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　It can support both the “f-MRP” function, which is strong in repetitive production, and the “mfg. no. control”, which is suitable for individual build-to-order manufacturing. It is also suitable for mixed management where, in custom production where the standard configuration is partially changed, the “f-MRP” function is used for versatile intermediate products and parts materials, and the “mfg. no. control” function is used for processes and parts configurations that differ for each sales order.

Shared Function Of Each System

Running Change Function

　By simply registering the old and new part codes in the Engineering Change Master, the current inventory and the consumption time of the arranged parts are calculated, and the purchase order is automatically switched to the new parts.

　Even if the production schedule changes or the inventory quantity changes, it will automatically respond. When the parent’s actual results are entered, the withdrawal of the used child parts is automatically switched. You can also directly specify the component switching date. (Bill Of Materials)

Options Related to Production Schedule and MRP Calculations

※See also the options section for details.

 ・Gantt Chart By Mfg. Sector option

　You can check the workload of the manufacturing department and adjust the plan on the Gantt Chart By Mfg. Sector from the production schedule created as a result of the MRP calculations.

・Automatic Leveling option

　It is possible to perform automatic allocation based on the production capacity, the mfg. lead-time, the standard working hours, the quantity, and the priority of allocation of the work center.

・Multiple-location option

　You can make the following plans:

- Production schedule that automatically divides products and units by ratio into multiple manufacturing locations

- Normally, it is produced in-house, but if the production limit is exceeded, a part of it will be outsourced to a partner company.

- Production schedule with arbitrarily assigned manufacturing locations

- Arrangement plan according to the post-process

- Plan considering each calculated inventory of the supply-to

・Alternative Production option

　When there is a shortage of constituent parts, you can make a production schedule using the future calculated stock for the specified substitute.

・Traceability option

　You can create MRP calculations that take into account the expiration date for each lot of parts and materials, and the expiration date for the units and products produced.

・There are three possible methods for the mfg. no. control of TPiCS
B-Seiban　Basic mfg. no. control. An arrangement plan, in which products, intermediate units, materials, and parts are connected by the mfg. no., is created from the Mfg. No. Schedule according to the product structure by the mfg. no. explosion. You can change the product structure for each Mfg. No. Schedule.
S-Seiban　Mfg. no. control by mfg. no. of preceding arrangements. The intermediate unit can be arranged and produced by the mfg. no. of preceding arrangements, and a finalized mfg. no. can allocate this for production of the product.
F-Seiban　Mfg. no. control by f-MRP. A control method in which the required amount is calculated by f-MRP, which is flexible to demand fluctuations, and the created Schedule Detail is linked by the mfg. no.

　TPiCS provides a very advanced function also in the mfg. no. control.

・Lot-sizing is possible by the quantity of the Mfg. No. Detail.

・It is possible to allocate all of the lot-sized quantity to the mfg. no., to allocate only the required quantity by the mfg. no., or for another mfg. no. to automatically and manually allocate the lot balance at the time of explosion.

・You can allocate the mfg. no. to the purchase order data that is being arranged as well.

・It is possible to arrange a large amount depending on the yield rate, etc., and release the surplus parts from the mfg. no. due to the completion of the product or unit, and allocate it to another mfg. no.

・Insufficient parts due to defects can be re-arranged and parts that have not been allocated to mfg. nos. can be allocated.
・You can manage revisions and select the inventory to allocate.

・You can take inventory by mfg. no.

Structure Change Function 

　There are two ways to change the product structure for each mfg. no.:
・Method to use the option code
　You can change the structure by master-registering different parts to be used by the Option Code in the Bill Of Materials, specifying the Option Code in the Mfg. No. Schedule, and executing the mfg. no. explosion.
・Method to change the structure after the mfg. no. explosion
　After creating the Mfg. No. Detail according to the product structure registered in the master by mfg. no. explosion, you can easily change the structure for each mfg. no., such as adding units and deleting or changing parts.

Cost Accumulation Function By Mfg. No

・Unfinished work can be calculated as predetermined cost even during manufacturing and can be included in the budget control in comparison with standard cost.
・Parts calculated by f-MRP can also be included in the cost by mfg. no.

