Presentation on theme: "Version 2 There are THREE Modules to this JOB / Production System. (1) TurboTime – Production Job Costing (Barcode) (2) TurboTime – Time & Attendance."— Presentation transcript:
Version 2 There are THREE Modules to this JOB / Production System. (1) TurboTime – Production Job Costing (Barcode) (2) TurboTime – Time & Attendance Software (3) TurboTime – Big Wall Clock & Siren system OPTIONAL : CCTV to monitor production controls. Since 1992 – almost 21years ago, SENTRI has been designing systems to take care of a number of issues related to Staff, Profitability and Efficiency..
The Job we just completed, was it profitable? Are we making money or haemorrhaging on some products? Can we measure how long it takes to complete a Job? Can we cut back on Overtime but still increase productivity? Do we really need to know what it costs to make things?
That is easier said than done! Currently you Pay staff for being at “Work” i.e. 40 Hours with 15 Hours Overtime! But only 32 hours are allocated to Work orders for that WEEK What happened to all the other hours you are paying for? Times that by 40 Employees and it will not take you long to figure out: PROBLEM Are you paying your staff to be at work, or paying them to work? Have you ever measured the COST of LOST production time at your company? Companies know they have a problem but how can you begin to measure it? How can you measure the time being paid to an employee for being at work versus the hours allocated to Jobs and productivity? Would you like to know w ho is Productive and Who is Not? Do you WANT to do something about it! IS ! TurboTime IS a solution! A Honest Day’s Pay for a Honest Day’s Work!
Most companies out there use the old “Thumb-suck” method to guess HOW MUCH TIME is actually needed to complete any given Job! This “Projected Time” is then built into the quote / project for the customer, and if accepted, a Work Order is generated based on these “Thumb Suck hours”. Under Quoting versus Over Quoting! Not allocating enough time to a Job means you will get business you don’t necessarily want and your profit margins are way to tight. Production Timing Failure? Well, there goes that profit! Over quoting on any Job is dangerous as you could unwittingly lose potential business as your quote is based on incorrect information. NOT KNOWING IS EXPENSIVE Did you consider... you could be losing money _ _ _ _ _ _ on every Quote.
Most companies have a good idea of the cost of MATERIALS, even before they begin to manufacture their products. But when it comes to accurately forecasting the “TIME REQUIRED” to manufacture YOUR products! This is where the Wheels Fall Off. How can you stay competitive if you are not absolutely sure how long it takes to complete the JOB and the COST?
So what is Production Timing? * Production Timing is the ability to measure the “Time” taken to manufacture a product from START to FINISH. * Each “Task” has a duration! (Cutting, Welding, Grinding, etc.) * Each TASK has a COST to the company (this includes all overheads) * Measure the “Budget Time” versus the “Actual Time!” * Tasks! - Did they exceed the time allotted for that Job? * Measure Wage cost against Production Cost during your production * Profit and Loss is accurate because you now know manufacturing FACTS. * Here is a TOOL to dramatically increase your P roductivity and PROFIT.
If your current system to measure the time taken to manufacture your products is non- existent or a dismal FAILURE, then you will be looking for something that is easy to use, reliable and gives you the information you need. This is what we came up with. Now you can accurately measure how much TIME was taken for each Job, from Start to Finish. Measure the MONEY used (Labour & Overhead Cost) to complete not only the JOB but each and every TASK. Excessive time taken to complete any JOB can now be investigated. Is more training required for that operator? Was the time allowed simply inadequate for the task at hand? It might be that a machine is faulty, but whatever the reason is, it will be brought to your attention and resolved one way or another. Hind sight gives you vision. As each Job is completed, you have all the information at hand to know if it was profitable project or was it running at a loss! Information allows Action to be taken. With time, quotes can be adjusted accordingly and you increase your accuracy. Look at your Profit & Loss report. Allow for the appropriate action to be taken before you start the next Job or send out the next Quote. Production Timing solutions.
Your employees cannot beat this Production Timing system. Either they book too much time to a Task / Ops number and the system will highlight this fact, or they are getting paid for to many man hours that are not being accounted for! A honest days pay for a honest days work! Start paying staff for working and not for being at work! Either way, THEY are accountable for THEIR “TIME”. Here is an unbiased system that gives everyone a fair opportunity to prove that they are delivering.
