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REALTRAC Performance ERP

A software system designed by REALTRAC.
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Because of Realtrac’s intuitive shop floor perspective, you will know instantly a job’s cost, where it is, and when it will be finished. Work-in-process screens and reports provide up-to-the-second history of jobs to evaluate costs vs. estimates, profitability and on-time delivery.

Assemblies / Complex Jobs

Job Tree

Complex jobs such as assemblies, split jobs, lots and jobs with multiple fabrication routers can be linked together in a tree structure for scheduling, tracking and costing.

The Job Tree shows how the component jobs are related and displays key information about each one.

You can quickly drill down to display all job detail for any component.

Complex Job Schedule A Gantt Chart display shows the overall schedule for each component job in a tree.

A change in the schedule for any component will automatically re-schedule all related jobs.

From this screen, you can quickly view the detailed operation by operation schedule for any job component.

How it works

Often it is desirable to link manufacturing jobs together for scheduling the manufacturing process and totaling job costs. The Complex Jobs (Trees) module provides an easy way to link jobs and to graphically view the relationships and schedules.

Following are examples of where the Complex Jobs (Trees) module can be used:

Assemblies - The finished product comprises many parts, each of which is manufactured separately. As parts are completed, they are then assembled into the final product. An example is the manufacture of an engine.

Repair – A product has to be disassembled in order to work on each component separately. For example, an engine needs to be torn down for evaluation and possible repair of components.

Similar Parts - Similar parts may be run together in the initial manufacturing steps, but then are separated for different processing of the final manufacturing operations. For example, an order for several door panels of different colors may be fabricated together, but separated into different jobs for finishing and painting.

Lots - The same part may be manufactured repeatedly, with each lot requiring a different delivery date.

Split Jobs – An order may be received for a quantity of 600 parts, but after the job has started, the customer requests quick delivery of 100 parts. The order is then split into two jobs for finishing, one with a quantity of 100 for rush shipment and the other with a quantity of 500 to be delivered later.

Bar Code Tracking / Data Collection

Real-time Bar Code Shop Floor Data Collection

Shop employees, with PC’s or Realtrac Micro Terminals, report time as activities occur on the shop floor using bar code scanning or touch pad data entry. A two-way communication process guides the worker at each step, checking and confirming input. Realtrac’s unique system design maintains work center loads, schedules, job status and costs in real-time.

Micro Terminal Emulation

For operations such as purchasing, shipping and receiving, an employee can quickly log on and log off directly from the Realtrac Router Screen using the Micro Terminal Emulation feature.

How it works

Realtrac allows you to choose among several methods to report data regarding shop activities, including full real-time bar code data collection using shop floor PC’s or micro terminals, PC data entry by administrative personnel and computer assisted entry from employee time tickets. This versatility allows you to balance your company’s needs for up-to-date job and scheduling information, flexibility for allocating costs for special types of operations and minimizing initial investment and employee training.

Realtrac Shop Floor Client Using PC’s with a standard CRT monitor, the Realtrac Shop Floor Client software provides an easy and paperless way for shop personnel to report their activity in real-time, as well as view job and work center scheduling information.

Advantages are:

  1. Shop personnel have real-time visibility of important job information.
  2. Real-time screen displays supplement or replace paper documents normally needed for processing jobs:

Work Center Dispatch Lists for scheduling job operations and machines. Job Routers describing the process plan for a job. Full multi-media shop floor documentation, including still pictures, video, drawings and sound tracks to supplement router specs and job information. 3. Logging on and off is fast. Most required data can automatically be entered using a mouse, bar code scanner or touch screen monitor

  1. An existing PC LAN (Local Area Network) can be used. No special network for shop terminals is required.

Data Reporting Using Administrative PC’s. Administrative personnel who normally works at a PC., e.g. Purchasing, Shipping and Receiving can enter job activity at a PC with a mouse or a touch screen monitor using Realtrac’s Micro Terminal Emulation feature.

Bar Code Shop Floor Micro Terminals Employee time is reported as activities occur on the shop floor using Micro Terminals with either bar code scanning or touch pad data entry.

Job schedules, machine loads and job costs are continuously updated in real-time. You have up to the minute information concerning the status of jobs, machines and employees, as well as labor and overhead costs.

An interactive dialog at the Micro Terminal guides the worker, checking and confirming accuracy of input.

Computer Assisted Data Entry From Employee Time Tickets If employees complete daily time tickets or time sheets, operation time and piece counts can easily be entered at a PC by clerical personnel. Much of the information to be entered is duplicated from the last entry. The elapsed time for a session can be automatically calculated if the start time and end time are entered.

