Shop floor traveler

[maddaddy]

Hello everyone,
I'm an experienced prototype machinist just getting started in a shop management situation and I'm trying to get up to speed.
My question is does anyone have a basic shop traveler format or template they would be willing to share? Or perhaps a few good pointers on creating one?
What about tool and material inventory management? any ideas?
We are a very small shop(3 people) doing very short runs(less than 10pcs) of complicated aerospace parts and I'd like to clean up our handling of job paperwork. Also repeat jobs are rare.
By the way, buying shop management software is out of the question I've been told.
Thanks for the help.

[yoopertool]

Honestly, most shops use an ERP software to do this. I really think that you should look into some less expensive ERP systems because the amount of time you would save would more than pay for itself in a short period of time. I know one system that is very affordable is made by Xtuple. That is just my opinion. Having a software that can track all of this for you will be much more efficient and accurate than multiple excel spreadsheets doing individual tasks. Good luck!

[Jan de Ruyter]

ERP is a very expensive solution, if not the software, then the implementation. It is a data hungry monster and unless your are totally dedicated in doing it right, don't even attempt it.

You need a simple system (preferably on MS Access) consisting of:

Work order: WO, Item, Description, Start Date, End date
Routing: WO, Operation, Work Centre (Machine or manual), Set up time, Run time per piece, person who completed the operation.
Tooling: List of all the tooling required, jigs, fixtures, inserts, tool holders, whatever. State whether they are consumable or not.
Test results: A list of all the attributes that need to be checked/measured, instrument to be used, the expected result, minimum, maximum, person who did the checking as well as the actual result.

I am sure your customer requires a certificate of conformance for each piece produced. This can then be printed from the system.

If you need more info, send me a PM

[frazz]

If your shop isn't bigger than 50 employees investing in ERP would be a freaking NIGHTMARE for you! Remember...KISS. If you have a computer network around the shop then just put up the schedule and folders with relevant info on the network server. No network? Get one computer and a big screen LCD tv and BAM! Production schedule, engineering data, procedures, updates and notices....

These are just a couple things I have seen implemented effectively, it really depends on the size of your shop and how many employees there are. Physical folders/packets work OK, but they get dirty and things get spread out or lost and can cause some real headaches.

Hope that helps!

[metlcutr55]

i use a simple spreadsheet system, inputting full operation description, setup time, cycle time, hourly rates, etc. a separate line for materials inc minimum buy and per unit, and if needed another separate line for perishable tooling, minimum buy, tool cost and tool life in # of pcs per tool. formulas applied so you can adjust qty and see needed hours req'd, costs, tooling & matl needed etc. i save that in a processes folder as a master, and clone it off into a workorder folder when ordered, adjust by quantity, so i can see total job time, ea operation time, costs, yada yada for that particular workorder.