PlatformProcess designer & planning
Plan — process designer & scheduling
Production planning starts with a drawing that runs the factory.
Planning software earns its money on the day the plan breaks. Two screens do the planning here, and they answer different questions. The process designer says how a part is made: the stages, in order, and what each one consumes. The schedule board says when: which press, which shift, which tool change. Get the first one right and the second one stops being an argument.
Process designer
Ninety seconds from an empty canvas to a released process.
Most systems in this bracket ask you to type a routing into a grid, one row at a time, and hope somebody remembers to update it. SmartFactory gives you a canvas: drag the work centres on, connect them into the flow the part actually takes, attach the materials each stage consumes, and release it.
Two components are on the bill of materials but nobody has said where they are consumed, so they sit in the amber tray rather than being quietly attached to the first operation.
- Drag three work centres onto the canvas, connect them, attach two materials to the first stage and a sub-assembly to the third, and press Release. That is the whole flow, and it is genuinely under two minutes on a part you know.
- You place work centres, not machines — a bank of four interchangeable presses, a trim cell, an inspection bench with no machine at all. The palette is grouped by area, because that is what a work centre is, and each one carries its machine count so “any of these four” is a real instruction rather than an empty field.
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Every stage shows its operation number, its work centre and area, and its times —
setup 20m · 45s/ea— so the picture is readable across the room and not just by the person who drew it. -
Cycles are refused as you draw them: an edge that would loop the flow back on itself greys out mid-drag, and if one already exists the message names the path —
10 → 20 → 30 → 10— instead of saying “invalid routing”. - It works on a shop-floor tablet: long-press to move a stage, long-press a port to connect one, and a finger that was scrolling never leaves a node somewhere you did not put it.
- Auto-layout tidies what it drew and leaves alone what you moved — a planner’s arrangement is never discarded to make the algorithm’s picture neater.
Which stage consumes what
It records which operation consumes which material — and refuses to guess.
This is the detail that separates a drawing from a system of record. Knowing a part needs 2.4 kg of polypropylene is a bill of materials. Knowing the moulding stage consumes it and the assembly stage does not is what makes back-flushing, scrap analysis and traceability mean anything.
- Components sit in an amber Unallocated tray under the canvas until a human drops one onto a stage. Nothing is ever attached to the first operation because it was the easiest guess to make.
- Where a component genuinely is unallocated, the number still works — the system falls back to the first operation to keep the arithmetic complete, and flags that line as assumed everywhere it appears. Complete for the report, honest about which part of it is evidence.
- A tenant-wide data-quality report lists every released process with assumed allocations, part by part, so cleaning up a decade of inherited data is a work queue rather than an archaeology project.
- One material can be split across two stages — “also consumed at” — with the two portions edited side by side and the live sum turning red above 100%.
- Sub-assemblies expand in place: click the chevron and the child part’s own flow is drawn inside the parent, at the stage that consumes it. A sub-assembly pulled from stock stays collapsed, because its production is not part of this build.
- The full-build view flattens every level into one canvas in true manufacturing order — deepest sub-assembly first — so the picture reads left to right in the order the factory actually builds it.
- Preview jobs before you commit anything: the operations, their sequence, the candidate machines, the planned quantity scaled for scrap. It writes nothing, and where the preview cannot express the shape you drew, it says so on the job rather than quietly simplifying it.
Controlled documents
A released process is a controlled document, not a drawing somebody edited.
- Draft, Pending approval, Released, Superseded. A released version cannot be edited at all — the screen has no unlock button, because an editable-looking form that cannot save is worse than a disabled one.
- Revise deep-copies a released version to a new draft, canvas positions and all, and releasing it supersedes the old one in the same transaction. Nothing is overwritten and nothing is lost.
- Where approval is switched on, the approver cannot be the author — submitting freezes the document exactly as releasing does, so the approver signs off the thing they read rather than the thing it became while they were reading it.
- Versions carry effectivity dates. A works order raised last month still resolves the version that was in force last month, so a two-year-old job stays reproducible after two process changes — the same discipline the specification approval trail applies to inspections.
- Who submitted it, who released it, who rejected it and why — recorded on every version whether or not approval is switched on, so turning the control on next year does not leave a hole in the history behind it.
- Two planners editing one process is caught rather than merged: the second save is refused with “this process was changed by someone else — reload and try again”, and neither person’s work quietly disappears.
The designer says how a part is made. The schedule board says when it runs. The designer has no time axis, no calendar and no view of machine availability — a process drawing that knew about capacity would be a scheduler with a worse interface.
Works-order import
Get your orders in from any ERP — and see what will happen before it happens.
Import is where most MES rollouts quietly go wrong: a bad date format, a duplicated part code, and three weeks of history is junk. SmartFactory shows you the damage before it commits any of it.
| Row | Column | Value | Code |
|---|---|---|---|
| 48 | DueDate | 03/04/2026 | INVALID_DATEAmbiguous format — set DMY or MDY and re-preview |
| 91 | PartCode | BRK-LH | PART_CODE_AMBIGUOUS2 active parts match |
| 117 | Quantity | 1,2OO | INVALID_QUANTITYNot a number — never coerced to zero |
| 160 | OrderNumber | WO-1042 | ORDER_STARTED_IMMUTABLEAlready running — left untouched |
- ERP-agnostic by design: a CSV or Excel file with named columns, up to 5,000 rows — no ERP project, no middleware, no waiting for your vendor’s integration quote.
