Overview: Tool Tracking
The tool tracking feature enables you to associate tools with operations.
This topic has these subtopics:
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Introduction
Tools include an estimated life; as you report operation completions, the number of operations or the run time is accumulated for the associated tool(s). Reports detail tools approaching the end of their useful life; i.e., they are due to be replaced, repaired or recalibrated.
Consumable tooling is not tracked by serial number. These are typically low cost items that are frequently replaced. Drill bits, router bits, saw blades, etc. are examples. Link consumable tools to operations to identify where they are used. When the tool leaves the tool crib area the item is simply written off as a periodic expense. Safety stock should be assigned to such items to enable the planning system to identify when to restock the tool crib.
The need for a tool at a work center is identified with the Tool Availability Report or from it being listed on the Work Center Operations display. It is assumed that the tooling is either in a tool crib area or stocked within the confines of the work center. The warehouse and bin location of the tool identifies were it is currently located. The Tool Movement (MTM) program is used to move the tool from its stocking location to the work center and machine where it is required. Multiple tools can be moved to a work center (i.e., if the tool is likely to be replaced during a production run); however, only one tool serial number can be active at a time. The Tool Activity Maintenance (MTA) program is used to de-activate one serial number and activate another. When the tool is changed, the operator must record the production completed to that point so that it is tracked as having been completed with the correct tool.
Tool tracking is in real time: when operations are reported (i.e., in Barcode Labor Entry or WIP Movement), the tool serial number is updated with the number of completed operations or the elapsed time of the operation (depending on the attribute being tracked).
If all required serialized tools are not active in the reporting work center at the operation start time, the work center department administrator is emailed. If the tool is still not active at operation completion, the administrator is sent a second email and must apply the work center activity to the correct tool.
Labor Entry (LLE) and Labor Import (LEI) do not support tool tracking as they are batch processes that do not identify tooling.
Setup
Enter tool classifications in Tool Classification Maintenance (TICC).
Enter tool classification types in Tool Classification Type Maintenance (TICT).
Enter the builder of the tool in Manufacturer ID Maintenance (VGM).
Enter the work center's default stocking location in Work Center Maintenance (WCM).
Enter the administrator for work center departments in Department Codes Maintenance (TDP).
Add Tools to Inventory
Enter tools in the Enterprise Item Maintenance (IM) program. Tool items are identified by order code 4; they must be controlled by warehouse and bin location and optionally can be serially controlled. If you want usage of a specific tool to be tracked, it must be serially controlled.
Enter tools in the manufacturing branch where they physically reside in the Branch Item Maintenance (IMB) program.
Tool Attributes
Use the Tool Crib Maintenance (MTM) program to add tooling-specific attributes to the tools. You identify how the estimated life of the tool is determined. Options include:
Period of time has elapsed
Number of operations have been completed
Calendar time tool has been used has elapsed
Assign Tools to Standard Operations
In the Standard Operations Maintenance (ROM) program, use the Tools button to assign tools to standard operations. You can include specific tool usage information if required. When you add a standard operation to a routing, the tools associated with it are automatically associated with the item.
Assign Tools to Routings
In Routing Maintenance (RTM) use the Operations/Tools button to assign tools to routings. You can include specific tool usage information if required. Tool information added in Routing Maintenance (RTM) is associated with the work center and machine for a routing operation sequence. A drill in Work Center Maintenance (WCM) shows all tools linked to a given work center.
Tool Inventory
Use the Material Issues and Adjustments (IMI) program to add existing tool inventory. Tools can be purchased and received like are other inventory items. Tools can also be manufactured against a manufacturing order (i.e., by entering an order in Manufacturing Order Maintenance - MIM). Bills of material and routings for tool items can be added as they can for any manufactured item.
Tool Movement
Tools are moved from a stocking location, typically a tool crib, to the work center with the Tool Crib Movement (MTC) program or with the RF tool movement program. Tools at the work center can be active (allowing usage to be tracked) or inactive (allowing for replacement of a currently active tool as needed). Only a specific serial number for a tool can be active at a work center and machine at any given time. Use Tool Activity Maintenance (MTA) to change the currently active tool in a work center.
Tool Availability
The Work Center Operations (WCO) program indicates if all the tooling for a specific manufacturing order number and operation sequence is available at the work centers' assigned warehouse and bin locations. Selection of a specific operation sequence enables you can drill to tool details.
The Tool Availability (MTAI) program allows you to look into a future period of time to view the upcoming tooling requirements.
Tool Usage
As operation quantities are reported tools' usage is updated. Use can be based on number of operations completed or the elapsed time of tool use. Once tools are moved to the work center no additional input is required for the tracking data to be updated.
Tool Listing
The Tool Crib Listing (MTCL) prints tools. The report offers options to limit the scope of the list, such as including only those tools with a remaining life that is less than an input percentage threshold or when the next service date is within an entered parameter.