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
Saudi Arabia Manufacturing Applications
Industrial Area Operations
Saudi Arabia'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 Saudi Arabia)
- 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 Saudi Arabia 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. See also our guides on BOM management and work order tracking.