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

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128 MFG/PRO USER GUIDE — MANUFACTURING open for an operation is this starting quantity minus the quantities completed and rejected at that operation. Quantity Completed. The number of acceptable units produced at this operation, used to calculate variances, work center efficiency, and GL transactions. • If Move Next Operation is Yes, the quantity completed for an operation automatically moves to the next operation. This occurs regardless of whether the previous operation is complete. • If Move Next Operation is No, the quantity completed for an operation does not affect the quantity open at the next operation. Set the default value for this field in the Shop Floor Control File (17.24). Quantity Rejected. The number of unacceptable units produced at this operation that cannot be moved to the next operation. Quantity Reworked. The number of unacceptable units requiring additional processing produced at this operation. These do not all need to result in good units that can be moved to the next operation. Quantities reported as completed, rejected, and reworked do not affect the quantity open for a work order. If the reject quantity significantly reduces the expected receipt quantity for an order, you should use Work Order Maintenance (16.1) to reduce the order quantity to the expected quantity so that MRP plans based on the correct order quantity. Rejected and reworked quantities are independent of each other. For example, if you report 25 units as rejected and later report 25 units as reworked, the system shows both the reject and rework quantities as 25. If you want to change the reject quantity to zero, you must specify a reject quantity of –25 units. Reject and rework quantities have no impact on GL, since no transactions are created when they are reported. They are not used to calculate variances or work center efficiency.
Times You can enter setup times, run times, and downtimes in decimal hours (D) or clock hours (H). For example, an hour and 15 minutes can be entered as 1.25 decimal hours or 01:15:00. Enter elapsed setup and run times directly, or let the system calculate them from the start and stop times. For example, for a start time of 08:00:00 and a stop time of 14:45:00, the system calculates an elapsed time of 6.75 decimal hours. Operation Status Operation status codes indicate the detailed status of individual operations. The system automatically assigns status codes to operations as transactions are processed. Queue. An operation’s status is automatically set to Queue when material is moved to that operation, either by releasing a work order, entering labor feedback for that operation, or using Operation Move Transaction (17.6) to manually move material. When Move Next Operation is Yes in a labor feedback transaction, the next operation is automatically set to status Queue and quantities reported complete are moved to that operation. Setup. An operation’s status changes to Setup when you report setup time for that operation. Running. An operation’s status changes to Running when you report run time for that operation. This is not affected by the number of units reported as completed, rejected, or reworked. Complete. An operation’s status changes to Complete when you: • Report it as completed using one of the labor feedback transactions. • Close it using Operation Complete Transaction (17.5). • Run Work Order Accounting Close (16.21). When an operation is complete, you cannot process additional transactions against it. However, you can reopen operations if required using Work Order Routing Maintenance (16.13.13). SHOP FLOOR CONTROL 129 Ï For more information, see “Closing Operations” on page 131.
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User Guide Volume 3 MANUFACTURING P
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Contents ABOUT THIS GUIDE . . . . .
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CONTENTS V Defining Processes . . .
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CONTENTS VII Lead Time Calculations
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CONTENTS IX Common Transaction Data
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CONTENTS XI Maintaining Master Sche
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What Is in This Guide? 2 Windows Ke
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QAD Web Site or MFG/PRO users with
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Navigation Commands User Menu F6 Ct
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CHAPTER 1 Introduction to Manufactu
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Formula/Process The Formula/Process
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CHAPTER 2 Product Structures This c
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If a single company manufactures th
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Alternate Structures/Formulas An it
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Setting Up a Product Structure Defi
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equired, consider changing the comp
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Relationship with Configured Produc
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Assembly or Component Lead Time Sun
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CHAPTER 3 Routings/Work Centers Thi
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Some of these capabilities are espe
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Account Type Use Burden Usage Var E
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Machines. Enter the number of machi
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Yield %. Enter the order percentage
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Planning Maintenance (1.4.7) or Ite
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Work Center Routing Standards Somet
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If you examine this formula, severa
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Set the work center labor and burde
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CHAPTER 4 Formula/Process The Formu
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The Formula/Process module works in
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BOM/Formula as an alternate using A
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Use this frame to specify which scr
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CHAPTER 5 Co-products/ By-products
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Overview A base process is a manufa
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More About Co-products and By-produ
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Setting Up Mix Variance Accounts If
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Order Policy. Enter POQ or FOQ. MRP
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Qty Type. Enter B for batch, P for
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To set up a structure for a recycla
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Only a base process can have altern
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Although prune juice is a significa
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Rolling Up Costs Roll up lower-leve
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Allocation by Price The percentage
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• Closed. Co-product costs are re
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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: You can calculate employee efficien
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
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Using Scheduled Orders You can hand
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If there is no WIP item number ente
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CHAPTER 9 Repetitive The Repetitive
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Defining Control File Settings Sett
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Operation Reporting The reporting o
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• If the remainder is positive, t
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CHAPTER 10 Quality Management MFG/P
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Setting Up Quality Management Befor
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A comparative symbol (, =) and a nu
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Defining Sampling Patterns Define s
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Type. Specify the type of testing t
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Conducting Process Inspections When
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Use inventory sampling patterns to
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CHAPTER 11 Forecasting/Master Sched
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6 Load the detail forecast records
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FORECASTING/MASTER SCHEDULE PLANNIN
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Forecast Methods FORECASTING/MASTER
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Copying and Combining Forecasts FOR
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Generating Reports FORECASTING/MAST
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Fully Automatic Scheduling FORECAST
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Available-to-Promise FORECASTING/MA
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Generating Master Schedule Reports
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CHAPTER 12 Material Requirements Pl
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Sources of Demand MRP considers the
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Item Planning Data MATERIAL REQUIRE
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Order Policy Description Order Modi
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Time Fence MATERIAL REQUIREMENTS PL
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Component Effective Dates MATERIAL
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MRP Pegged Requirements MATERIAL RE
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MATERIAL REQUIREMENTS PLANNING 253
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Message Meaning Shipment Past Due I
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CHAPTER 13 Capacity Requirements Pl
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CAPACITY REQUIREMENTS PLANNING 259
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Generating Load Reports You can gen
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Adjusting Capacity and Load If a wo
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Numerics 1.1.5 58 1.1.13 57 1.2.1 5
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A Account Code Maintenance co-produ
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defined 53 demand for 77 material r
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Formula Maintenance 45 co-products/
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MPS. See master production scheduli
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epetitive 154, 183-189 completions
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sources for MRP 241 System/Account
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