Routing In Production Planning And Control Ultimate Guide For Smes | Optiwise
Learn what routing means in production planning and control, why it matters for SMEs, routing steps, examples, challenges, and how ERP improves manufacturing execution.
Routing in Production Planning and Control: Ultimate Guide for SMEs
A production order can look clear on paper and still fail on the shop floor if the route is unclear.
The material is available. The customer order is confirmed. The product drawing is ready. But which operation comes first? Which machine should be used? Where does inspection happen? How much time should each step take? Which department receives the job next? What happens if one operation is skipped or delayed?
Routing answers these questions.
In production planning and control, routing defines the path a product follows through the factory. It lists the operations, sequence, work centres, machines, labour requirements, inspection points, and sometimes standard time needed to manufacture an item. For SMEs, routing is often the difference between controlled execution and everyday confusion.
This guide explains routing in production planning and control, why it matters, how it works, common SME challenges, and how AICAN Optiwise helps manufacturers connect routing with work orders, inventory, production tracking, and reporting.
What Is Routing in Production Planning and Control?
Routing is the process of deciding and documenting the sequence of operations required to manufacture a product.
It tells the production team:
- what operations must be performed
- in what order
- at which work centre or machine
- with what tools or resources
- how much time is expected
- where inspection is required
- how WIP should move
A route can be simple or complex. A fabrication part may move through cutting, bending, welding, grinding, inspection, painting, and packing. A machined component may move through raw material issue, turning, milling, drilling, deburring, inspection, and dispatch.
Why Routing Matters for SMEs
Many SMEs depend on experienced supervisors to remember production routes. That works until product variety increases, people change, urgent orders arrive, or errors start repeating.
Routing matters because it creates repeatability.
It helps SMEs:
- reduce shop-floor confusion
- improve production planning
- estimate lead time more accurately
- calculate capacity requirements
- reduce skipped operations
- improve WIP visibility
- support costing
- standardize quality checks
- train new operators faster
Without routing, production depends too much on memory.
Routing vs Scheduling
Routing decides the path of production.
Scheduling decides when each job or operation should happen.
For example, routing says the product must go through cutting, bending, welding, and inspection. Scheduling says cutting will happen today morning, bending in the afternoon, welding tomorrow, and inspection before dispatch.
Both are required. Routing gives the sequence. Scheduling gives the timing.
Routing vs BOM
A bill of materials, or BOM, defines what materials are required to make the product.
Routing defines how the product is made.
BOM answers: what do we need?
Routing answers: what steps do we follow?
A manufacturing ERP becomes more useful when BOM and routing are both connected because material and process are planned together.
Main Elements of a Routing Sheet
A routing sheet may include:
- product name and code
- drawing or revision number
- operation number
- operation description
- work centre or machine
- tool or fixture requirement
- setup time
- run time
- labour requirement
- inspection point
- expected output
- remarks or special instructions
For SMEs, the format does not need to be complicated. It must be clear enough for execution.
Routing Process Step by Step
1. Study the Product
Understand the product drawing, specification, customer requirement, tolerance, and finish.
2. Identify Operations
List every operation needed to convert raw material into finished goods.
3. Define Operation Sequence
Put the operations in the correct order. Sequence matters because one operation may depend on another.
4. Assign Work Centres
Decide which machine, line, department, or work centre will perform each operation.
5. Estimate Time
Define expected setup time and processing time where possible.
6. Add Quality Checks
Identify where inspection is required: incoming, in-process, final, or dispatch.
7. Validate on Shop Floor
Routing should be checked against actual production experience.
8. Update When Process Changes
If machine, tool, sequence, or quality requirement changes, the routing should be revised.
Example of Routing in Manufacturing
A sheet metal enclosure may follow this route:
- Raw material issue
- Shearing or laser cutting
- Punching
- Bending
- Welding
- Grinding
- Surface treatment
- Powder coating
- Assembly
- Final inspection
- Packing
If this route is not defined, production may miss inspection before coating, or assembly may wait because a part was not bent correctly. A route card helps prevent these mistakes.
Common Routing Challenges in SMEs
Routes Exist Only in People’s Heads
Experienced supervisors know the process, but the system does not. This creates dependency.
No Standard Time
Without operation time, scheduling and costing become weak.
Process Changes Are Not Updated
The shop floor changes the sequence, but documents remain old.
Quality Checks Are Not Linked
Inspection points may be missed if not built into the route.
WIP Is Hard to Track
If operations are not defined, it is difficult to know where the job is stuck.
How ERP Improves Routing
ERP helps turn routing from a static document into an operational workflow.
A connected ERP can:
- store product-wise routing
- link routing with BOM
- create work orders with operation sequence
- track WIP stage
- capture operation completion
- connect quality checks
- support production scheduling
- improve costing and capacity planning
- generate reports on delays and bottlenecks
Optiwise by AICAN helps SMEs connect production planning, inventory, work orders, and reporting so routing becomes easier to manage and review.
Best Practices for Routing
Start with critical products.
Document real shop-floor steps, not ideal assumptions.
Use operation numbers.
Link inspection points clearly.
Review routing after repeated delays or rework.
Keep routing connected with BOM and production planning.
Train supervisors and operators on route discipline.
Founder’s Note
At AICAN, we often see production delays that are not caused by lack of machines or people. They are caused by unclear flow. Everyone knows the product must be made, but not everyone sees the exact route.
AICAN Optiwise is built to help manufacturers make that flow visible. When routing, inventory, work orders, and production tracking are connected, SMEs can execute with more confidence and fewer surprises.
FAQs
What is routing in production planning and control?
Routing is the sequence of operations, machines, work centres, and inspection points required to manufacture a product.
Why is routing important for SMEs?
It reduces confusion, improves production planning, supports costing, improves WIP tracking, and makes manufacturing more repeatable.
Is routing the same as scheduling?
No. Routing defines the production path. Scheduling defines when each job or operation will happen.
How is routing different from BOM?
BOM defines materials required. Routing defines the process steps used to make the product.
How does Optiwise help with routing?
Optiwise by AICAN helps connect routing with work orders, inventory, production planning, WIP tracking, and reporting.
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