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

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178 MFG/PRO USER GUIDE — MANUFACTURING Report Description WIP Valuation Report (18.22.4.13) Reports the value of the WIP queues at the operation cost contained in the selected cumulative orders. Either the cumulative order operation standard costs, the cumulative order average costs, or the current GL standard operation costs can be used for valuation. Cost elements can optionally be displayed. Scrap/Adjust Valuation Reports (18.22.4.14 and 18.22.4.15) Managing Subcontracts Report the value of material scrapped/ adjusted within an interval of time. The data can be sorted by either Site and Item or by descending value. Either the cumulative order operation, the cumulative order average costs, or the current GL standard operation costs can be used for valuation. You have the option of displaying cost elements. Use Advanced Repetitive with other programs in MFG/PRO to manage subcontract operations. • You can use supplier-scheduled orders to support repetitive purchasing of subcontract services. • You can use subcontract shippers to create shipment paperwork and register the physical shipment of materials to the subcontractor. • You can receive an advance shipment notice (ASN) via electronic data interchange (EDI) to register the receipt of processed materials. All of the processing that occurs prior to the subcontract operation uses standard Advanced Repetitive functions. The last operation reported just prior to the subcontract operation (milestone or non-milestone) must have Move Next Op set to No. This leaves the WIP in that output queue. Items are then ready to be processed through the subcontract operation.
Using Scheduled Orders You can handle the purchasing side of a subcontract operation through a supplier schedule. Create supplier-scheduled purchase orders using Scheduled Order Maintenance (5.5.1.13). Enter a purchase order line record type, work order ID, and operation, as in Purchase Order Maintenance. You can also set the Type field to S (subcontract) or blank. These fields are used by PO Receipts, Supplier Schedule Update from MRP, and PO Shipper Receipt. Use an item number in the subcontract scheduled PO order line to show the service being purchased, such as CRANKSHAFT-HEAT-TREAT-SERVICE. This ensures consistent pricing for what is being purchased. At this point, you can update the routing with the scheduled order number if it does not exist there already. Next, create a cumulative order using Cumulative Order Maintenance (18.22.6), or by completing the first window of Backflush Transaction (18.22.13). Then, enter the cumulative order ID in the work order ID of Scheduled Order Maintenance. Note The work order ID represents a cumulative ID for the part number being sent to a subcontractor. When you execute Supplier Schedule Update from MRP, scheduled PO lines with type S (subcontract) are processed. The system passes through work order routing records (for released work orders) and routing file records (for planned work orders) and collects operation demand data used to create an updated supplier schedule. Shipping Subcontract Items Shipments to subcontractors can be recorded using functions on the Subcontract Shipping Menu (18.22.5). These programs create shippers in the same way as the container and shipper maintenance programs associated with sales orders and customer schedules. The major difference is in the Contents Items frame. Work Order ID, Operation, and Item replace Item, PO, Order, and Line. The Work Order ID and Operation fields identify a subcontract operation record on a cumulative order. The Item field identifies any component items used at the ADVANCED REPETITIVE 179 Tip For Purchase Cost, enter the subcontract cost per item.
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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
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Closing Work Orders To close a work
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6 Print Work Order WIP Cost Report
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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: Generating Repetitive Reports Table
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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Fully Automatic Scheduling FORECAST
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Available-to-Promise FORECASTING/MA
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FORECASTING/MASTER SCHEDULE PLANNIN
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FORECASTING/MASTER SCHEDULE PLANNIN
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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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