Form Issuing Function

Work Instructions, Purchase Orders, Outsourced Orders, Transfer (Supply) Instructions
　You will perform the MRP calculations, perform the mfg. no. explosion, or issue a slip of the plan made manually.
Automatically setting the least expensive supplier
　You register different unit prices in the Unit Cost Master depending on the supplier, season, quantity, urgency, and when creating a Schedule Detail, TPiCS looks at the season, quantity, etc. and searches for the least expensive supplier that meets the conditions, and sets it in the Schedule Detail so that you can issue a purchase order.
Ordering by supplier part code
　You can place an order with the supplier’s part code (catalog number, etc.).
Parallel Ordering
　You can place an order divided by ratio to multiple vendors, or place an order for a quantity that exceeds the quantity limit to another vendor.
E-mail Transmission
　You can send the purchase order by e-mail.

Identification Tag
　At the same time as work instructions, outsourced processing request forms, etc., you can print the required number of identification tags obtained by dividing the planned quantity by the quantity of contents set elsewhere. It is also possible to register the expiration date and lot name of the actual article in the Actual Acceptance Result Entry for parts, and print the identification tag with the expiration date and the lot name from the Actual Results data.
Issuing a delay list
　It is possible to issue a purchase order list or work list that is delayed in delivery, but instead of responding after a delay in delivery, to prevent delivery delays, you can issue something for each supplier, for example, as a list of acceptance schedules for next week.
Quotation Request
　For parts for which the unit price has not been set, a Quotation Request Form can be issued. It is also possible to issue competitive quotes to multiple vendors
Supported Excel

　The following Excel desktop application versions are supported:
・Microsoft Excel 2016

・Microsoft Excel 2019

・Microsoft Excel 2022
・Microsoft 365(Compatible with the above Excel versions)

Actual Result Working Hours Entry
　The actual result entry of the quantity is for the next step, so it is performed in real time, the actual result working hours can be entered later from the dedicated Actual Result Working Hours Entry form. It is also possible to allocate the total working hours of the work team to multiple work results and automatically set as each actual result time.
Actual Receiving / Acceptance Results
　It is also possible to perform two levels of Actual Result Entry, one is the actual receiving results for receipt confirmation and the other is the actual acceptance results for which inspection is completed and payment is to be made. 

　It will be displayed on the Accounts Payable Detail depending on the actual acceptance results. 

Actual Result Cost
　You can carry over the purchase unit price of the purchase order data to the actual result, or change the purchase unit price of actual result when entering the actual result. In addition, in the Actual Work Result Entry, the result of (Actual Result Working Hours x Processing Cost Rate) is reflected in the actual cost.

　Inventory can be evaluated by the real-time moving average method,monthly moving average method (monthly gross average method), final unit price method, gross average method, and lower-of-cost-or-market value method.
Batch Entry
　If you can produce as planned, you will want to reduce the daily input effort. In such a case, you can automatically set the provisional actual result quantity from the plan scheduled to be completed today, change and enter only some of the Schedule Detail that could not be produced as planned, and enter the actual results in a batch.
Entering lot name (Mfg. Traceability option)
　If you have to enter the lot number at the time of receipt for important raw materials, you can do the setting of Lot Name Required.
　When entering the actual production results, you can enter which raw material (lot number) was used. The data can be viewed retroactively at any time. If necessary, the manufacturing history can be recorded from the time of acceptance to the time of completion of production (time of shipment).

Inventory
　Inventory processing is carried out at the end of the period or the end of the month, and the Current Inventory for each storage location is adjusted to the inventory quantity of the actual stuff. Not only simultaneous inventory, but also partial circulation inventory and temporary inventory are supported.
　If there is an inventory difference, Actual  Inventory Result data for the inventory difference is created, so it is easy to aggregate how much the inventory difference was.
　The reflection of the physical inventory is retained as the stock before inventory at the start of the inventory, the inventory difference is reflected in the current inventory that moves daily due to the input of the physical inventory value and the end of the inventory, and actual results can be entered during the period of inventory aggregation work.

