# Define the production method (/docs/product-development/methods-and-routings)

A production method says how a product is made: its operations in order, the machines and moulds that
can run each one, the work instruction and the validated process parameters. The planner and the machine
tablet read it. The engineer (Daniel Tan) writes it as a **Draft**, and it goes through review before
production can use it.

```mermaid
%% title: Status of a production method
flowchart LR
  A["Draft"] -->|"Submit for review"| B["In review"]
  B -->|"Approve, three levels"| C["Released"]
  B -->|"Return to draft"| A
  C -->|"New revision (needs an approved change note)"| A
  C -->|"Make obsolete (QA manager)"| D["Obsolete"]
  A -.->|"Operations have gaps"| X["Refused"]
```

## Create a method and its operations [#create-a-method-and-its-operations]

<Steps>
<Step>

Open the product (for example `General-SDS-01`) and choose **Setup** on the **Engineering** tab. Choose
**+ Add method**. To work on a method that exists, open it by number (for example `RT-SDS-02`, a Draft
method of `General-SDS-01`).

</Step>
<Step>

The **Method** number is assigned on save. Enter the **Rev**, an optional **Description** and **Internal reference**, **Valid from**, **Valid to**, and the
lot size range (**Lot size from (pcs)** and **Lot size to (pcs)**). Choose the **Preference**:
**Primary** or **Alternative**.

</Step>
<Step>

In the route, choose **+ Add operation**. Give the **Operation** a name and choose the **Station
(machine)**, or choose **Or store bin** for an operation done at a location. Enter the **Std time
(min / 1,000 pcs)**. An operation done only at a store bin (a hold, such as finished goods awaiting
outgoing inspection) needs no work instruction, standard time or machine option.

</Step>
<Step>

Add the other operations. **Insert after** places one between two others. **Duplicate** copies one five
numbers on. **Remove** deletes one and asks you to confirm. To start from another method, choose
**Copy operations from…**, pick the method, and confirm **Replace**.

</Step>
<Step>

Reorder by dragging. The operations are renumbered 10, 20, 30 and so on. The components, machine options,
parameters and checks that name an operation follow it to its new number.

</Step>
</Steps>

Each operation can also carry: an **Alternative** and **2nd alternative** station, a **Work instruction**,
a **QC gate**, a **Rework route** and **Rework station**, a **Parallel group** (A to D), **Required** or
**Optional** with a **Run when** condition for optional operations, and first-piece and IPQC settings
(see [Set the inspection plan](/docs/product-development/inspection-plan)).

## Read the layouts [#read-the-layouts]

- **Canvas** shows the method as a map with zoom and **Fit**. **Cards** shows the same as cards.
- **Flow**, **Table** and **List** are three layouts of the operations.
- The summary line gives the operation count, the minutes per 1,000 pieces along the critical path (an
  optional operation is left out and a parallel group counts once, by its longest branch), the line rate
  in pieces per hour and the setup minutes.
- **Lead time** estimates the run hours and the shifts of 8 hours for a quantity you type.
- **Compare methods** puts two methods of one product side by side and shows how much slower or faster
  one is.

<GuideStep
  title="A Draft production method"
  description="The method canvas of RT-SDS-02 with its operations and the readiness list."
  src="/guide/methods-and-routings/1.png"
  alt="Production method RT-SDS-02 canvas with operations in order, the Primary mark and the readiness checklist"
  width={1440}
  height={1000}
  callouts={[
    { x: 25, y: 14, caption: "The method, its revision and status. Draft can be edited." },
    { x: 35, y: 45, caption: "Operations in run order. The gaps count shows how many operations are incomplete." },
    { x: 85, y: 30, caption: "The readiness list: operations complete, components, method approved." },
  ]}
/>

## Add machine options and moulds [#add-machine-options-and-moulds]

A machine option says which machine, and which mould, can run one operation. The planner chooses from
these.

1. Open the operation. In the drawer choose the **Machines** tab and choose **+ Machine**.
2. The **Operation** is the one you opened; when you add an option elsewhere, choose it from the
   method's operations (for example `10 · Moulding`). You do not type an option code: the option is
   shown by its machine and mould, for example `MC-03 · M-217 · OP 10`. Enter the **Machine**.
   Choose whether it **Uses a mould**; then the **Mould**, or the **Parts per cycle**. Enter the
   **Cycle (s)** and the **Setup (min)**.
3. Choose the **Preference**: **Primary** or **Alternative**. Set the **Status** to **Active** or
   **Inactive**. An **Inactive** option is kept for history and does not count as a machine option.

A mould needs a cycle above 0 seconds. An operation without a mould, such as trim or pack, may keep 0.

