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Production and warehouse explained, without the jargon.

What an MES does, how to calculate OEE, what FEFO means. Short, honest explanations for manufacturers who make to order.

  1. Recording deviations and non-conformances: what belongs in a deviation report?A deviation, or non-conformance, is anything in production that goes differently than agreed: a product outside specification, a skipped step or the wrong material. Recording it means you capture straight away what happened, in which batch, what you do with the product and who investigates the cause. A good deviation report is short, complete and stays open until someone closes it.
  2. What is CAPA? Corrective and preventive action in productionCAPA (Corrective and Preventive Action) is the set way in which a manufacturer does not just fix a problem, but finds and removes its cause. A corrective action stops a deviation that has happened from coming back; a preventive action stops a potential problem from ever happening. Every CAPA has an owner, a deadline and a check that the action works.
  3. Production planning in Excel, and when a digital planning board works betterA production plan in Excel is a sheet with one row per order: which line it runs on, when it starts, how long it takes and when it is finished. For a few lines and a quiet week that works fine. Once rush orders, changeovers and progress from the floor come into play, the file falls behind and a digital planning board that the office and the floor both see live works better.
  4. What is an electronic batch record? Contents, release and moving off paperAn electronic batch record (eBR) is the digital account of how one batch was made: which recipe and instruction version, which materials and lots, which checks with which result, which deviations and who signed off each step. It is built during production from what actually happens, so quality can review and release the batch without hunting for paper.
  5. How to calculate OEE: the formula with a worked exampleOEE (Overall Equipment Effectiveness) shows which share of planned production time actually produced good product. You calculate it as availability times performance times quality. An OEE of 70% means that 30% of the planned time was lost to downtime, a slower pace or rejected product.
  6. MES or ERP: what is the difference, and do you need both?An ERP (Enterprise Resource Planning) runs the business: orders, purchasing, stock, cost price and invoices. An MES (Manufacturing Execution System) directs and records execution on the shop floor: which order runs on which line, with which lots, which checks and where time is lost. The ERP knows what should happen, the MES knows what really happened.
  7. What is an MES? An explanation for manufacturersAn MES (Manufacturing Execution System) is software that directs and records production on the shop floor: which order runs on which line, with which materials and lots, who did what, which checks were carried out and where time was lost. It sits between the ERP, which plans and invoices, and the machines and people who do the work.