Quantity Conversion Function

　For the planned quantity of production schedule table, you can convert the planned quantity according to the unit displayed in the instruction sheet, convert the display of Inventory List, convert the structure table, and change and display the unit for each product, intermediate unit, and member.

　For example, the purchase order quantity of liquid raw materials can be calculated as 200 liters or 400 liters, and when ordering, the purchase order form can be converted into 1 can or 2 cans per drum can (200 liters). The conversion can be returned at the time of actual goods receipt results of 2 cans and 400 liters can be reflected in the inventory.

Aggregation Function

Group Aggregation, Item Aggregation, Total Aggregation

　Analysis of the current situation is important for production control.

　It is possible to display the displayed data in group aggregation with any item, or to aggregate and display child and grandchild groups in multiple items.

　You can display the totals for each item and the total aggregation for any item. The aggregation method can be set for each item such as maximum value, minimum value, average, and total, and you can easily switch between saving and recalling by giving a name to the aggregation setting.

　You can export each aggregated value to an Excel file. 

Payment Management

　You can manage the actual payment results by aggregating the data to be paid from the Actual Acceptance Results data, creating a payment schedule according to the closing date.
　Since you can specify a payee different from the send-to of purchase order, you can make the supplier of parts to a branch and the payee to the head office of the supplier. It is possible to export payment journal data for the accounting system.

Accounts Payable / Accounts Receivable Management

Accounts Payable Management(Accounts Payable Detail)

　When entering the actual acceptance results, you can enter the amount purchased, supplier, etc., which will be reflected in the Accounts Payable Detail.
　You can write out the journal data of the Accounts Payable Detail and the Accounts Receivable Detail according to the “journal data import format” of the general accounting system for personal computer.
Accounts Receivable Management(Accounts Receivable Detail) Customer Order & Sales Management option

　出荷実績入力により、売上金額が売掛明細に反映されます。

Linked Interface with Other Systems

Text Export and Import
　Data of all tables such as master, transaction data such as Schedule Detail and purchase-ordered data, and aggregated data such as Inventory List, cost accumulation by item, cost accumulation by product, etc. can be written and read as a text file.
Transaction Data Text Import
　The related tables are updated at the same time as importing the text file, as when operating on the form, such as sales order entry, Schedule Details, actual work results, actual shipping results, actual issue results, and inventory movements. When reading the Sales Order data, it will be reflected in the production schedule table at the same time as the Sales Order data is registered.
Automatic Transaction Import / Export (Transaction Interface option)
　With a text file base, if frequent data reading is assumed,it will be difficult to deal with reading errors due to data inconsistency. With the Transaction Interface option, when a read error occurs, the contents are written on the table and status management is performed, which makes it easier to link. In addition, transaction data operated on the TPiCS form can be automatically written to the writing table, which enables bidirectional linkage with other companies’ systems.

Operating Calendar

　You can register calendars with different holidays and working hours.
　There is no limit to the number of calendars, and you can specify the calendar to be used in detail for each supplier, each partner company of the processing request destination, each customer at the time of shipment, each in-house manufacturing department, each process, and so on. You can manage up to 24 shifts for day and night shifts. It is possible to set operations with different granularity in one calendar, such as a day shift and night shift calendar for the current month, a daily unit calendar for the next month, and a weekly unit calendar for the months after that, and it is possible to create a production schedule according to these.

Capability Calendar

　You can set the capability for each production location, which changes from day to day, in the capability calendar. You can check the load factor from the production volume for the daily capability on the Gantt Chart By Mfg. Sector, and it is possible to level the workload by combining it with the Automatic Leveling option. The capability for every Wednesday is reduced for planned maintenance of production equipment. It can be used to check the number of part-timers and workload that change daily.