**Uses a mould** says whether the option needs a mould. Select **Yes** and choose the **Mould**:
the **Parts per cycle** come from the mould's **Cavities** and you cannot type over them. Select
**No** and enter the **Parts per cycle** yourself (1 when one cycle makes one part); they are
required, because planning needs them to estimate the run time. An older option with no mould and
no parts per cycle shows the gap "parts per cycle" on its operation until you fill it in.

<GuideStep
  title="Machines of an operation"
  description="The Machines tab of the operation drawer lists every machine that can run the operation."
  src="/guide/methods-and-routings/2.png"
  alt="Operation drawer on the Machines tab showing machine options with machine, mould, parts per cycle, cycle and setup"
  width={1440}
  height={1000}
  callouts={[
    { x: 60, y: 14, caption: "The six drawer tabs: Machines, Work instruction, Parameters, Inspection, QC gates, Components." },
    { x: 60, y: 38, caption: "Each machine option shows its machine, mould, parts per cycle, cycle and setup time." },
    { x: 60, y: 80, caption: "+ Machine adds another option." },
  ]}
/>

## Build the method in the studio [#build-the-method-in-the-studio]

On the production method, the operations view has a fourth choice: **Studio**. It shows the whole
method on one screen, one section for each operation, from top to bottom.

- **Release readiness** at the top lists what the product still needs before production, for example
  **PFMEA** or **process validation**. Choose an item to add it.
- Each operation shows **Where it runs** (machine options), **Components** (BOM lines that the
  operation uses), **Machine settings**, **Checks** and its **Work instruction**. Each row shows its
  status. Choose **Add machine**, **Add component**, **Add setting** or **Add check** to add a row: the
  form opens with the product, production method and operation filled in. Choose the edit button of a
  row to change it.
- **Open in studio** opens the work instruction of the operation in its step editor.
- **Add operation** adds an operation at the end. To change the order, use the **Flow**, **Table** or
  **List** view.

Every row keeps its own rules and approvals: releasing the method covers its operations, machine
options and components; a work instruction, a setting and a check keep their own controls. On a
phone, each operation is a section that you can close.

## Set the process parameters [#set-the-process-parameters]

On the **Parameters** tab choose **+ Parameter**. The dialog shows the product and production method
under its title and has three steps:

1. **What to control**: the **Parameter** and its **Unit**. Select a common name (for example
   `Barrel temperature`) and unit (for example `°C`), or type your own.
2. **Allowed range**: the **Set** value and the **Validated min** and **Validated max** that process
   validation proved. A bar shows where the set value is in the window and says when it is outside.
3. **Where it applies**: the **Op** from the method's operations and, for one machine only, the
   **Machine option**. Leave them empty to use the parameter for all of them.

The set value must sit inside the validated window.
The tablet shows these set points during setup, and readings outside the window block the next step.
Each parameter can be saved once for a product, method, machine option and operation.

## The primary method [#the-primary-method]

A product can have several methods. The planner uses the primary one. The rule:

1. An **Obsolete** method is ignored.
2. A brand-new **Draft** is ignored while the product has a **Released** method, an **In review** method
   or a revision of a released one.
3. The method whose approved preference is **Primary** wins. If none is, the oldest released one wins.

Changing **Preference** on a Draft does not change the primary method until the method is approved.

## Submit, review and release [#submit-review-and-release]

When every operation is complete, open the method record and choose **Submit for review**. The method
needs at least one operation, and every operation needs a station or bin, a **released** work instruction,
a standard time and a machine option. Approval then goes through three levels, see
[Release the product documents](/docs/product-development/document-release).

A released method is read-only. To change it, start a new revision under an approved change note, see
[Change a released product](/docs/product-development/engineering-changes). While the new revision is a
Draft or in review, planning, orders, material issue, the traveller and inspection keep using the
released revision of the method, with its operations and the bill of materials, machine options,
parameters and characteristics that name it. They move to the new revision when it is released.

If the system refuses a step here, see [Product development: why the app refuses](/docs/product-development/refusals#define-the-production-method).

<NextSteps>

<NextStep href="/docs/product-development/work-instructions" title="Write work instructions" description="Write the steps the technician follows at setup." />

<NextStep href="/docs/product-development/inspection-plan" title="Set the inspection plan" description="Set what QC checks at first piece, in process and at handover." />

<NextStep href="/docs/product-development/document-release" title="Release the product documents" description="Take the method and product through review and e-signed approval." />

<NextStep href="/docs/product-development/refusals" title="Product development: why the app refuses" description="Every message on these pages and what to do." />

</NextSteps>