MFG/PRO 9.0 User Guide Volume 3: Manufacturing - QAD.com

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X <strong>MFG</strong>/<strong>PRO</strong> USER GUIDE — MANUFACTURING Entering Quality Order Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Deleting Quality Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Conducting Process Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Conducting Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Inventory Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 First Article Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Process Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Printing Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 CHAPTER 11 FORECASTING/MASTER SCHEDULE PLANNING . . . . . . . . . . 205 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Creating Forecasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Forecast Creation Work Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Forecasting Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Setting Up Forecasting Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Creating Criteria Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Calculating Forecasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Manually Creating Forecasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Modifying Forecast Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Copying and Combining Forecasts . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Generating Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Making Forecast Data Visible to MRP . . . . . . . . . . . . . . . . . . . . . . . . 222 Deleting and Archiving Forecasting Detail Records . . . . . . . . . . . . . . 223 Maintaining Forecasts Outside of Forecast Simulation . . . . . . . . . . . . 224 Consuming Forecasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Sales Order Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Net Forecast Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Forward and Backward Forecast Consumption . . . . . . . . . . . . . . . . . . 226 Creating Master Production Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Master Scheduled Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Approaches to Master Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Available-to-Promise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 Multilevel Master Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
CONTENTS XI Maintaining Master Schedule Orders . . . . . . . . . . . . . . . . . . . . . . . . . 234 Verifying Capacity for Master Schedules . . . . . . . . . . . . . . . . . . . . . . 235 Master Scheduling for Seasonality . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Generating Master Schedule Reports . . . . . . . . . . . . . . . . . . . . . . . . . 237 CHAPTER 12 MATERIAL REQUIREMENTS PLANNING. . . . . . . . . . . . . . . . . 239 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 MRP and Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Sources of Demand and Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Setting Up MRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 MRP Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Item Planning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Inventory Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Product Structures and Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Executing MRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 MRP Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 MRP Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 MRP Pegged Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 MRP Planning Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Reviewing MRP Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Action Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Planned Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Approving Planned Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 CHAPTER 13 CAPACITY REQUIREMENTS PLANNING. . . . . . . . . . . . . . . . . 257 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Defining Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Executing CRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Back Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Generating Load Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Reviewing Input and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Adjusting Capacity and Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Adjusting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Adjusting Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Page 1 and 2: User Guide Volume 3 MANUFACTURING P
Page 3 and 4: Contents ABOUT THIS GUIDE . . . . .
Page 5 and 6: CONTENTS V Defining Processes . . .
Page 7 and 8: CONTENTS VII Lead Time Calculations
Page 9: CONTENTS IX Common Transaction Data
Page 13 and 14: What Is in This Guide? 2 Windows Ke
Page 15 and 16: QAD Web Site or MFG/PRO users with
Page 17 and 18: Navigation Commands User Menu F6 Ct
Page 19 and 20: CHAPTER 1 Introduction to Manufactu
Page 21 and 22: Formula/Process The Formula/Process
Page 23 and 24: CHAPTER 2 Product Structures This c
Page 25 and 26: If a single company manufactures th
Page 27 and 28: Alternate Structures/Formulas An it
Page 29 and 30: Setting Up a Product Structure Defi
Page 31 and 32: equired, consider changing the comp
Page 33 and 34: Relationship with Configured Produc
Page 35 and 36: Assembly or Component Lead Time Sun
Page 37 and 38: CHAPTER 3 Routings/Work Centers Thi
Page 39 and 40: Some of these capabilities are espe
Page 41 and 42: Account Type Use Burden Usage Var E
Page 43 and 44: Machines. Enter the number of machi
Page 45 and 46: Yield %. Enter the order percentage
Page 47 and 48: Planning Maintenance (1.4.7) or Ite
Page 49 and 50: Work Center Routing Standards Somet
Page 51 and 52: If you examine this formula, severa
Page 53 and 54: Set the work center labor and burde
Page 55 and 56: CHAPTER 4 Formula/Process The Formu
Page 57 and 58: The Formula/Process module works in
Page 59 and 60: BOM/Formula as an alternate using A
Page 61 and 62:
Use this frame to specify which scr
Page 63 and 64:
CHAPTER 5 Co-products/ By-products
Page 65 and 66:
Overview A base process is a manufa
Page 67 and 68:
More About Co-products and By-produ
Page 69 and 70:
Setting Up Mix Variance Accounts If
Page 71 and 72:
Order Policy. Enter POQ or FOQ. MRP
Page 73 and 74:
Qty Type. Enter B for batch, P for
Page 75 and 76:
To set up a structure for a recycla
Page 77 and 78:
Only a base process can have altern
Page 79 and 80:
Although prune juice is a significa
Page 81 and 82:
Rolling Up Costs Roll up lower-leve
Page 83 and 84:
Allocation by Price The percentage
Page 85 and 86:
• Closed. Co-product costs are re
Page 87 and 88:
ecord for its base process. This de
Page 89 and 90:
When a planned purchase order is ap
Page 91 and 92:
Accessing and Modifying Joint Order
Page 93 and 94:
Mix Variance Acct. Enter the accoun
Page 95 and 96:
Backflush Calculation Methods Speci
Page 97 and 98:
Receiving Unplanned Items Use Unpla
Page 99 and 100:
(Supplier) Schedule Update from MRP
Page 101 and 102:
CHAPTER 6 Work Orders The Work Orde
Page 103 and 104:
• Schedule operations with Capaci
Page 105 and 106:
Creating Work Orders Work orders ar
Page 107 and 108:
Table 6.2 lists work order type cod
Page 109 and 110:
Scheduled Work Orders Scheduled wor
Page 111 and 112:
Planned Bills Bill created Routings
Page 113 and 114:
Released A released order is like a
Page 115 and 116:
• The release date is the date wh
Page 117 and 118:
the average order quantity, the les
Page 119 and 120:
Modifying Work Order Routings Use W
Page 121 and 122:
Creating Picklists After you releas
Page 123 and 124:
Issues are not restricted to what t
Page 125 and 126:
Subcontract Operations Work orders
Page 127 and 128:
Receiving and Backflushing When you
Page 129 and 130:
Example Ten phantoms are in stock.