Data Search, Narrowing Down, Sorting Function

　You can perform equal search, first match search, last match search, partial match search, equal to or more than, more than, equal to or less than, less than, and negative search on almost all forms and items. In addition, there is a quick search function that searches each time you type in the search value with the keyboard, you can display the necessary data while checking at any time. You can narrow down by AND or OR condition with multiple narrowing conditions, and if there are multiple conditions, you can sort by giving priority to either condition, or by double-clicking on the grid title row.

From Sales Order and Forecasting Data to Production Schedule

・You can also create a TPiCS shipping plan from the Sales Order data and calculate the required quantity as it is.
・Parts and materials can be arranged based on the forecasting plan by linking with the f-MRP function. Even if the forecasting plan changes, it can be directly connected to the next MRP calculations because it is based on the function of f-MRP.
・When receiving a sales order for a mfg. no. control product, a Mfg. No. Schedule is created at the same time as input, and the sales order is allocated to the preceding Mfg. No. Schedule. When the number of Mfg. No. Schedules to be allocated is insufficient, it is possible to automatically create a new Mfg. No. Schedule with the insufficient quantity.
・Sales Order data and Delivery Instruction data coming from the Internet etc. can be imported in CSV text file format.
・You can import sales orders from systems such as EDI and ERP via Transaction Interface option.
・It will fully respond to daily delivery instructions.
・You can reconcile the forecasting data while importing the firm Sales Order data.
・You can also leave it as a backorder without reflecting it in your production schedule.
・You can respond to sales orders for full-choice option production.
・Sales Order data can be entered at any level of the product structure. This makes it possible to ship intermediate products and parts at the OEM stage and manage them as repair parts. This makes it possible to ship OEM shipment at the intermediate product and parts stage and manage them as repair parts. You can calculate the required quantity by adding those required quantities.

Forecasting Data

・When firm delivery instruction data is sent daily, as in the automobile industry, you can import the data while reconciling the forexasting data in the order of the unofficial delivery date for the same item and the same delivery location.
・Processing for firm and forecasting orders can be performed.
・You can periodically delete the forecasting data and reload the new data.

Selling Price Registration

・It is also possible to operate with the selling price changing depending on the order quantity and order timing.

Billing and Cash Receipt Management

・Based on the Sales Detail, you can issue invoices using the qualified invoice save method (invoice system) and manage cash receipts.
・It is possible to register and display overseas customer information in the language of that country.
・You can export the Accounts Receivable Detail for the accounting system.

Sales Order Transition List

・There is a delay in delivery even though you have received an forecasting order. You are having trouble with having a surplus of material even though you are arranging the materials based on the forecasting order. In these causes, there may be a difference that cannot be covered within the range of error between the forecasting and firm orders. By analyzing the cause, in order to make a proposal to improve the accuracy of the forecasting orders or to make a production schedule including errors, you can check the number of increase / decrease and the rate of increase / decrease of the forecasting and firm orders.

　In the case of individual production, you make different products for each customer’s order, so it is not a business like repetitive production where masters are prepared in advance and uniform processing is performed. Therefore, the production control system, in which masters had to be prepared in advance, was very difficult to use. In order to solve these problems, TPiCS has strengthened the functions so that it can be used in various operation methods. In TPiCS, we have considered and enhanced functions that can support various operation methods. Even if it is individual production, instead of designing all products individually, common products and repair parts are arranged by the repetitive production function and incorporated into the configuration of one-item production, or the repetitive production function and the mfg. no. control function are used depending on the product, and it can respond to mixed fine management.

　This function assumes the case of operating the system without registering the master because the specifications change each time a sales order is received and it is a “one-time production”.
 

・Due to the extremely high operability, it is possible to make arrangements while registering the work contents and parts used each time.
・You can copy a similar mfg. no. from the past, modify it, and use it.
・The drawings are presented in a sami-dare style, and you can make arrangements from something “necessary” and “possible” among them.
・Once you have some patterning, you can use it with modifications based on it.
・By linking with the Structure Information Conversion option, “addition”, “improvement”, and “discarding” due to design changes can be processed seamlessly and can be quickly reflected in the arrangement.
・It is possible to use general-purpose units and general-purpose parts that have repeatability.
・You can issue an Quotation to your customers.
・You can issue an “quotation request slip” to the supplier and make transactions in accordance with the Subcontract Act (competitive quotes are also possible.)
・Parts that are no longer needed due to design changes can be managed and can be diverted to other projects.
・This option requires that you purchase the “Mfg. No. Control system.”