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Column names are matched forgivingly —
Order Number,order_numberandORDERNUMBERall land in the same place — and a column we do not recognise is a warning, never a failed import. - Preview before commit writes nothing at all. You see counts to create, update and skip, and an exception report naming the row, the column, the value and an error code you can send to whoever owns the file.
- Dates are never guessed. ISO and SAP formats are read directly; anything ambiguous is raised as an exception for you to resolve, not silently read as American.
- Re-importing an unchanged file is a no-op — the same rows are skipped, not duplicated — so a nightly drop can run without anyone watching it.
- Orders that have already started are never modified, and nothing is ever deleted: an order that drops out of the file stays exactly as it was.
Working calendar
The calendar is a fix, not a feature.
Ask any manufacturer why their OEE looks wrong in August, and you will get the same answer: the shutdown counted as downtime. This is the part of the product that ends that conversation.
- Shift patterns per site and per machine, with breaks, bank holidays, shutdowns, planned maintenance and overtime — the most specific rule wins, so one press on a Saturday shift does not need its own calendar.
- It is DST-correct by construction: a 06:00–14:00 shift is eight hours on an ordinary day, seven on the spring-forward Sunday and nine in the autumn — because each occurrence is resolved in your site’s timezone, not against a fixed offset.
- It retro-fixes your history. Mark a two-week August shutdown and availability re-states itself — that fortnight stops counting against you, in this month’s report and in last year’s.
- A machine with no shifts defined is treated as running around the clock, and the tile says so — the assumption is on screen rather than buried in a config table.
- Overtime works the same way in reverse: added hours count as planned production time, so the Saturday you worked shows up as capacity rather than a suspicious spike.
The board
A Gantt built for machines, not for projects.
A scheduling system for a factory has a different job from a project planner: one lane per machine, setup and run as separate segments, and a bar that fills from real cycle counts rather than from somebody’s percentage complete.
A job running 20% slow flips to Late-forecast before the schedule says it is late — the caret turns red while the bar still ends on time.
- Two-part bars — setup then run — on one lane per machine, with the run segment filling live from real cycle counts, so you can see progress without asking anyone.
- Schedule backwards from a due date and SmartFactory works out when the job has to start, using the working calendar; if that start is already in the past, it says so rather than pretending.
- Pin the jobs that cannot move. Everything else is arranged around them; a pinned job is never quietly shifted to make the picture tidier.
- Eight named conflict codes, colour-coded on the bar: pushed by a pinned job, pinned overlap, late, late-forecast, starts in the past, no cycle time, no capacity, machine inactive. Every warning has a name you can look up.
- The due-date caret turns red on forecast overrun before the job is late: a job running 20% slow flips to Late-forecast with no page refresh, while the schedule itself still says on time.
- An at-risk widget ranks the five jobs with the worst negative slack — the shortlist for the morning meeting, in the order the morning meeting needs it.
- Forecasts use a rolling average of recent completed cycles, and mark themselves low-confidence while they are still working off too few samples.
Tool changes
Changeovers plan themselves, because the tools are in the plan.
Two jobs on one press needing different tools is not an event — it is three tasks, a heated tool and a person from the toolroom. SmartFactory schedules all three.
- 09:35 PREHEAT T-0389 · Station 1 · ready by 10:05 Tool ready
- 09:40 REMOVE T-0412 (Bracket 4-cav) from IMM-03 Released
- 10:05 INSTALL T-0389 to IMM-03 — resumes WO-1044 Planned
- 13:20 REMOVE T-0377 (Cover 2-cav) from IMM-07 Planned
Change times are per machine. Preheat is booked so the tool is hot when the press is free — not before.
- When consecutive jobs on a press need different tools, the change derives itself: remove the outgoing tool, preheat the incoming one, install it — with times taken from that machine, because a 400-tonne press is not a 90-tonne press.
- Preheat stations are a finite resource with their own lane on the board. Two changes needing the same station at 10:00 is a conflict you see on Monday, not a row you have on Thursday.
- Preheat is booked so the tool is hot when the press is free — not two hours early, tying up a station somebody else needs.
- Where a tool is preheated in the machine, that time visibly blocks the machine’s own lane, because the press genuinely cannot run during it.
- The toolroom gets a shift run-sheet, not a Gantt: remove this, from that press, at that time; install this; the station it is heating on and when it is ready.
- Move a job and the changeovers re-derive around it — but anything the toolroom has pinned stays put, and a task that is no longer needed is marked as such rather than deleted out from under someone.
- Optionally check tool-change cover against who is actually on shift, as a warning or a hard stop — your choice which.
Plan versus reality
Know on Tuesday which promise you are going to break.
- Every running job carries a completion forecast built from its own recent cycle times, banded On Track, Behind or Critical.
- Schedule-late and forecast-late are reported separately, so “the plan says we are fine” and “the floor says we are not” never get averaged into one comfortable number.
- Schedule-adherence reporting compares what you planned with what happened, per machine and per period, with the variance signed so late is always positive.
- Material consumption and labour time are booked against jobs from the operator station — which is where cost per part starts.
SmartFactory computes durations, dependencies and conflicts for the sequence a planner chooses. The system does not re-order your factory behind your back.
See your factory live in thirty minutes.
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