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

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188 MFG/PRO USER GUIDE — MANUFACTURING Ï See Chapter 12, “Material Requirements Planning,” on page 239. Ï See “Defining Control File Settings” on page 185. Reporting Completions Completed units are received into inventory when quantities are reported as complete for the last operation for an item, using Repetitive Labor Transaction (18.14). The components can be backflushed when completed units are received if the components are linked to the last operation. As completions are recorded on nonscheduled dates, the reporting of quantities on these dates causes entries to be automatically added to the repetitive schedule. If you report completions for today’s date using Repetitive Labor Transaction, the report has the following effects. • Inventory is incremented by the completion amount. A backflush occurs. Component inventory is shown as issued to the repetitive order. The requirements for components at all previous non-milestone operations are decremented. Floor stock items are accounted for. • If there is a scheduled amount for today, the Quantity Completed is incremented and the Quantity Open decremented until the scheduled quantity is reached. These quantities can be reviewed in Repetitive Operation Schedule Report (18.7). • If there are previous non-milestone operations, the Quantity Completed at each previous operation is also incremented, up to the amount required to make the scheduled amount of the finished item. • If the quantity open at the last operation is still nonzero, indicating the quantity completed is less than the quantity scheduled, the quantity open is treated as supply by MRP, and shown as the current amount of the planned order in MRP Detail Inquiry (23.16). You can change the Consume Forward, Consume Back, and Start of Week values in the Repetitive Control File (18.24) so that the extra completions will show up as Quantity Complete on other days. When a repetitive labor transaction is reported for an operation, the following occurs. • The Quantity Complete on the effective date of the report is incremented up to the scheduled amount. This amount is then subtracted from the reported quantity completed.
• If the remainder is positive, the system then looks at the Consume Back and Start of Week flags. If Consume Back is nonzero (and the Start of Week flag allows), the system moves to the previous calendar day and increments Quantity Complete up to the amount of the schedule. • The previous step is repeated until the limits of Consume Back or Start of Week are reached. When that happens, the system looks at the Consume Forward flag. If this is nonzero, it moves to the calendar day after the report effective date, incrementing Quantity Complete until the total completed is exhausted or it runs out of Consume Forward days. • For each change in the Quantity Complete at a milestone operation, the Quantity Complete at all of the previous non-milestone operations is changed to reflect the fact that the later operation was completed. Completed planned orders are ignored by MRP. Repetitive Scrap Transaction An item scrapped in the first operation may have a lower cost than one scrapped on receipt. It will not have the accumulated labor, burden, and additional material costs that accrue during subsequent operations. Repetitive Scrap Transaction (18.18) reports scrap at the item’s accumulated cost through the operation where it is scrapped. The system uses the standard cost created by the most recent use of Operation Cost Calculation (14.13.17). However, if no operation costs exist for the item/ routing/cost set, Repetitive Scrap Transaction automatically rolls up and totals the material, labor, burden, and subcontract costs by operation. It also does this for scrap reported for alternate BOMs/routings not included in Operation Cost Calculation. The item cost by operation can be reviewed using the Operation Cost Browse, (14.13.18) or the Operation Cost Report (14.13.19). After the scrap transaction is recorded, the scrap cost can be verified using the Repetitive Operations Accounting Report (18.21.10). Repetitive Scrap Transaction debits scrap and credits WIP for the operation cost multiplied by the quantity scrapped. REPETITIVE 189
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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
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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 and 198: Defining Control File Settings Sett
Page 199: Operation Reporting The reporting o
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
Page 249 and 250: 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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