Page 131 and 132:
Generating Reports Many of the Work
Page 133 and 134:
Closing Work Orders To close a work
Page 135 and 136:
6 Print Work Order WIP Cost Report
Page 137 and 138:
CHAPTER 7 Shop Floor Control The Sh
Page 139 and 140:
You can calculate employee efficien
Page 141 and 142:
Times You can enter setup times, ru
Page 143 and 144:
You can review recorded downtime us
Page 145 and 146:
Downtime Review recorded downtime b
Page 147 and 148:
CHAPTER 8 Advanced Repetitive Repet
Page 149 and 150:
• Batches can overlap and visibil
Page 151 and 152:
Setting Up Advanced Repetitive Repe
Page 153 and 154:
• PO Shipper Receipt (5.5.5.5) Wh
Page 155 and 156:
production lines. To set up multipl
Page 157 and 158:
is 700 units per shift. If a second
Page 159 and 160:
Milestone and Non-Milestone Operati
Page 161 and 162:
In the first, there is a primary st
Page 163 and 164:
Whenever you create or modify a seq
Page 165 and 166:
Creating Repetitive Schedules A rep
Page 167 and 168:
The schedule explodes automatically
Page 169 and 170:
The Net Available is the material a
Page 171 and 172:
Transfer the Inventory Use Repetiti
Page 173 and 174:
• Cumulative Order Close (18.22.1
Page 175 and 176:
Processing Steps Cumulative Order C
Page 177 and 178:
Common Transaction Data All repetit
Page 179 and 180:
Rate Variance All transactions cons
Page 181 and 182:
Repetitive Transaction Programs The
Page 183 and 184:
The component backflush logic looks
Page 185 and 186:
Scrap Transaction Use Backflush Tra
Page 187 and 188:
cumulative order. The amounts to po
Page 189 and 190:
Generating Repetitive Reports Table
Page 191 and 192:
Using Scheduled Orders You can hand
Page 193 and 194:
If there is no WIP item number ente
Page 195 and 196:
CHAPTER 9 Repetitive The Repetitive
Page 197 and 198:
Defining Control File Settings Sett
Page 199 and 200:
Operation Reporting The reporting o
Page 201 and 202:
• If the remainder is positive, t
Page 203 and 204:
CHAPTER 10 Quality Management MFG/P
Page 205 and 206:
Setting Up Quality Management Befor
Page 207 and 208:
A comparative symbol (, =) and a nu
Page 209 and 210:
Defining Sampling Patterns Define s
Page 211 and 212:
Type. Specify the type of testing t
Page 213 and 214:
Conducting Process Inspections When
Page 215 and 216:
Use inventory sampling patterns to
Page 217 and 218:
CHAPTER 11 Forecasting/Master Sched
Page 219 and 220:
6 Load the detail forecast records
Page 221 and 222:
FORECASTING/MASTER SCHEDULE PLANNIN
Page 223 and 224:
Forecast Methods FORECASTING/MASTER
Page 225 and 226:
Page 227 and 228:
Page 229 and 230:
Copying and Combining Forecasts FOR
Page 231 and 232:
Page 233 and 234:
Generating Reports FORECASTING/MAST
Page 235 and 236:
Page 237 and 238:
Page 239 and 240:
Page 241 and 242:
Fully Automatic Scheduling FORECAST
Page 243 and 244:
Available-to-Promise FORECASTING/MA
Page 245 and 246:
Page 247 and 248:
Page 249 and 250:
Generating Master Schedule Reports
Page 251 and 252:
CHAPTER 12 Material Requirements Pl
Page 253 and 254:
Sources of Demand MRP considers the
Page 255 and 256:
Item Planning Data MATERIAL REQUIRE
Page 257 and 258:
Order Policy Description Order Modi
Page 259 and 260:
Time Fence MATERIAL REQUIREMENTS PL
Page 261 and 262:
Component Effective Dates MATERIAL
Page 263 and 264:
MRP Pegged Requirements MATERIAL RE
Page 265 and 266:
MATERIAL REQUIREMENTS PLANNING 253
Page 267 and 268:
Message Meaning Shipment Past Due I
Page 269 and 270:
CHAPTER 13 Capacity Requirements Pl
Page 271 and 272:
CAPACITY REQUIREMENTS PLANNING 259
Page 273 and 274:
Generating Load Reports You can gen
Page 275 and 276:
Adjusting Capacity and Load If a wo
Page 277 and 278:
Numerics 1.1.5 58 1.1.13 57 1.2.1 5
Page 279 and 280:
A Account Code Maintenance co-produ
Page 281 and 282:
defined 53 demand for 77 material r
Page 283 and 284:
Formula Maintenance 45 co-products/
Page 285 and 286:
MPS. See master production scheduli
Page 287 and 288:
epetitive 154, 183-189 completions
Page 289 and 290:
sources for MRP 241 System/Account
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