Every manufactured product follows a path through the factory. Raw material enters, transforms through a series of operations, and emerges as a finished product.
This path - the routing - determines efficiency, cost, and quality. Get it right, and production flows smoothly. Get it wrong, and problems cascade.
What Is Routing?
A routing defines the manufacturing process:
Operations
- Each step in production
- In proper sequence
- With time estimates
- At specified workstations
A Simple Example
Operation 10: Cut to size → Saw Station → 5 minutes
Operation 20: Drill holes → Drill Press → 8 minutes
Operation 30: Deburr → Manual Station → 3 minutes
Operation 40: Paint → Paint Booth → 15 minutes
Operation 50: Inspect → QC Station → 5 minutes
Each operation has a place in the sequence, a location in the factory, and a time estimate.
ERPNext Routing Capabilities
ERPNext provides comprehensive routing management.
Routing Definition
Create reusable routings:
Basic Information
- Routing name
- Description
- Active status
Operation Sequence
- Operations in order
- Time at each step
- Workstation assignment
- Setup and run times
BOM Integration
Link routings to products:
- BOM references routing
- Materials from BOM
- Operations from routing
- Complete production definition
Work Order Creation
Routing drives execution:
- Work order uses BOM's routing
- Job cards created per operation
- Sequence enforced
- Time estimates applied
Routing Components
Operations
Each operation defines:
What
- Operation name and description
- Work instructions
- Quality requirements
- Skills needed
Where
- Workstation assignment
- Equipment required
- Tooling needs
How Long
- Setup time
- Run time per unit
- Total operation time
Workstations
Where operations happen:
- Physical work centers
- Capacity definitions
- Cost rates
- Availability calendars
Time Elements
Time components:
Setup Time
- Preparation before production
- Machine configuration
- Tool changes
- Independent of quantity
Run Time
- Per-unit processing time
- Scales with quantity
- Core production time
Queue Time
- Waiting before operation
- Transfer time between stations
- Non-value-added but real
Dubai Manufacturing Applications
Industrial Area Operations
Dubai's industrial sector uses routing for:
Metal Fabrication
- Cutting, forming, welding sequences
- Multiple machine operations
- Quality verification steps
Plastics Manufacturing
- Molding, finishing, packaging
- Quick changeovers
- High-volume routing
Food Processing
- Recipe-based routing
- Quality and safety steps
- Regulatory checkpoints
Packaging Operations
- Converting, printing, cutting
- Multi-station production
- Fast-paced scheduling
Job Shop vs. Flow Shop
Job Shop (common in Dubai)
- Variable routings per product
- Flexible path through factory
- Machine grouping
- Complex scheduling
Flow Shop
- Fixed routing for all products
- Linear flow
- Line balancing focus
- Simpler scheduling
ERPNext supports both models.
Routing Optimization
Improve your routings:
Process Analysis
Examine each operation:
- Is it necessary?
- Can it be eliminated?
- Can it be combined?
- Can it be simplified?
Time Studies
Verify time estimates:
- Actual vs. standard comparison
- Update estimates with reality
- Account for learning curves
- Include realistic allowances
Sequence Optimization
Find better sequences:
- Reduce material handling
- Balance workloads
- Minimize queue time
- Improve flow
Continuous Improvement
Routings should evolve:
- Capture improvement ideas
- Test changes
- Update standards
- Train on new methods
Variant Routings
Product variations may need different routings:
Routing Alternatives
- Multiple routings for same product
- Different equipment options
- Quality vs. speed tradeoffs
- Customer-specific requirements
Dynamic Routing
- Select routing based on conditions
- Equipment availability
- Order quantity
- Special requirements
Costing from Routings
Routings drive manufacturing costs:
Operation Costs
- Time × workstation rate
- Labor component
- Equipment component
- Overhead allocation
Product Cost
- Sum of operation costs
- Plus material costs (from BOM)
- Total manufactured cost
- Margin analysis
Variance Analysis
- Standard cost from routing
- Actual cost from job cards
- Variance identification
- Improvement focus
Integration Benefits
Routing connects manufacturing:
Planning
- Capacity requirements from routings
- Material timing from operation sequence
- Lead time calculation
Execution
- Job cards created from routing
- Workstation assignment enforced
- Time tracking by operation
Quality
- Inspection operations in sequence
- Quality gates enforced
- Documentation by operation
Costing
- Standard costs calculated
- Variances captured
- Analysis enabled
Best Practices
Accurate Definitions
Start with accurate data:
- Verify operation sequences
- Time studies for estimates
- Correct workstation assignments
- Complete documentation
Standard Maintenance
Keep routings current:
- Update for improvements
- Reflect actual methods
- Remove obsolete operations
- Version control
Training Alignment
Train to the routing:
- Workers understand sequence
- Time expectations clear
- Quality requirements known
- Consistency achieved
Regular Review
Routings need periodic review:
- Annual minimum
- After process changes
- Performance problems trigger
- Improvement opportunity search
The Foundation of Manufacturing
For Dubai manufacturers, routings are fundamental:
- Define how products are made
- Drive work order execution
- Enable capacity planning
- Support accurate costing
ERPNext provides the routing framework. Your process engineering makes it valuable.
Define your paths. Optimize your flow. Manufacture with confidence.