Electronics Assembly Manufacturing can be a complex process, involving various stages from the order’s inception to its completion. This blog post aims to provide a clear and comprehensive overview of production flow and the associated processes using SparrowERP, a production management system. We will dissect each stage of production, discuss the pivotal roles of the Bill of Materials (BOM) and Components Placement List (CPL), and other fundamental elements like routing, operations, and the calculation of production costs.

The Electronics Production Flow: From Initiation to Completion

To better understand how a product is brought to life after an order is placed, let’s dive into each stage of the production flow within SparrowERP.

1. The Pending Phase

All new assembly orders submitted by customers are found in the ‘Pending’ tab under ‘Manufacturing Orders’.

Upon entering an order into SparrowERP, front-end engineers perform data verification. After the ‘BOM CC’ section is approved by the customer, the order moves into the pending phase for production management. During this phase, users can view order details, such as technical info (BOM, CPL) and general details (customer name, order ship date, etc.) by clicking on the MO. A purchase plan can be initiated to begin sourcing by assigning a purchase person.

Notably, SparrowERP categorizes orders as ‘Producer compatible’ or not and allows the assignment of different producers if required. An order remains in the ‘Pending’ stage until all parts are in stock. Kitting operations for Generic/EC-stock parts and any required technology checks for ‘Pressfit’ mount-type parts are automatically created.

2. Ready for Production

The expedition from ‘Pending’ to ‘Ready for Production’ occurs when all components required are in stock.

In this stage, parts are consumed and the stock is deducted from inventory as production ensues. Operators also prepare for production, which includes setting up technology, laying out the PCBs, determining the paste data, and configuring the SPI. Routing, which is the sequence of operations to be followed, is assigned. At this point, users can also modify operations by adding, deleting, or changing their order.

3. In Production

The engine of SparrowERP roars to life as you click ‘Start production’.

During this phase, users operate the various resources such as machines and operators to advance through the tasks. Operations can be partially forwarded to streamline the process. Moreover, rework quantities can be entered, triggering additional ‘Rework’ and ‘Inspection after rework’ operations. Crucially, manufacturing orders can’t be finished until the entire ‘In qty’ has been processed. Before an MO is moved to ‘Finished’, it’s essential to conduct a final reconciliation of parts used to ensure inventory accuracy.

4. On Hold

Interruptions happen, and the ‘On Hold’ stage is SparrowERP’s space for paused operations.

This stage lists orders that are temporarily suspended. Technical and general order details can still be updated, and jobs can be released from this stage to continue back in production.

5. Finished

Finality is captured in the ‘Finished’ section, where completed orders are listed.

No further actions are taken on orders in this stage.

6. Canceled

Orders can be canceled at any point before they reach the ‘Finished’ state. Once an order is canceled, it cannot re-enter the production flow.

7. Forwarded

An MO can be forwarded if necessary, implying it is moved to a different system or process for further action.

General Guidelines for Managing Production

Maintaining flexibility within a structured system is key for an efficient production environment. Here are some general guidelines to be followed in SparrowERP:

• An MO can be put on hold at any stage, provided it’s not finished, canceled, or forwarded.
• Canceling an MO is permissible before it is finished. Once canceled, it cannot return to production.
• Routings and operations can be assigned and altered before and during production.
• Operations can be added or deleted in bulk in the ‘Operations’ tab.

Routing: Setting the Path for Production

Routing in SparrowERP is a critical blueprint — a list of tasks and operations essential for creating the final product.

Routing is akin to the sheet music for an orchestra; each note must be laid out correctly to achieve harmony in the production symphony.

It must be well-defined before production can begin. Details of the Routing master are accessible in SparrowERP for in-depth reference.

Operations: The Building Blocks of Manufacturing

Operations are the particular tasks executed to transform raw materials into the finished product.

In practical terms, operations in SparrowERP are listed in the ‘Operations’ tab, indicating each specific task to be completed in the work center.

Details of the Operation master are provided for users to accurately manage these tasks.

Bill of Materials (BOM) and Components Placement List (CPL): The Essential Ingredients

A BOM is the recipe for manufacturing a product—a comprehensive list of all items required. In the context of SparrowERP, this is housed within the ‘BOM’ tab of an order’s details page. Meanwhile, the CPL serves as the map, detailing where to place each part in the manufacturing sequence, including their X and Y coordinates on the PCB.

Work Centers

Work centers in SparrowERP represent the physical locations—machines, production lines, assembly areas—where operations turn plans into tangible outcomes.

Think of a work center as a station within a workshop where each product attribute is molded, assembled, or refined.

Details of the Workcenter master are available to help organize and understand the functionalities of each station.

Crunching the Numbers: Production Cost

Production costs reflect the monetary amount necessary to manufacture a product. In SparrowERP, it’s calculated by multiplying the cost unit type by the cost attribute for each step of the process.

To put it simply: Production cost = Cost unit type * cost attribute.

This includes both actual costs based on the time spent and estimated costs projected for each operation.

The details of production cost calculation are laid out in SparrowERP, providing transparency and control over financial aspects of manufacturing.

Conclusion

Production is a detailed and continuous loop of events that transforms an idea into a tangible product. SparrowERP serves as the conductor of this intricate symphony of operations, ensuring each step is performed with precision and adherence to planned tasks, costs, and quality standards. Understanding each phase of production, from ‘Pending’ to ‘Finished,’ alongside the core elements like routing, operations, BOM, and CPL is critical for the success of any manufacturing endeavor.

This blog post emphasize how to navigate these processes within SparrowERP, allowing for a smoother, more predictable, and efficient production environment. Whether you are a front-end engineer, operations manager, or a production operator, a clear grasp on these practices ensures that every manufactured product meets expectations, both in quality and in delivery, sustaining customer satisfaction and business growth.