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

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172 MFG/PRO USER GUIDE — MANUFACTURING Tip This method requires an additional Move Transaction (18.22.19). • To reject units from an operation’s input queue and record the reject at the previous operation Enter up to 10 different reject codes at a time. You cannot report hours, and no backflushing takes place. Use Backflush Transaction (18.22.13) for most reject reporting. This transaction backflushes the rejected units and records all costs at the operation. When you use this transaction to report rejects at a milestone operation, the quantity must be in the input queue of the current operation or in the input/output queues of prior non-milestone operations. Note If you are rejecting with backflush at a non-milestone operation, the quantity to be rejected must be in the input queue of that nonmilestone operation. Rework Transaction When you first report rejected quantities, use the Reject to Op field in Backflush Transaction (18.22.13) or the To Operation field in Reject Transaction (18.22.16) to send the quantity to the operation where rework occurs. In WIP Status Browse/Inquiry (18.22.12), the rejected quantities appear as negative numbers in the output queue of the operation where the reject occurred, and as a positive number in the reject queue of the receiving operation. Reworked units are backflushed at the operation rejecting them. After reworking items, use Rework Transaction (18.22.17) to move rejected items back into the production line. Use the To Operation and To Queue fields to select the operation and queue, typically: • From an operation’s reject queue back to the rejecting operation’s output queue, or • To the input queue of the operation following the rejecting operation. You can enter rework hours and issue additional components. However, no automatic backflushing takes place. Enter up to 10 reject quantities and reason codes at a time.
Scrap Transaction Use Backflush Transaction (18.22.13) for most of your scrap transactions. It backflushes the scrapped units and records all costs at the operation. There must be a quantity in the input queue operation in order to record scrap with this transaction. Use Scrap Transaction (18.22.18) to scrap or remove quantities from any queue of an operation without backflushing. Enter up to 10 scrap quantities and reason codes at a time. When scrapping from the input queue, the scrap quantity is first moved back to the prior operation’s output queue and then posted as scrap at that operation. This ensures a proper balance in the queues and cumulative quantities (as seen in the WIP Status Report and Browse). You cannot report hours, and no backflushing takes place with this transaction. WIP Adjust Transaction You can reconcile actual WIP quantities with those stated in MFG/PRO using the WIP Status Inquiry (18.22.12) or WIP Status Report (18.22.4.11). When quantities do not match, use WIP Adjust Transaction (18.22.21) to adjust quantities at an operation’s input, output, or reject queues. The current queue balances display when you run the program. • When you adjust the output or reject queues, you change their balances at the current operation. • When you adjust the input queue, the net change is made to the prior operation’s output queue as well as to the current operation’s input queue. Each adjustment creates operation history records and generates GL transactions. A queue increase debits WIP and credits the inventory discrepancy account. Negative adjustments credit WIP and debit the inventory discrepancy account. You can designate a GL account and cost center for the transaction. The default is the inventory discrepancy account. ADVANCED REPETITIVE 173 Tip This transaction is often used to scrap previously rejected units. Tip Labor hours cannot be entered, and there are no backflushing capabilities.
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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
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Example Ten phantoms are in stock.
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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: The component backflush logic looks
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
Page 233 and 234: Generating Reports FORECASTING/MAST
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FORECASTING/MASTER SCHEDULE PLANNIN
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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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