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

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168 MFG/PRO USER GUIDE — MANUFACTURING Method Change Variance Method change variance (MCV), when calculated, is posted by the following transactions. • Cumulative Order Close (18.22.10) • Backflush Transaction (18.22.13) • Run Labor Transaction (18.22.14) • Setup Labor Transaction (18.22.15) • Rework Transaction (18.22.17) • Move Transaction (18.22.19) In the backflush and move transactions, MCV can be posted when moving from the output queue of the last operation to finished material inventory. MCV is calculated as the difference between the final operation cost contained in the cumulative order and the current GL standard cost of the finished material, extended by the quantity being reported. In the transactions where labor is reported, MCV can be posted when reporting at a work center other than the cumulative order operation work center. MCV is calculated as the difference between the standard labor and burden rates of the work center being reported and the standard labor and burden rates of the cumulative order operation work center, extended by the number of hours reported. This prevents charging unexpected rate variances to the work centers. In Cumulative Order Close, MCV can be posted when transferring WIP quantities to new cumulative orders. MCV is calculated as the difference between the operation cost in the former cumulative order operation and the operation cost of the future cumulative order operation, extended by the quantity transferred. Method change variances are posted only if GL standard costing is in effect for the finished item. MCV is not posted if GL average costing is in effect.
Repetitive Transaction Programs The following sections describe the use and application of various transaction programs on the Advanced Repetitive menu. Backflush Transaction Backflush Transaction (18.22.13) is the primary tool for reporting production line activity and the only transaction that automatically backflushes component inventory. You can report the number of gross units processed, scrapped units, rejected units, and labor hours. If the transaction is made from the last operation, you can receive items into inventory. You can backflush components of the current operation and any preceding non-milestone operations. You backflushing occurs is affected by the setting of Zero Balance WIP in the Repetitive Control File. You can also backflush standard labor and burden if the routing record of the reporting operation, or any preceding non-milestone operation, has Auto Labor Report set to Yes. When you report you have completed and moved items at the final operation, the quantity is posted as complete at the operation, and is also posted to the repetitive schedule and the related work order. If there are multiple schedules for an item, the system determines the earliest open schedule date and posts the completed quantities from that point forward. If the system cannot find enough open balances, the operation is posted with the transaction quantity. However, the repetitive schedule and work order record are posted with the open quantity available. You can modify repetitive schedule completions using Cumulative Completed Maintenance (18.22.2.6). You can view the repetitive schedule completions using either Schedule Inquiry (18.22.2.2) or Operation Schedule Report (18.22.2.5). You can view work order completions using Work Order Browse (16.2). When units are moved to stock or scrapped, information is posted to the repetitive schedule and the MRP exploded work order. When MRP is run, issued component quantities remaining on the production line are visible for requirement planning. Purchase order receipts and supplier schedule ADVANCED REPETITIVE 169 Tip Backflush Transaction can be used at both milestone and non-milestone operations. Ï See “Zero Balance WIP” on page 140 for details.
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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
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When a planned purchase order is ap
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Accessing and Modifying Joint Order
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Mix Variance Acct. Enter the accoun
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Backflush Calculation Methods Speci
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Receiving Unplanned Items Use Unpla
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(Supplier) Schedule Update from MRP
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CHAPTER 6 Work Orders The Work Orde
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• Schedule operations with Capaci
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Creating Work Orders Work orders ar
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Table 6.2 lists work order type cod
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Scheduled Work Orders Scheduled wor
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Planned Bills Bill created Routings
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Released A released order is like a
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• The release date is the date wh
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the average order quantity, the les
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Modifying Work Order Routings Use W
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Creating Picklists After you releas
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Issues are not restricted to what t
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Subcontract Operations Work orders
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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: Rate Variance All transactions cons
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 229 and 230: Copying and Combining Forecasts FOR
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FORECASTING/MASTER SCHEDULE PLANNIN
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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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