Why some employees will HATE this system! Employees, now, for the first time, are accountable for their time! Those who have been getting away with working at the old two speed rate (Stop and Reverse) surely will not be ecstatic with the introduction of this system. We will even tell you who they are after installing this system and without us even going onto the Job-floor or talking to them! Either way, they cannot beat the system. First Trick - They try not to clock “OFF” a Job! Result = Missing clocking – Short Time – please explain. Second trick - They don’t clock “ON” to a Job! Result = Missing time – please explain. This system means that they are accountable for their time and either way they need to explain why it took too long, or why they have not accounted for their time PAID to them.
Lets get started, so what is needed? * A number of JOB DATA CAPTURE units are installed at convenient points around the factory (Needs a TCP IP point). * Barcode readers are attached to the Data Capture Readers. * Barcodes are printed for each EMPLOYEE * Barcodes are printed for every JOB stick it on your current Doc. * Barcodes are printed for each TASK * Barcodes are printed for EXIT codes.
* POWER FAILURE * Waiting for Instruction * Emergency Change Job * Machine Breakdown * Going to Stores * Waiting for SPARES * Task Completed * Task Completed & Shift END * JOB Completed * END of SHIFT. * Machining * Cut & Punch * Boiler Making * Welding * Drilling * Sand Blasting * Painting – Spray booth * Milling M27 machine * Long Seam Welding * Straightening * Quality Control * Helping Hands * Warranty – No charge! * Pack & Ship EXIT REASONSTASK Codes ON:
Barco-de Scanner in Cradle WITH STEEL CABLE SO THAT IT CANNOT FALL ON THE FLOOR. EXIT CODES Picture from a real live system JOB START JOB STOP TASK Codes
TASKS & EXIT Codes are printed onto A4 Paper and placed on Each side of the Job costing reader. TASK Codes Now you have the Barcode DATA Capture reader on the wall with the ”START TASK” on the left and the “EXIT REASON” on the right hand side – Is that Visualised? EXIT Codes The readers all have their TCP IP points and are installed on the walls in the factory – Now what?
You saw from the previous page that you can ADD and setup all your tasks. Then you can ADD a VALUE to each Task. The report will show you the $$ COST $$ of each Task, or at any stage of the final cost of that $ $ JOB $ $
How Does It Work? Each employee receives TWO Employee Numbers, 1 x for Time & 1 x JOB The TIME / Attendance can be card, fingerprint, Facial. But the JOB number is always a BARCODE in the form of a ID type card with a barcode label. This Employee Number (without the preceding E) can be used clock the employee “In” and “Out” for Time & Attendance as well as Production timing. * Access Control for unlocking doors can also be added at a later stage. Clock In – Time & Attendance (Optional.) Clock “ON” a Job. Clock “OFF” a Job. Job Status – Tells you the current status of all Jobs open. Clock Out – Going Home - Time & Attendance (Optional.)
Clocking ON (Starting) a Job: Push on the Data Capture Clock * SCAN the Employee Number. * SCAN the JOB Number, * SCAN the TASK Number. F1
Clocking OFF (END) a Job: Push on the Data Capture Clock * SCAN the Employee Number. * SCAN the EXIT REASON. That’s it. We cannot make it easier than that! F5
This system can work using only ONE PC. But typically there are between ONE & FIVE PC’s that might want to see JOB information from this system. PC1 - System-Operator - Use this PC to ADD Job's & PRINT BARCODES. Jobs are added to the system using PC1 and only closed once you have Invoiced. Network Overview: PC2 & PC3 – Production Director / Workshop manager. These PC’s allows the user to easily see the status of all the Jobs on the system and if any Job is “Waiting for spares” it will be highlighted in RED. To ADD a Job – Enter the job number i.e. J Description then ADD all the Tasks from the Pop-up list plus all the time allowed for each operation. To close this Job you need to
Network Overview. PC4 – Stores. Allows stores to see what Jobs are “Waiting for PARTS” and the Job number as well as what section (Task) that the Job has stopped on. - Cannot invoice if the job is not Completed. PC5 – Workshop Floor – Allows staff, foremen to see who is working on what Job and the status of the Jobs. PC6 – SALES DEPARTMENT – can log in, type a JOB number in and SEE where that Job is – Painting Shop, etc. Quit bugging Production. Staff can also clock IN/OUT when at STORES for “Collecting Parts” as an enormous amount of time is wasted whilst standing around at stores pretending to be “Waiting” to collect parts. *NB* Stores needs its own separate DATA Terminal.