Bill of Material

The Bill of Material (B.O.M.) function allows you to maintain a list of materials and outside services needed to produce one finished part, including for each item the quantity required, vendor and price. Once a B.O.M. is created or modified, it is available for any current or future estimates or jobs for the same part or drawing number.

How it works

A Job Bill of Materials reflects the total quantities of each item on a B.O.M. that are required to complete all the parts being manufactured for a specific job.

A special Job Bill Screen records actual purchases of materials, sub-contractor services and other items as they are consumed, including when they occurred and the cost. If Purchase Orders are issued through Realtrac for job related items, detail information and costs are automatically inserted in the Bill Screen upon receipt of those items. Finished parts transferred to a Sales Order are also inserted on the Bill Screen. In addition, you can manually enter materials, services and other items to record their use and costs.

Estimating and Quoting

When you receive a Request for Quotation, you are able to quickly estimate labor and buyout costs (material and outside services) and prepare a quote.

The same Router and Buyout Cost screens found in Realtrac jobs are used, allowing for easy retrieval and duplication of prior estimates, use of templates for preparation of new estimates and conversion of estimates to jobs.

Quotation Screen

The cost each, selling price and quoted amount for up to five quantities are calculated and displayed.

Changing the markup percentage for Labor / Overhead or Buyout recalculates the prices.

The number of weeks lead time required to produce each quantity is calculated based on shop capacity.

How it works

The procedure for creating a new estimate is almost identical to creating a new manufacturing job. As in a job, the “heart” of an estimate is the process plan or router. By using a process plan approach, the Sales and Engineering Departments have access to and can take advantage of actual manufacturing experience when estimating costs for a new part or repeat order. In addition, since an estimate is created from a manufacturing viewpoint, the impact of accepting the order on key work centers and possible shop bottlenecks is easily determined.

Key features of Realtrac’s estimating system are the ability to:

  • Create a job from an estimate.
  • Retrieve and duplicate a previous estimate.
  • Duplicate a job into an estimate.
  • Print quotes for up to five quantities on plain paper or on the same pre-printed forms used for invoices and packing lists.
  • Quote multiple items on a single quotation.
  • View and print detail and summary reports for analysis of estimates.

Inventory

You can maintain control of raw material, finished and semi-finished parts, customer-supplied material, tooling and other classes of Inventory, including serial number and lot traceability.

Quantities on hand and on order are automatically updated through the Realtrac purchasing system.

You can allocate material to a job, customer or drawing and easily move material from inventory to a job.

You can quickly see what vendors supply an item to expedite preparation of Purchase Orders.

How it works

Job Part Inventory The Job Part Inventory section located at the bottom of the Job Order Entry screen allows you to maintain a continuously updated record for a part’s quantities Completed, Shipped, On Hand and Back Ordered.

Inventory Control You are able to maintain a comprehensive database of different types of items in inventory, including raw material, finished or semi-finished parts, customer material, tooling, supplies, etc. The database can be quickly filtered and sorted in order to view and/or report only the items you want, including the total value. You can track quantities on hand and on order and see at a glance items that need to be re-ordered. Items can be allocated for customers and/or jobs and moved to and from jobs.

Job Order Entry

From the Job Order Entry screen, you are able to enter new jobs and review and modify existing jobs. You can designate a shipment schedule for jobs with multiple delivery dates.

You can also quickly retrieve jobs by Description, Part No., Drawing No., P.O. No., Customer Code, Reference No. or Job No.

Once a job is retrieved, you can duplicate it for assistance in preparing a new shop order.

A separate Sales Order function may be used to handle multiple manufacturing orders to be billed under a single invoice, items to be sold from inventory and invoicing for services requiring lengthy descriptions.

How it works

A job may be entered by duplicating a previous job, converting an estimate to a job or creating a new job from scratch.

The Start Date for a job is calculated by the system based on estimated time, shop capacity and due date.

As parts are completed and shipped, the Job Part Inventory is automatically updated.

Management Analysis and Reporting

Custom management reports can be generated from Realtrac’s Access® database of all jobs and estimates.

Purchasing

You can purchase material and services directly for a job or for inventory, as well as ordering general, non-inventory items.

To quickly prepare P.O.’s, vendors and item names and descriptions can be automatically inserted from an Item Master database.

As items are received, job and inventory costs are automatically updated. A Purchase Order History Screen allows you to track open and completed P.O.’s by vendor, job, drawing, date expected, etc.

