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Material Control in AcornPipe
Software
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AcornPipe Material
Control
Drawing
The
drawings are the key to all Material control as all reports and files are
created from information generated as drawings are created. It is a great
advantage to put one Spool per drawing as this will be the only way to track
individual spools. All tracking and records are generated by drawing. For
example it will not be possible to issue part of a drawing for fabrication.
Reports/Files
As drawings
are saved, a record in the Status file is created for each with Spool number,
Ref. drawing, Revision, Weight, Diameter-inches and more. Plus user defined
fields for tracking production status through the fabrication.
A list of
any number of drawings can be made, and this list is used to generate reports
for Status, Material summaries, Cut sheets, a Material Search, Labor summaries,
and more.
As drawings
are created, all material and labor in each drawing will also add any new items
into Reference files. These files are common to all jobs in the Client folder
and all have a field for entering and storing the base unit price of every item.
There are separate files for Material, Welds, Automatic labor and Extra user
defined labor. Each file will allow the entry of a unit price. These prices will
be used for pricing unit price drawings. The welds and end prep will be the
prices for Group 0 materials and will be multiplied by a factor for other
material groups. The Automatic labor includes all Cuts, Bevels of various kinds,
Bends in a bent pipe system, Extruded outlets and End protectors.
Inventory
As drawings
are completed they are used to create an inventory file for the job, which
contains an accurate tally of every item in all drawings. The inventory file
contains fields for Estimated, Purchased, Received, Drawn, In Stock, In
Fabrication, Complete, Unit Price and Price factor. The Drawn field will show
the total for each item from all drawings in the job. Estimated, Purchased and
Received quantities are manual entries into the file. Any amounts received will
also go into the ‘In Stock’ column. As drawings are released for fabrication the
material for those drawings will be transferred to the ‘In Fabrication’ column
and then to the Completed column.
Material
Receipt
Material receiving reports can be generated with the reports having an entry for
Heat number, MTR number and PMI number for each item. This will be used to
create a receiving report for the job, with Item code, Heat number, quantity
received and used, etc. for all items. This file will be referenced as heat
numbers are entered into drawings to verify the correct item is used. It will
also confirm numbers and amount used for all items in the job. As heat numbers
are verified, the PMI and MTR numbers will be added to the drawing
automatically. It will be preferable to check the numbers before fabrication to
catch errors before they are made.
We are also
looking at the possibility of generating Bar codes (or RFID tags) from the file
to tag items so they can be scanned as they are picked for fabrication and can
be checked faster.
Release
to Fabrication
If material has been received into inventory it will also be added to stock. A
list of drawings ready for fabrication can be made. These drawings will then be
checked against the stock available and the list reduced to the ones which can
be fabricated. The program will decide which spools are the best to release
based on the material available and the greatest number of spools which can be
fabricated. For example if there are 6 olets in stock and one spool in the list
requires 6, but there are 6 spools which need just one each, the 6 spools will
be left on the list. Users can designate items in inventory which are not
essential for fabrication so they do not restrict the release. These could be
items such as End plates, Re-pads, Blind flanges, End protectors, etc.
As drawings are released, the material for them will be
transferred from Stock to the In Fabrication column of inventory. The release
date will also be entered into the status file and the status of that spool will
be updated with the revision of the drawing issued. A drawings will not be able
to be released a second time unless its material has been returned to stock
first. Revised drawings which have already been released or completed must have
the previous revision material returned before they can be released again with
the new revision. When saving changes to a drawing which has been released to
fabrication, the user will be informed of the drawing status. Then given options
such as returning it from fabrication, scrapping the previous drawing and saving
it with another file/control number or making a new revision of the current
drawing. Each revision will add separate records to the job item file so that
the correct materials will always be returned from Fabrication to Stock as
needed. As spools are designated as complete the date will again be entered in
the Status file and material moved to the Complete column in inventory.
Material
Purchase
We are looking at the possibility of using the material summaries to generate
purchase orders. This would allow materials purchased to be entered into the
inventory file automatically. The purchase order would also be used as a
receiving report to track items and heat numbers, etc. for each fitting or pipe
as it is received. This in turn will add to a single receiving file with every
item having a heat number, MTR number, PMI number as needed, to verify final
information added to each drawing.
Material
Tracking
The system will be able to keep track of all material used on the job and
generate reports as needed. Users will be able to generate a data file
containing the complete record of every item used on the job. This will enable
the search for any heat numbers and all drawings which contain items with a
specific number. There will be a reduced chance of errors from entering
incorrect heat numbers into drawings or the wrong quantity of any number.
Production Tracking
The status report can be customized to track any spool as it travels from
drawing release to final shipping. It will enable users to track how many
spools, weight, and diameter-inches of weld goes through each stage of
production per day, week, or any other time period. It will also be possible to
post the status information to a company web site where remote customers can go
to check on the status of the job or any spool in the job without needing to
contact production staff directly. Inspection information could also be posted
on a web site for access by customers at any time.
Pricing
Drawings
There are reference files created of all items and labor functions used on every
job in a specific client folder. Base unit prices can be entered into these
reference files for all items. As drawings are produced in any job these will
also create files of each item and labor function in that job. Item records will
be in the Inventory file. These files will have the base prices transferred from
the reference files and will also have a price factor column. These files are
used for entering the discount factor for every labor and material item in the
job and changes to prices for that job if necessary. These files will be used to
automatically price completed drawings as needed with a drawing format printed
with unit price, price factor and extended price calculated automatically. Items
will also have prices adjusted with factors applied for different material
groups, Cuts and End prep. on fittings, etc. There will also be the ability to
adjust the factor of some items on individual drawings to reflect revisions on
those drawings. This will eliminate the tedious manual pricing of drawings.
Weld
Tracking/Non Destructive Testing
Welder ID, inspection, weld procedures, consumables, etc. can be entered into
the drawings as they are completed. All of this information will be added to a
Job weld file so that at the completion of the job there will be a single data
file of every weld completed. Each weld will show all information needed for
complete traceability. The welds will show size, type of weld, specification,
welder ID, inspection, etc. The weld file can also be used to track the
inspection record of any individual welder or to trace which welder completed
any weld which may have a future problem.
Welder
Productivity
As jobs progress reports can be generated showing the productivity of each
welder for any time period desired. Problems can be flagged and corrected if
needed.
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Download Material Control
Info as above:
This document outlines the material control section of the AcornPipe software
as above.
To download this document, right click and select "Save Target As"
click here to download
More information PDF files and videos coming soon
Contact Information
- Telephone:
-
780-963-3303
800-363-9777
888-476-9777
- Fax:
-
780-963-7156
- Postal address
- Acorn Pipe
Systems Inc.
- Box 67, Site 4, RR #2,
Stony Plain, Alberta,
Canada, T7Z 1X2
- Electronic mail
- General Information:
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