Your FLOW of Events: 1. Quotation accepted by customer and purchase order received 2. Works order number issued 3. System-Operator prints barcode labels and attaches to Job Cards. Sends to shop floor. 4. Employee Clocks - ON JOB. Remember How? !!!! F1 Scan Employee card, Scan Job Number, Scan Task. Done. 5.Employee Clock’s - OFF JOB. Push F5 Scan Employee card, scan EXIT code-Done 6. ** Repeat steps 4, 5 until Job is finished. ** 7.Do post mortem. Analyse the results of any or all your Jobs, especially those over budget. 8.Was the time allowed enough, or not realistic? 9.So was it the Job or the Person? The Hi-resolution CCTV system will solve this issue. 10. Invoice & Close Job. Start again at step 1 – ADDJOB.
Some of the Reports Available. JOB Status report. Shows which Jobs are currently Open and what the current status is. Indicates ”When“ they were opened and ”Who” is working on them now. Note on the PC screen - All “Waiting for parts” are highlighted in RED for Action. Time Allocated to any JOB report. Shows the hours booked to a job. Select Summery or Detailed. All Start / Stop times are indicated with the hours calculated and accumulated for you. Time Allocated to an Employee report. Shows what time employees clocked ON / OFF Jobs #, Time spent on the Jobs for the day or for the Week, Month, Year! If an employee only booked 6 hours to Jobs for the day but was actually paid for 10 (TEN) Hours Then what happened to the LOST hours?
Some more Reports Available. Excess Time report. Shows all Jobs where the time allocated exceeds the time allowed. Action needs to be taken to make sure the problem is identified and does not re-occur. Daily Exception report. Shows all Jobs that have missing clockings. Shows who clocked onto a Job but not off a job! Take action to make sure the problem does not re-occur. Over budget Jobs. Shows all Jobs that have exceeded their monitory value. Shows the % over budget by Job and Task. These get better with time as you have the tools to measure. Shows you Time and Money. Budget 160 hours but when finished, took 240 hours Budget was R final cost was R % over budget and that cost you R
Gives your company the ability to accurately measure how much TIME was taken to complete any given Work Order, versus just guessing. You can measure the pre-determined time for each Operation. Now you know how many man hours are taken to complete any Job / Works order, all broken down into bite size “time” chunks. This allows you to build up accurate data over time so that you don’t under / over quote. Once you can MEASURE, you can increase productivity. Increase productivity means an increase in efficiency and PROFIT. You can quickly and accurately highlight any excessive time taken to complete a Work Order and Who / What is eating up time. How does the “Production Timing” system help your company?
The status of all “Works Orders/Jobs numbers” are highlight as to what the current status is and the reason for the stoppage. What % of the Job are currently (50%) (85%) (175%) etc., What Jobs are still outstanding, “Waiting for SPARES”! Should any paperwork gets lost, all the appropriate information is now on your PC, dates, times, who worked on that part, etc. Guarantees and re-work can be quickly addressed and resolved. NOW – you can tell how long it took to manufacture your product(s) You have the TIME and MONEY it took to complete your production run/Job Once you have this information your QUOTES will be far more realistic and you PROFIT will be accurately measured. Monitor your “Time Costs”, your profitability and know the progress and status of each Job. Ensure that the jobs are completed within the expected completion date and budget.. How does the “Production Timing” system help your company?
Once you have a “Recipe” of a product, you can “Save the Recipe” We know how many hours it to took Cutting, Welding, Grinding, Polishing, Assembly, Sandblast, Paint, Final inspection, Pack, Load & Ship. We know all these things. Hours and money. i.e. Fact – it took 174 hours = which is equal to bucks. Save your “Formula” – Next time, “RESTORE” your formula. A PDF report of all the hours and figures pop up, and a NOTES pad is their for you to “refresh” that rusty memory. Lookup what you did the last time, now plan what you are doing to do this time round. If you cannot measure, you have no control. – We measure real well. *Use the past to plan the future. *Increase productivity, get rid of guessing by having facts. Accurate quotations bring in profitable business. As the Marketing executive told the board meeting. “FIFTY percept of our advertising works and the other FIFTY% does not. If only we knew which 50%! ! ! !” Hope that is not like your Quotes & Production! What else can the “Production Timing” system help your company?