How it works

Realtrac provides a convenient way to buy materials for stock or for specific jobs, as well as for purchasing outside services and non-stock items. You can generate Purchase Orders, track open P.O.’s, control item receipts, and update job costs for materials and outside services. Purchase Orders can be created from the following screens: Job Order Entry, Purchase Order History, Inventory and Bill of Material Detail. Quality / Vendor Performance can be analyzed through several Purchase Order History Report options.

Routing

The Job Router allows you to define each operation you want to track, select Work Centers and insert estimated time in hours or minutes each.

The actual time and status for each operation are continuously updated through Realtrac’s real-time data collection system.

Shop Floor Router (Traveler) The printed shop floor router travels with the job and includes all pertinent job and operation information.

Bar codes are included for accurate and easy real-time data collection.

Several versions of the Router are available for customizing, depending on the desired layout and how much detail you want to show.

How it works

The Router is where you enter the process plan for a job or estimate and where you obtain real-time status on the progress of the job. The printed version of the Router is sometimes referred to as the ‘Traveler’.

The electronic Router contains four screens, each screen having 20 lines. Each line can have 100 lines of additional descriptive information called Specs. You have the option of a printed Router which embodies all of the additional descriptive information (Specs) in one continuous document, or appending the additional descriptive information (Specs) as separate pages. The Spec pages can be used to link multimedia pictures and documents such as CAD files and word processing documents to specific Router operations and to apply certain scheduling options to Router operations. Quality non-conformance reporting can be generated in real-time from the shop floor via comments entered on Router Specs.

Scheduling

Job Schedule Gantt Chart

The Gantt Chart for a job schedule shows all unfinished operations and where the job is in the manufacturing calendar.

You can automatically schedule jobs backward from the due date, forward from the start date or manually.

Finite modeling lets you see the effect on the shop of moving operations to different date periods.

Active Job Status

With this spreadsheet display of all active jobs, you can view up-to-date information concerning where every job is and what jobs are behind schedule.

Data can be sorted and filtered to display only jobs of interest at the moment in the order desired.

The Priority No. indicates if a job is ahead of or behind schedule calculated in tenths of a day.

Detail for any job can be displayed within seconds, including order information, operation and shop status and the schedule for remaining operations

Dispatch List

Print Dispatch Lists for overloaded Work Centers so that shop personnel know the order in which jobs should be handled.

You can first sort queued jobs by Priority No. so that the jobs furthest behind schedule are processed first.

Before printing, you can modify the sequence to account for any special circumstances.

How it works

Job Schedule Gantt Chart The Job Schedule Gantt Chart provides a graphical display of the daily schedule by Work Center for a specific job. The current status of the job, delivery status and the schedule for remaining operations are clearly visible. Operations may be re-scheduled using forward, backward or manual scheduling techniques. You can use “What if?” analysis to view the effects of proposed schedule changes and then revert back to the original schedule if desired. The Finite Modeling graph can be accessed, which provides the ability to view the effect of drag and drop moving of work center loads.

Active Job Status The Active Jobs Status screen displays the current status of each active job in Realtrac. You can quickly determine a job’s current location; whether it is ahead or behind schedule; and the estimated, actual and remaining hours. You can retrieve only those jobs of specific interest and generate a customized Open Order Status report.

Job Priority The Job Priority No. is determined automatically after entering a job into the system and is updated in real time to reflect the job’s current status against its schedule. The Priority No. reflects the number of days a job is scheduled to be finished ahead of or behind the due date.

Dispatch List Report The Dispatch List Report can be a powerful tool to help shop employees determine the order in which jobs should be run to maximize throughput at a work center. Separate reports can be prepared for Active / Queued, Pending and Distant jobs. The default Report Type is for Queued jobs.

Shipping and Invoicing

Invoices, packing lists and bar code shipping labels can be generated as shipments are made.

Customer and job data are automatically inserted on the Invoice screen.

The Job Part Inventory and Shipment Schedule are automatically updated when documents are printed.

An Invoice History is maintained so you can analyze past sales by date, customer, part, P.O. No., etc.

How it works

As quantities are completed for a job, you are able to record shipments and print packing lists, bar coded parts labels and invoices. The quantities completed, shipped, on hand and on back order will be updated on the Job Order Entry screen. Shipment schedules will be updated to show the actual date and quantity shipped.

You can view Packing Lists, Invoices and Credit Memos using the Invoice History screen.

