In order to track the progress of production orders accurately and make data-driven decisions, it is essential to review the Production Order (PO) Report. This guide explains how to access the report and read its data, from costs and the order timeline, through batch creation, production start, and completion, to quality inspection, AQL inspection, and packing pieces into boxes.

How to Access the Report Page

• From the orders table on the Production Orders page, select the order whose progress you want to check.
• Right-click on the desired order and choose "Production Order Report" from the list.

How to Access the Report Page

Report Overview

The report provides key details at the top, including the style code and the order timeline. Additionally, it presents a comparison between the actual cost and the estimated cost:

• Estimated cost is calculated by multiplying the estimated production time for one piece by the machine cost and overhead costs.
• Actual cost is determined by multiplying the actual time spent by the employee rate and overhead costs.

Order Creation

• Displays the date and time when the order was created.
• Includes details about the required quantity for the order.
  

Production Order Details

Batch Creation and Bundling

• Indicates when batches are created and bundled within the factory.
• Shows the percentage of the required quantity that has been batched.
• Displays the first date a batch was added to the order and the last date of batch creation.
• Calculates the cut quantity percentage (cut quantity ÷ required quantity).
  • Some factories cut more than the required amount to compensate for potential defects or missing pieces, which may result in the progress bar exceeding 100%.
• Provides details on the total cut quantity and the number of batches created.
• Also shows the number of in-feeding pieces (pieces that have been cut but have not yet started any production process).
• Clicking this section reveals a breakdown of bundled quantity vs. required quantity for each color and size.
  

Batch Creation and Bundling

Production Start and Inline Status

• Tracks the start of production for the order.
• Displays a progress graph illustrating the order's movement through different stages, sections, or production lines.
• Allows filtering by cutting orders for better tracking.
• Shows the percentage of batches that have entered inline production.
• Provides key production timestamps:
  • Start date: first instance of a piece beginning production.
  • End date: if the order is still in progress, this field displays "Ongoing." If completed, the timestamp of the last recorded process serves as the end date.
• Displays the number of pieces and batches in inline production, and a progress bar reflecting the percentage of completed processes out of the total mandatory production processes for all cut quantities.
• Clicking this section reveals a Section Status Card, which illustrates the dependencies between production sections, along with:
  • Actual progress rate for each section (number of completed processes ÷ mandatory processes per section for all cut pieces).
  • First recorded production timestamp and last recorded production timestamp.
  • Number of pieces in inline production, number of in-feeding pieces, and number of completed pieces.
  • Status of each production section.
• A progression card summarizing each stage, section, or production line is also shown, with an option to filter by cutting orders.
• A table compares inline quantities vs. bundled or required quantities for each size and color.
  

Production Start and Inline Status

First Batch Production and Order Completion

• Marks the first batch produced within the order.
• Tracks the completion process of the order and displays the percentage of completion.
• Includes a daily throughput graph to monitor productivity.
• Provides key timestamps:
  • First completed piece date.
  • End date: if the order is still in progress, this field displays "Ongoing." If completed, the timestamp of the last recorded process on the last piece serves as the end date.
• Displays the number of pieces and batches produced so far, and a progress bar reflecting the percentage of produced pieces out of the cut quantity.
• Clicking this section reveals:
  • Two cycle time comparison graphs: actual cycle time vs. expected cycle time. Expected cycle time is defined in the Production Order Planning page, while actual cycle time represents the working time (within planned shifts) from the first recorded timestamp of the first piece until at least one piece is finished.
  • Expected vs. actual throughput per hour: expected throughput is defined in the Production Order Planning page (defaults to 0 if no plan exists), while actual throughput is the average number of pieces completed per hour.
  • A throughput graph displaying the daily number of finished pieces.
  • A table comparing produced pieces vs. bundled or required quantities per size and color.
    

First Batch Production and Order Completion

Inspection and Quality Information

• Tracks the start of batch inspections and provides detailed quality insights.
• Includes key quality metrics such as:
  • Inline quality.
  • Quality level.
  • First-grade pieces.
  • Defects and defect rate.
  • Repair rate.
  • Number of pieces currently in repair.
• Displays the first inspected batch date. If the order is still in progress, the end date field displays "Ongoing." If completed, the timestamp of the last recorded inspection serves as the end date.
• Provides the total number of pieces and batches inspected so far, the number of pieces currently in repair, and a progress bar reflecting the percentage of inspected pieces out of the cut quantity.
• Clicking this section reveals:
  • Inline quality metric: number of defect-free pieces ÷ total inspected quantity (assumed 100% if no inspections were conducted).
  • Quality level: number of non-graded inspected pieces ÷ total inspected pieces (assumed 100% if no inspections were conducted).
  • First-grade pieces: pieces that passed inspection without being graded.
  • Stopped pieces: number of scrapped pieces that will not proceed further.
  • Defective pieces: number of pieces flagged with defects.
  • Repair rate: number of pieces sent back for repair.
  • Pieces in repair: number of pieces currently undergoing repairs.
  • A table comparing inspected pieces vs. bundled, produced, or required quantities for each size and color.
  • A Defects Pareto Chart, which highlights the most common defects within the order, with an option to filter by quality grades.
  • A daily inspection graph showing the number of inspected pieces per day.
    

Inspection and Quality Information

AQL Inspection

• Indicates when the order has undergone an AQL (Acceptance Quality Limit) inspection.

The PO Report serves as a comprehensive and dynamic tool, enabling users to track the progress of a production order, monitor key events, assess quality performance, analyze costs, and make informed decisions throughout the order's execution.

AQL Inspection

Packing Pieces into Boxes

The report displays the date packing started, the number of pieces packed, and the number of completed boxes.

Clicking this section reveals:

• Number of assortments.
• Fully packed boxes.
• Partially closed boxes.
• Partially open boxes.
• A daily graph showing the number of pieces packed per day.
• A table comparing required pieces vs. packed pieces for each color and size.
  

Packing Pieces into Boxes

Frequently Asked Questions (FAQs):

• What are the seven main events tracked by the report?
  Order creation, batch creation and bundling, production start and inline status, first batch production and order completion, quality inspection, AQL inspection, and packing pieces into boxes.

• How are the estimated and actual costs calculated?
  Estimated cost is calculated by multiplying the estimated production time per piece by the machine cost and overhead costs, while actual cost is calculated by multiplying the actual time spent by the employee rate and overhead costs.

• What does "Ongoing" mean in the end date field?
  It means the production order is still in progress and hasn't been completed yet; once it's completed, the timestamp of the last recorded process is shown as the end date.

• How do I see the details behind each card in the report?
  Click on the card you want, and the system will display more details underneath it.

• What's the difference between inline quality and quality level?
  Inline quality is the number of defect-free pieces ÷ total inspected pieces, while quality level is the number of non-graded inspected pieces ÷ total inspected pieces. Both are assumed to be 100% if no inspections have been conducted.

• What is an AQL inspection?
  It's the inspection that shows whether the production order has undergone an Acceptance Quality Limit (AQL) check, and the report displays the date this inspection took place.

• Why might the cut quantity percentage exceed 100% of the required quantity?
  Because some factories cut more than the required amount to compensate for potential defects or missing pieces, which can push the progress bar past 100%.

• What does the Packing Pieces into Boxes section show?
  It shows the date packing started, the number of pieces packed, and the number of completed boxes, along with details such as the number of assortments, fully packed boxes, partially closed boxes, and partially open boxes.

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