CELLS WORKFLOW FAQ
Below we have listed questions asked by our clients. Many of the questions are of a later stage where they had started to implement the CELLS WORKFLOW Product Tracking MES system into their manufacturing floor.
Q: DATA ENTRY/COLLECTION - 1.0 The
CELLS WORKFLOW system supports data entry by people via barcode
scanning or manual entry. We need the system to be able to exchange data with manufacturing
equipment and test equipment. How is this interchange of data accomplished?
A: CELLS WORKFLOW uses a variety of methods to interface production
equipment to CELLS WORKFLOW such as XML, Active-X, OLE Controls, Visual Basic scripts, etc.
Q: ROUTING/TRAVELER - 2.0 Can the Tracking function be interfaced to an automation process. The
goal here is an end of the line automatic check sheet insuring the serialized
device has successfully completed all required processes before being
automatically forwarded to the ship station.
A: yes an automated check sheet is possible, the serial number is looked up in
the database to see that all operations have been performed.
Also a paper report for the unit can be created, attached are samples of reports generate from
CELLS WORKFLOW.
Q: SPC/REPORTS - 3.0 For the report generation what type of query utilities are available? Is
there a server thin client utility that can be used for data based queries ?
A: Either you or Unisoft can generate any custom reports that you need. The
database is ODBC compliant and report generation tools such as Crystal reports
etc. can be used.
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Q. SPC/REPORTS - I did not see any menu selections for
showing/printing SPC charts. Will we need to create our own charts and reports
for trend identification and analysis? What format are SPC reports in?
A. There are standard reports that CELLS WORKFLOW can generate ( see
the View menu). For custom reports the initial design would be designed at your site through
MS Access query by linking tables (I can call you and
go over this). Any format and data combination can be created...Every
manufacturer has a specific format so you are not locked in.
Q. SECURITY - Is the ability to modify information
user and data area restricted?
A. Yes, there's a table that gives every user a password w/restricted access.
Q. DOCUMENTS - Can data be imported from other file
types such as AutoCAD (dxf/dwg), SolidWorks, Pro-E, Visio, Excel, ASCII, PDF,
JPG, GIF, etc.? We can receive information in a wide variety of formats.
A. Yes, many can be directly imported or a html link can be associated which
launches the viewer software which enables you to view the data.
Q. DOCUMENTS - How are schematics and test procedures
handled?
A. Most schematics I'm familiar with are pfd's and if your lucky searchable. You
can archive the files through a html link or by importing the board file many of
the troubleshooting features are gui based. Test procedures can be gated in a
variety of ways to insure all boards have been tested...
Q. SETUP - What is the typical time to incorporate all
the data needed and to create all the screens and reports for a new
product of average complexity?
A. Depends on how you want to control the files and what depth in the data set
your customer requires (complexity and number of annotated instructions). If it
is a high mix low volume contract manufacturing environment I would just link
all data sets through a HTML control page and import files as necessary. We'll
discuss some approaches in the data sets to manage at our
upcoming meeting.
Q. SPC/REPORTS - What if all that I wanted was to
implement SPC (FPY)?
A. No problem...You dont need to import any files just design the routing and
data to collect. I'll discuss some possible configurations with you when you're
available.
Q. BOM - Are the failure report
unit data BOM based for the given unit or
derived from a master listing [accumulated collection]?
A. You can bind it to a part from a
BOM or enable the
other id feature to allow free form or make a master list that grows as needed.
There is a table to categorize the failure types.
Q. LABOR - What is the typical labor burden per unit
that your system imposes? What is the typical time spent at each data
entry/tracking point per location?
A. Point, click or scan, press enter unless you force certain data to be entered
before the workorder can proceed.
Q. DATA ENTRY/COLLECTION - What means of data entry/tracking can
be handled? Do I need to go in through a PC workstation at each location or
could I directly enter data through a fixed barcode scanner or direct file
reading or some combinations there of?
A. Yes, a combination can be performed including API calls or directly input the
data into the database.
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Q. RFID TAGS/BARCODES - We may be using RIFD Tags in the future. We will start
with tags on a single line and expanded out later. We're currently using
barcodes and my question is will the UniSoft CELLS WORKFLOW software support both
barcodes and RFID Tags.