Ship Orders - Sales Forecasting You can track future and past single and multiple shipments for all active jobs from the Ship Order screen. The window is accessed from the Active Jobs Status screen by clicking on the Ship Orders button, or by selecting Ship Orders on the Menu option at the top of the Realtrac main screen. All future scheduled shipments will be displayed in job number order. To assist in sales forecasting, you can arrange and filter the list to view and report only the shipments desired. For jobs with multiple shipments, a separate line will be displayed for each shipment.

Shop Floor Control

Shop Floor Status

You have a real time window to the shop floor to see at any moment which employees are utilizing what machines for what jobs.

You can quickly drill down to display detailed information about Jobs, Work Center Loads and previous Work Sessions.

Actual times are displayed in red the moment they exceed estimated time.

Active Job Status

With this spreadsheet-like display of all active jobs, you can view up-to-date information concerning where every job is and what jobs are behind schedule.

Data can be sorted and filtered to display only jobs of interest in the order desired.

A Priority No. indicates how much a job is ahead of or behind schedule.

Detail for any job can be displayed within seconds, including order information, operation and shop status and the schedule for remaining operations

Work Session Review Screen

The equivalent of a time card record of all job work sessions is displayed in chronological order.

Incorrect information is easily edited on this screen.

The data can be filtered by machine, job, operation or employee in order to quickly locate specific sessions and analyze problem areas.

How it works

Shop Floor Status Screen The display shows you which jobs are running on which machines. For each job, you can see the drawing no., operation no., estimated and actual hours, run status, the employee and their Log on time.

You may edit the work sessions on the Shop Floor Status screen. The screen is updated (refreshed) every 14 seconds. To edit a work session, you should first freeze the display by selecting the Freeze button. You may then edit any of the user-changeable fields (Job, Operation, Status, Employee No. and Logon time). After the editing is completed, click on the AutoRefresh button. You can find an employee by entering their number in the field above the employee no. column and pressing Enter. Active Job Status Screen The Active Jobs Status screen displays the current status of each active job in Realtrac. You can quickly determine a job’s current location; whether it is ahead or behind schedule; and the estimated, actual and remaining hours. You can retrieve only those jobs of specific interest and create customized Work in Process reports.

Work Session Review Screen

The Work Session Review screen allows you to view, change or add work sessions in the system. These work sessions determine job costing, employee efficiency, load hours, scrap counts and piece counts.

Shop Loading

A graphical display of the shop load is arranged from the most heavily loaded work center to the least loaded.

From this screen, you can access the detail Load / Schedule for a Work Center, with jobs grouped by Active (running or available to run), Pending (one operation away) and Distant (more than one operation away).

Load by Days

The Load By Days screen for a Work Center identifies potential bottlenecks over the next several weeks because of overloading.

You can view the detail for any specific day to see what jobs will be scheduled at the Work Center.

Perform modeling and “What if?” analysis to see the probable effect of increasing Work Center capacity and/or modifying job schedules.

How it works

The Loading module organizes all open operations for active jobs by Work Centers. The module automatically maintains real-time information that allows you to determine potential shop bottlenecks, prioritize operations at Work Centers, expedite jobs and allocate resources to optimize shop throughput. A Dispatch List Report can be viewed, printed and sent to the shop floor for shop personnel to determine the most efficient sequencing of jobs while meeting customer delivery requirements.

After a job is entered and has been automatically scheduled, the Loading module presents shop floor activity in real-time as it occurs on several screens:

Load by Days- The Work Center Load by Days graph provides a snapshot of a particular work center’s scheduled load on a day-to-day basis and identifies overloaded Work Centers and potential bottlenecks.

Contributing Jobs- The Work Center Contributing Jobs screen provides a list of all jobs scheduled at a particular Work Center for a selected day. You can drill down to the details of each scheduled operation to help determine how the Work Center load can be adjusted to meet your shop demands.

Load / Schedule- The Work Center Load / Schedule screen provides a tool for analyzing the load at a specific Work Center and suggesting the order in which work should be performed prior to printing or viewing a Dispatch List Report.

The screen displays a list of all jobs and their operations scheduled for the selected Work Center with appropriate scheduling information. You are able to view the total current and planned work for the Work Center, as well as display separate lists for active / queued, pending and distant operations.

Job Queue Status- The Job Queue Status screen provides a real-time status of a job’s operations. You can monitor the job’s progress on the shop floor and compare estimated versus actual hours for each operation. Also, real-time loading information is displayed for each Work Center on which the job is scheduled.

Finite Modeling- The Work Center Finite Modeling screen graphically displays the daily scheduled load for a Work Center and provides “What if?” analysis capability to see the effect on the daily load of moving a job’s operations.

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