.

7. Configure the analysis according to the images below. (Left image - average waiting time, right image - average procedure time)

8. For both analyses, add the following filters within the app editor to enable adaptive filtering using the variable inputs on the step.

Work Order Dashboard - WO Details - Times

The “Procedure Time”, “Waiting Time” and “Total Time” analyses are all single number analyses similar to the ones you already built for the “IN QUEUE” and “IN PROGRESS TRACKING”. Set the basic analysis up following the instruction for those and configure them as depicted below:

After this setup, add the following filter to each analysis in the app editor:

Note: There is a transparent box in front of the “Total Duration” analysis widget. You need to move that to the side before being able to click on the analysis and move it back after you have configured the analysis. This box hides the widget for non-completed WOs.

Work Order Dashboard - WO Details - Working Time / Waiting Time per Procedure

Both of these analyses are “One Operation” analyses similar to the pareto chart. But you do not need to switch to pareto in the “Display” menu. Just create two new “One Operation” analyses following the instructions above and configure them the following way:

After this setup, add the following filter to each analysis in the app editor:

Now you have successfully set up all analyses for the Work Order Tracking bundle.

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