A. Yes CELLS WORKFLOW can support both RFID Tags and barcodes. The way barcodes, RFID Tag and for that matter manual data entry looks to the
CELLS WORKFLOW software is very similar. Basically when somebody manually type something,
for instance a serial number, it comes in through the keyboard and a fixed
character set this generated by the keyboard driver software on the PC and those
characters are then captured by CELLS WORKFLOW. Similarly when a barcode is read by a
barcode scanner device the scanner device converts the barcode into a standard
character set which CELLS WORKFLOW then captures. When either active or passive RFID Tag
is activated by a RFID Tag reader device that tag data is then converted to a
standard character set that is then captured by CELLS WORKFLOW.
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Q. NPI - Can CELLS WORKFLOW be our platform for NPI for (1) data entry
and (2) document control...
A. CELLS WORKFLOW is an excellent platform for New Product Introduction (NPI):
(1) Data Entry - Through the task list (data items table) the revision and lab
reworks (tracking fixes for design issue's) can be tracked. In addition,
failures and historical issues can be archived for analysis later. Daily export
of inventory through SQL query statements can easily be customized by the user
to arrange and export data in a variety of formats (excel spreadsheets, charts,
active server pages, etc.).
(2) Document Control - Through the documents table in the database, links can be
established to control document delivery through the CELLS WORKFLOW front end. Use any
HTML or
PDF or other popular document formats directly. Also overlays and manufacturing
instruction sheets can be generated in the Unisoft ProntoVIEW-MARKUP module.
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Q. SUB-ASSEMBLIES - Can CELLS WORKFLOW manage our box built manufacturing requirements?
A. Typical Box Built Manufacturing Flow - CELLS WORKFLOW is structured to join
subassemblies into a higher assembly with out limit. NOTE: For box build app's
modules that are subassemblies must be completed (passed to the $Done area)
before they can be allocated to a higher assembly. Assuming all subassemblies
are being received as piece parts then a typical flow would be as follows -
Incoming inspection (bom revision and any other reference data should be entered
here per unit)>(A branch to either "return to vendor" or pass to "unit ready for
subassembly"...Once all subassemblies have been received and entered into
CELLS WORKFLOW
open the highest level assembly and choose install subassembly from the file
menu and begin allocating each subassembly. Proceed to each subassembly if a
lower layer needs to be associated...
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Q. ERP EXCHANGE - Can CELLS WORKFLOW interface to Peoplesoft ERP
A. Peoplesoft system and reporting system (i.e. SAS, Crystal, etc) typically
have an ODBC driver that enables access and updates from open data sources and
ODBC compliant applications. Unisoft CELLS WORKFLOW is an open data source, is ODBC
compliant, and is a Microsoft Window’s based application so that systems like Peoplesoft has easy access to all the data in our tables. We checked with
Peoplesoft and found that PeopleSoft 7 (and later versions) have an open query
API in the form of an ODBC driver which is registered to any Windows application
that supports ODBC. If you need any additional details or want us to speak with
your IT people we’ll be happy to do that.
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Q. - INVENTORY - I am a distributor of many different plastic products that we
receive directly from multiple manufactures. I need to know if CELLS WORKFLOW can help me
manage my inventory? We receive product direct from the manufacturer on pallets
and my problem is that we currently do a walk though paper inventory at the end
of the day to find out how much product we have a
stock and where our in-process orders stand. We need to know how much product is
at receiving, how much is on our packing floor being prepared for shipping, what
is in our shipping warehouse and what has actually been shipped. The additional
problem is that the pallets contain varying amounts of units. Sometimes the full
pallet is shipped, other times the pallet is broken down and single or multiple
units are shipped to various clients. Also we need to track damaged goods at
incoming and other problems and defects throughout our process. Additionally we
need to track return materials from our clients and associate those materials
with the original shipment.
At present we do not have PC's throughout the warehouse and plan to manually put
entries into CELLS WORKFLOW off our paper tickets. Later we will implement barcode
scanners at key stations.
A. Yes we can certainly help you. Receiving would enter into
CELLS WORKFLOW the pallet details (product, pallet quantity, manufacture, etc.)
and CELLS WORKFLOW would then track all pallets through the process. Either the
full pallet or portions of the pallet can move forward with complete tracking
and sales orders assigned as
required. Reports would be generated showing current
inventory in all areas with details on product,
pallets, units left on partial pallets, etc. Entries for
damaged goods and defects would be logged at the appropriate steps via
CELLS WORKFLOW data
entry table and reports available as required. Return materials would be
associated with the original order created in CELLS WORKFLOW and the return materials
history would then be associated with the original shipment history.
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Q. SERIAL NUMBERS - We are HEX serial number based. Can CELLS WORKFLOW track hex serial
numbers?