Each Employee is allocated to a Task Group as to what he can and can not do. The *** indicates an employee has clocked onto a TASK he is not supposed to do! - To-date this has NOT been a problem as each employee knows his 2, 3, or 4 task that he is qualified to do.
What is needed! * Data Collection Terminal (s) * Barcode Printer * Barcode Scanner. * TurboTime Software * Production Timing Software
GIVE US A MINUTE. We will give you HOURS!
MD Sales Manager us at: MD Sales Manager If you cannot measure, you have no control. Designed and developed by SENTRI Systems. Manufactures of fine Time Attendance and Production / Job Costing software. 011 – – There are a few ways that you can Buy this system :- Buy It, Rent it, Lease it! Will it pay f or its self? You can you write this off against TAX. (within a year?) Return on investment. We have no doubt that this will be one of the BEST TINGS you will do. Do you own SUMS - What is your annual turnover? ______________________ What is 2.5% of your annual turnover:________________ We would like to tell you we will increase efficiency by at least FIVE / TEN % - but that would be hard to prove on paper without your input. BENEFIT Know where the Job is at any time and the status of any JOB. (Sales pay attention here) Manage your business by making informed decisions based on accurate information. Which product make Money & which one cost money? Profit & Loss a reality. Know how to eliminate guessing and quote with confidence. We have seen a job run at 48% of projected time, making it highly profitable :-O) Reduction of overtime but at the same time a noticeable increase in production. Increase in productivity leads directly to a increase in the companies profitability! What would happen if your company could increase PROFIT by 5% – 15%?
This system gives you invaluable feedback as you can now measure how much time is allocated to a Job and how long it actually took. Also the time wasted by employees booking time to “Waiting for instructions” The employee’s need to work with the system, not against it. Employees have to account for “their time” no matter what! If they book too much time to the job, you will find out, because the system warns you that the time you Quoted has been exceeded. The System THEN QUESTION WHY! Is it a “ Machine ” problem, a “ Employee ” problem or a “ Quote ” problem? Now that the Job is complete, click on the icon that says “Close Job.” This saves and stores Job and when you need it, you retrieve that data and make a comparison. You know how long it took for the last Job, did this take longer or less time? Build up HISTORY as you go along. Get to know which jobs are PROFITABLE and which are NOT! Accurate information available at your fingertips means Decisions are based on FACTS, not wishful thinking. Job Security, Company Stability and Profitability.
When was the last time you watched a Sports game, be it Rugby, Soccer, Tennis and.... NO ONE KEPT SCORE! Yet here you are running a business & NO ONE is keeping track of the score! If that did not scare you.... Then don’t keep this magic number
You already know what your Material Costs are, so just ADD the following info into the Job Costing input screen. Your MATERIAL COST, your SELLING PRICE. TurboTime will calculate your ACTUAL LABOUR COST.... We will calculate your Profit & Loss! Get a Overview Profit & Loss report Grouped by your CUSTOMERS. Which of your Customers are Making you $Money$? Which of your Customers are Costing you $Money$ Summery – One Job on One line. Look for “+” or “—” Get a DETAILED P&L report & LOOK at each job Making You $MONEY$ If that did not raise an eyebrow... Then don’t PHONE this magic number LOOK at each job Costing you MONEY
Have you phoned yet? Dilemma : - Should you first buy another machine for the workshop, OR should you increase the efficiency of what you got NOW! Do you REALLY need to know which Jobs are making MONEY and which Jobs are COSTING you? I used to be indecisive But now.... I’m not so sure!
QUICK OVERVIEW. PRODUCTION / JOB TIMING – How many “UNITS” will you need for your factory (Job On Job Off Points) Remember “Walking is Talking” so think about that nicely. Phone us and tell us how many units you will need. Lets get you out of the Dark ages and into the PROFIT ZONE. If you are making a profit (impressive when you nor sure where its coming from sure :-O) But this system will cost somewhere between R 500 – R per month! TIME & ATTENDANCE – Measure the TIME PAID against TIME WORKED. A “ON SITE” inspection which will determine the best method to recording your ATTENDANCE. First choice is “FACIAL RECOGNITION” else Fingerprint reader(s), Prox cards, etc. PLEASE ASK for the TurboTime P ower Point Presentation. Else click here :http://www.sentri.co.za/Powerpoint.html WALL CLOCK SYSTEM : A man who has a watch knows the TIME, but the man who has TWO is not so SURE! The wall clock system ensures that all clocks tell the same time, and is linked to the Siren for Start, Lunch End. There is only ONE TIME and that is the “ BOSSES TIME!”
