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

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186 MFG/PRO USER GUIDE — MANUFACTURING Ï See “Simulating Schedules in the Workbench” on page 149. Ï See “Creating Repetitive Schedules” on page 153. Ï See “Using Repetitive Picklists” on page 155. Ï See “Managing Cumulative Orders” on page 160. Ï See Chapter 7, “Shop Floor Control,” on page 125. Simulating Schedules in the Workbench Line Schedule Workbench (18.1.10) is exactly the same as the workbench (18.22.1.10) in Advanced Repetitive. Creating and Exploding Repetitive Schedules These functions are almost identical in the two modules. Internally, the system processes additional information for Advanced Repetitive schedules, but the interface and input values are the same. Using Repetitive Picklists The functions on Repetitive Picklist Menu (18.8) are identical to the functions on Picklist Menu (18.23.3). Managing Cumulative Orders Cumulative orders track repetitive activities in much the same way as in Advanced Repetitive. Cumulative orders can be added manually using Cumulative Order Maintenance (18.9). However, its primary purpose is to change the status of an existing cumulative order to Closed so that Cumulative Order Accounting Close (18.12) can be used. Cumulative orders should remain open for the periods used by accounting to monitor WIP costs. Procedures should be in place to ensure they are closed at the end of each fiscal month or period. Executing Repetitive Transactions Repetitive transactions provide feedback for repetitive operations. Like those in the Shop Floor Control module, they require use of an employee code. Repetitive Labor Transaction is an exception, because it triggers inventory transactions to backflush components and receive completed units.
Operation Reporting The reporting of setup hours, labor hours, downtime, reject quantities, rework quantities, and scrap quantities works much the same in Repetitive as in the Shop Floor Control Module but with the following differences: • The reason codes for nonproductive labor should use DOWNTIME instead of DOWN. • Operation scrap can be reported in Repetitive but not in Shop Floor Control. Like the reporting of reject and rework quantities, scrap quantities have no impact on the general ledger and do not affect costing. • Reports for reporting reject quantities are available in Repetitive. • The Repetitive module includes some reports specific to that module. Repetitive Completions When a routing has many operations, there may be a few that are used to report completions, called milestone operations. Milestone Operations In Routing Maintenance (14.13.1), you can define any operation— including standard operations—to be a milestone. At a milestone operation, that operation and all previous non-milestone operations are backflushed when repetitive labor is reported. The last operation is always treated as a milestone. The following rules govern reporting: • You cannot report labor against a non-milestone operation. • You can report setup, downtime, reject, and scrap against a nonmilestone operation. However, this reporting does not affect WIP. • If you report scrap or reject at a non-milestone operation, it will backflush at that operation. If you do not report setup at non-milestone operations and report labor at milestone operations, the standard setup will be backflushed. If you report setup at the milestone operation, then no setup will be backflushed. REPETITIVE 187
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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
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You can calculate employee efficien
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Times You can enter setup times, ru
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You can review recorded downtime us
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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: Defining Control File Settings Sett
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
Page 241 and 242: Fully Automatic Scheduling FORECAST
Page 243 and 244: 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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