A. I was successful at getting the CELLS WORKFLOW program to work easily with Hex type
serial numbers. Just had to have a dummy work-order, a declared serial range,
defined 'Next Step's for the assembly, and (of course) an update to the 'WIP'
table for each serial number. You can do it from the barcode labeling program,
etc.
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Q. SECURITY/COMPLIANCE - One question that arises from an FDA perspective is
how does your system get around signatures? The FDA are very reluctant to have
operator barcodes scanned in as proof of inspection, operation completed etc.
Any views?
A. Compliance to CFR21 Part 11 is achieved through the use of operator specific
Login ID’s and Passwords. Allowing the operator Login ID to be bar-coded (IE: on
an ID badge) would be acceptable as long as only the operator (and
administrator) has access to the individual password. CELLS WORKFLOW has additional
compliance features include a preset timeout and selectable forced password
entry for each “move” of the product being tracked. The only area of
non-compliance is periodic password expiration, which can be managed manually or
moved up to the Network or Server login level operated as a “Closed System”.
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Q. MACHINE INTERFACING - Can data for production equipment such as CNC,
placement, AOI machines, functional test equipment data, etc be downloaded to
the CELL system (GEM interface..)
A. In most instances this should not be a problem with CELLS WORKFLOW ODBC compliance,
active X and OLE interfacing.
Q. CELLS WORKFLOW CONTROL TABLES - Can the user do the route configuration for error
proofing (eg. Units that go to rework are routed back through inspection)
A. Yes, this is handled in the "Next Step" table in CELLS WORKFLOW
Q. LABELING - Can end product packing label be configured as per user
requirements, output to printers, software (Codesoft, loftware..) supported?
A. Yes, as long as the printer software is ODBC compliant. The data will be
captured by CELLS WORKFLOW with a user generated query.
Q. SPC/REPORTS - Can SPC graphs, Pareto charts be plotted for any of the process
step in a Manufacturing setup.
A. Yes, data is output to ACCESS or other report writing software (SPC, Crystal,
SAS or other ODBC compliant software)
Q. ROUTING/TRAVELER - Machine part loading - the system needs to track what lot
code of material goes into a specific assembly.
A. Yes, CELLS WORKFLOW tracks materials that go into assemblies. Components are tracked
through the use of data entry variables.
As an example reels of components loaded can be scanned and the data archived in
in CELLS WORKFLOW.
Q. ERP EXCHANGE - Can CELLS WORKFLOW be customize to exchange information with an ERP.
For example SAP ERP for traceability to component lot codes, etc.
A. Yes, CELLS WORKFLOW is open ended and through its ODBC compliance can export tables to ERP systems.
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Q. SPC/REPORTS -
I need to analyze and report on the data that
CELLS WORKFLOW collects. How can I do this?
A. Once your work-in-progress, failure/quality or other data is in the
CELLS WORKFLOW database, you can report against it with CELLS WORKFLOW or any report writer or
analysis tool that supports ODBC (Crystal Reports, Access, SAS, Excel, etc.).
You can even publish the reports to your CELLS WORKFLOW intranet, or provide dynamic
report generation through CELLS WORKFLOW or any web browser.
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Q. ROUTING/TRAVELER - Can CELLS WORKFLOW create a route/process plan for a product that consists of series
of steps
- Ideally, we will be able to name these steps the way we do today,
with 4 char sector, 4 char oper, and 4 char process type
A. Already structured in CELLS WORKFLOW
Q. ROUTING/TRAVELER - Can CELLS WORKFLOW identify "recipes" for each step
- Create a 12 character lot i.d. that will follow a certain route/process
plan
A. Already structured in CELLS WORKFLOW
Q. WORK ORDER/LOT - Can CELLS WORKFLOW assign 25 serialized units to the lot
A. Already structured in CELLS WORKFLOW
Q. WORK ORDER/LOT - How is this initial set up of lot and units automated?
A. The workorder administrator will create the lot (called assembly in CELLS WORKFLOW)
and you specify a range of serial numbers associated with the lot.
Q. WORK ORDER/LOT - Will CELLS WORKFLOW be able to split lots
- i.e. Take half the units in LOT01 and put them in child lot LOTC01
- Be able to merge lots
A. Renaming lots can be done by obsolescing the LOT01 parts (send to scrap) and
creating another work order for LOTC01. Merging them back will require the same
process.
Q. MACHINE INTERFACING - is there
an API in CELLS WORKFLOW? We want a
separate program of ours, the automation
program at the manufacturing tool, to be able to talk to the MES and
find out what step we're at, auto log lot in/out
A. Access is open architecture so you can extract data by using
SQL or some other means recognized through the ODBC
driver. Access can auto export reports on a time basis also. <--- I've currently
customized this.