JOB-SYS / PASTEL Compatible with Pastel Xpress and Pastel Partner 2009 & V11 JOB-SYS helps you prepare Quotations or Estimates for your Customers. * Manage your Resources, Material Issuing and Purchasing. * Create Bill of Material templates that can be used in quotations and jobs. * View history of all open and closed jobs - to be viewed by means of serial number, unit number, registration number, customer, job category, date, progress status, etc. * Compare the Estimated material costs versus the Actual costs of the Job. * Compile an Invoice and monitor the profitability for each Job. * JOB SYS Will print a BARCODE on the JOB CARD for you. * GREAT PLAINS We are working on an Excel interface. Currently the report tells you the Total time it took to complete the Job in TurboTime and you type the “ACTUAL HOURS” into Great Plains. Print invoice, close Job. NEXT Wall Clock & CCTV SAP We received an order (another clever customer) who uses SAP to do stock control, invoicing, etc. SAP creates an Excel, we import the TASKS from that Excel into TurboTime JOB, reducing the manual input. SAP prints the BARCODE on the Order form for us.
The idea behind the Wall Clock is to have “ONE UNIFORMED TIME” in the workplace. Ask four people the time and you will get four different answers (test this theory) so irrespective of who’s watch says what, whatever the time indicated on the wall clock, then that is what the time is. The HH:MM is circled by “Hi-Bright” LED’s to emphasize the seconds. When the seconds are in RED the workers are expected to be on the work floor working. When the seconds change from red to GREEN then they can go for their break. The clock can sound both a Siren / Bell and to linked to your PC via a Radio Frequency (RF) signal. The time is received from the Greenwich “atomic time”. There are NO CABLES as the RF transmits the time from the PC to the various wall clocks around your factory. Wall clock system! 1 – 10 clocks all over the factory The whole concept cannot be explained on one page, but the idea is to keep the workers on the shop floor “working” for those few extra minutes and the wall clock system will ring a “Warning” at the correct time. The warning signal is 2 minutes before the shift restarts, because it gets them back to work sooner, these few minutes here and there ADD UP and if you take into account what the COST PER HOUR is to run your business, then that time accumulated in additional productivity is astounding. (Ask us for more info on this concept)
Need CCTV ! Look no further Mark the AREA or Spot you want to recorded (paint it) and any movement will automatically trigger the 3 Terabyte drive to start RECORDING 10sec before :-O) Camera’s? – Indoor, Outdoor, Pan 360, Tilt Up/Down, Zoom IN OUT, Auto rotate, Auto focus, Auto Detect, Infra Red Night Vision, Hidden, Pinhole, Dome’s, Lens to suit every need. SONY 1/3” CCD Colour, DVR’s 16 way, 32-Way, Hi Def, Analogy, etc. Name it, we got it, else we will get it for you. Use it to record the flow of a JOB, a Product, a Machine, a Person! And YES we can do your Front Gate, Server, Reception, & Stores for you as well.
It has taken many years to make Sentri Systems a front runner in the Time, Attendance, Job Costing and Production Timing Industry. It will be difficult for you to find another company who has as much PASSION about developing in-house leading edge Software. Our TIME ATTENDANCE would be one hand and the other hand would be our JOB COSTING software. TurboTime has been installed in over 2500 different sights over the years, so are already well know out there. We are directly responsible for calculating and paying over employee’s their wages, each and every week. Our solutions include Accuracy, Reliability and Easy to Use software. All crucial when dealing with your staff’s wages. We measure the time taken on Job and the Time spent on Job and $Cost$, measure your staff, what have they done? What is their efficiency? The focus being on the increase of YOUR Profit and Production. 20 Years Later - Who are we? That task is beyond most. BUT NOT US. We are the best “Bang for your Buck” out there today.