　The “product structure information” and “change information” of the design are imported as structure information in a CSV file from the parts list managed by CAD or Microsoft Excel, and reflected in the production information of TPiCS. Since linked processing can be performed with a single piece of data, design changes can be reflected in production without omission and quickly.
 
・You can register work that is not in the design BOM, such as supply and outsourced processing, in the manufacturing BOM.

・It is also possible to take in information that is not in TPiCS, such as implementation information and supplier information described in the parts list, and print it on the purchase order or work order.
・Even design changes after modifying the design BOM to the manufacturing BOM can be quickly reflected in the arrangement.
・The design-changed part is displayed in status and color to prevent processing omissions.
・When used in combination with the One-item Production option, design changes can be seamlessly reflected in the arrangement data.

Use of CAD Data
　Customer needs have become more diverse, product life cycles have become shorter, and it has become increasingly important to shorten the cycle of ordering, designing, and production even for individual production.
　Therefore, in order to make things in a fast cycle, you will consider using design information to arrange for production. However, the product structure information (E-BOM) considered by the designer and the structure information (M-BOM) considered by the person in the manufacturing department are often different, and it is common to add human judgment and recreate it as structure information for production. Then, when there is a design change, it cannot be directly changed to the system and reflected in the arrangement. Therefore, the reflection of the design change have been done by human beings comparing E-BOM and M-BOM one by one.
　However, by using the Structure Information Conversion option of TPiCS, even if there is a difference between the two structure information, if there is a design change, with just a few button clicks, you can find out what you no longer need or need additional arrangements from the data you have already arranged (ordered), create a cancellation slip, or create an additional arrangement slip. This feature should greatly ease the production control work of individual production.

　This is a system for performing the process control at the site, and it is a system that we would like to use for those who think as follows:

“When I give instructions to the site, the site complains that the load cannot be managed, so I want to make a plan that supports the pile of load.”
“I don't have control because the site does it on their own. I want to be able to manage it somehow using the system.”
“The setup effort differs depending on the production order. I want to make a plan that requires as little effort as possible.”
“There are multiple machines in each process, andtheir capabilities are slightly different, and there are some that can be made and some that cannot be made depending on the product to be made. I want to make a plan that is as efficient as possible among them.”
“Whenever a customer inquires about the delivery date, I can't answer unless I go to the site each time. I want to be able to understand it in the system.”

"Parts are arranged using the MRP system, but we cannot improve the mess and respond to fluctuations in demand. In order for us to respond to the times of rapid change, we want a system that can quickly create an inter-process schedule backed by the parts.”

・Apart from the result of the MRP calculations, the daily production level (quota) can be specified clearly. This makes it possible to suppress the required level of leveling of production schedules.
・From that screen, you decide what you want to do next and press the Start button.

　When you are done, click the Register button to register the actual results.
・When you press the Start button, you can see what time the previous process has been started from the next process.
・When you register the actual results, it disappears from the plan instruction screen.
　On the contrary, if you do not register the actual results, it will not disappear from the screen.
・When displaying the work that must be done, it can be color-coded according to the work content and work method, so you can think of an efficient work order in consideration of setup etc. by selecting work with similar color.
・When you register the actual results on the start signal screen, they will be reflected in the inventory quantity of TPiCS in the office at the same time.
・The actual results entered in the previous process will be reflected on the start signal screen of the next process immediately, and the red display on the screen will disappear.
・In the evening, you can output today’s daily report and the leftoverlist on your office computer without bothering anyone.

　The Shop Floor Control option is a system that solves the problems behind the needs, rather than just meeting the needs that appear on the surface. Alternatively, it is a system that aims to perform true “management” in terms of “soil improvement” by removing the mess that leads to those problems, and enables the site to make the right decisions, rather than having the site put in the actual results to collect the actual results.