Q. ROUTING/TRAVELER - Can CELLS WORKFLOW mark units in a lot as scrapped out
A. Already structured in CELLS WORKFLOW
Q. ROUTING/TRAVELER - Can CELLS WORKFLOW mark units in a lot as "bought" by engineering for analysis
A. Already structured in CELLS WORKFLOW - should be
accomplished by entering a comment in defects screen or create an area called
engineering to move the material into.
Q. WORK ORDER/LOT - Can CELLS WORKFLOW assign status to lot at any time - Active, Ready, Held
A. Already structured in CELLS WORKFLOW -
either create an area for active, ready, or held and move the material
into the locations. Another way is to have a text variable pop up window that
requires a status
Q. DATA ENTRY/COLLECTION - Does CELLS WORKFLOW allow the operator to enter comments at each step - ability to
customize that screen
A. Already structured in CELLS WORKFLOW -
comments can be added in the defects window which is set in the
Access
database
Q. ROUTING/TRAVELER - Can CELLS WORKFLOW maintain traceability of what units were in a lot at each step,
since this can change through the process
A. Already structured in CELLS WORKFLOW -
history is archived in CELLS WORKFLOW which can be selected through
CELLS WORKFLOW - custom reports can be created and auto
exported on a time basis
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Q. NETWORK - - I need to run CELLS WORKFLOW in a network environment how do you install clients? do
you just map drives and point to the access location? give me detail
A. If you are using MS ACCESS as the database then, yes, you can map drives and
specify the drive path in the ODBC configuration.
I believe you can also specify a UNC path (\\server\data\CELLS WORKFLOW.mdb) in the ODBC
configuration.
If you are using SQL Server or MSDE, then you configure your ODBC to connect to
the server in a more direct client/server way.
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Q. DOCUMENTS - 1. Simple one: I'd like a document to appear as the default screen when the
operator opens a unit, but I must be missing something simple in the DOCUMENTS
table. It seems to ignore my default setting and still shows the circuit boards.
Ideally, I'd like text in the left frame and pictures on the right, in the form
of HTML documents, depending on the OPERATION taking place. (Later on we'll look
at capture of test data).
A. can't do it. a simple answer, sorry it's not the one you wanted. the left and
right frames will ALWAYS show one of the circuit board views. the html document
view will ALWAYS be in a floating window. DOCUMENTS.YN_DEFAULT, when applied to
"PCB", allows you to choose which of several .F2B files will be shown. The other
F2B files, if any will appear in the view menu. The DEFAULT field will also
allow you to specify one or more .F2P (overlay) files to apply to a specific
.F2B file. Cool idea, though. Maybe in a future release.
Q. CELLS WORKFLOW CONTROL TABLES - 2. I understand most of the tables and their relationships, but I need a bit
of coaching on configuring a system as we discussed: Top Level Assembly
comprised of serialized circuit cards and unserialised parts. I have set up a
DATA_ENTRY step at KITTING to record PCB Serial Numbers, but I'm unsure how to
use $SERIALIZE Operation properly (putting it as a NEXT_STEP seems to have no
effect.). Also, please help with the removal/replacement of cards during the
flow, and the use of $ANYTIME. Also, how do I use
the SUB_ASSY table for generic subassemblies? It looks like these are used for
specific items. I'm close, but going in circles.
A. $Serialize is internal and should not be specified in the next_step table.
Rather, use YN_WORK_ORDER_ID and YN_SERIAL_NO in the OPERATIONS table.
YN_WORK_ORDER_ID set to "Y" indicates that it is acceptable to come to the
operation as workorder only (no serial num). YN_SERIAL_NO indicates whether it
is acceptable to come to this operation with a serial number.
If you arrive at a YN_SERIAL_NO="Y" step, and specify a serial number for the
first time, then the system automatically routes the item from the previous
step, to $SERIALIZE, and then to the current step, effectively stating that the
item got serialized as part of the transition.
$ANYTIME is used to indicate that, for example, a roving inspection can occur at
anytime in the process. In the NEXT_STEP database, the OPERATION_ID can be set
to "$ANYTIME" to indicate that the NEXT_OPERATION_ID can happen at any time
during the process.
The SUB_ASSY table is maintained by the program. It is not a table that you need
to set up. It is where we store information about which subassy's have been
installed at which locations on other assemblies.
To specify that some sub assembly needs (or optionally needs) to be installed at
a particular step, use a DATA_ITEM record to indicate a DATUM_TYPE of SUBASSY.
DATUM_DESC is how you tell the tech what to attach, SUB_LOCATION tells them
where, eg, "PCI SLOT 4". The system will collect a serial number, and it itself
must be an assembly in the system with a serial number, and that serialized unit
must be in the "$DONE" state before it can be installed. If you want to track
the installation of sub assemblies which are not serialized items in the
CELLS WORKFLOW
system, just use plain data entry.
You can specify that only certain kinds of sub-assemblies can be installed by
specifying the list of ASSY_ID's allowed in the DATUM_MIN field, separated by
"|" characters. If you leave DATUM_MIN blank, then no ASSY_ID checking is done.
sub assemblies can be removed and replaced just about any time by the FILE |
ADD/REMOVE SUBASSEMBLY menu item.
Q. SUB-ASSEMBLIES - 2a. I'd like to route
some of the pieces in the kit though a
Test operation before they are
kitted. Can CELLS WORKFLOW allow me to track subassemblies by themselves? I don't think I
can have more than one $START to separate serialized Units's from
machined parts (which need only be inspected). This makes my NEXT_STEP
table confusing, because a Top Assembly doesn't exist as a serialized item
until KITTING, when the pieces are placed in a bin and a top-level serial
number is assigned arbitrarily. Note that incoming inspections are not at the
"end item" level.
A. yes, subassemblies are by (our) definition serialized and trackable
assemblies in their own right. They are completely separate from the mother
assembly until they are associated via the Add Subassembly (or Data Entry)
dialog. From that point on, they are tracked together. The sub-assemblies
can/should even have their own process flow, seperate from the main
assembly. In fact, a sub-assembly MUST have progressed to "$DONE" before it
is eligible to be added to another assembly, however if you
add a sub-assembly that has not been run though a process in CELLS WORKFLOW then you can
use a simple data entry to collect the sub-assembly
serial number, etc.
Q. DATABASE - 3. The integration of CELLS WORKFLOW to Oracle may be tricky. It seems that
Windows2000 has ODBC drivers for Oracle. Any thoughts? Have Win2000 and
CELLS WORKFLOW been integrated before? Not sure if we were clear: Can we use SQL 7.0
or even Oracle as our CELLS WORKFLOW database, to avoid any ODBC difficulty in
connecting to our main ERP system?
A. CELLS WORKFLOW does run just fine on Win2k. I have not personally tried the Oracle
drivers that comes with Win2k, but you can use any ODBC compliant data
engine. SQL 6.5 and 7.0 are known to work, and SQL2000 should be just fine
as well. You will have to convert/upsize the sample ACCESS database to your
desired client/server engine using utilities supplied by that vendor, or
else create the schema some other way.
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Q. SUB-ASSEMBLIES - Would you provide some information on how to set up the sub-assembly tracking
features.
A. In the data items table (this is a look up table for the
data entry table) create a datum_id. The datum_id you create will be looked up in the data entry table. Next
enter a datum_desc such as "Choose a subassy to
installed in position 1". Next enter "SUBASSY" in the
DATUM_TYPE which flags CELLS WORKFLOW that this is a subassy.
The other variables in the datum min and datum max are
to restrict the entry...leave them blank to accept any
txt variable entered.
Next, go to the Data Entry table and enter the process
which will use the subassy installation. Enter the
Operation ID that you would like to load the subassy
at...I would choose the $DONE area which is the final
area once a board is complete. One note is that the
lower level subassy must be completed (in the $Done
area) before it can be allocated into the higher level
assembly. Enter the datum ID that you created in the
Data Items table. Choose a sub location such as
Position 1 (could be numbers or a given name). Finally
enter the YN required...this is a flag that prevents the
board to go to another area unless a subassy has been
installed.
Once your done and have a board in the $done area choose
another board and click on install subassembly and you
should see the option of entering a serial number to
install. Once done look at the history to see that it
has been installed.
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Q. SPC/REPORTS - Need to use third party for reports or does
CELLS WORKFLOW already
have it ?
A. Already built in through sql/access query reporting "real time".
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Q. SETUP - Can you estimate the implementation TimeLine (estimated there are six
lines for box built - apps with 15 clients each).
A. CELLS WORKFLOW must be loaded onto each terminal (5 minutes each terminal).
Installation Strategy Note: Try to keep the CELLSDOC variable pointing to a
subdirectory on the main network drive that all computer terminals can link to.
If you point this to a local drive you'll need to update every computer vs. only
one directory on the network. Also the main database needs to be customized to
the customers process flow, estimate 1 to 2 hours per process.
