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

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230 MFG/PRO USER GUIDE — MANUFACTURING Ï See Chapter 12, “Material Requirements Planning,” on page 239. Computer-Assisted Master Scheduling By defining time fences for master scheduled items, you can let MRP control orders outside of a specified time period and allow the master scheduler to control orders within that time period. To use this approach to master scheduling, in the Time Fence field in Item Master Maintenance (1.4.1) or Item Planning Maintenance (1.4.7), specify a planning horizon, in calendar days, for each master scheduled item. When MRP plans orders for these items, it will not schedule order due dates within this time fence. Note The time fence for an item should generally be equal to the cumulative lead time for that item. To use the computer-assisted approach for master scheduling, set the following values for each master scheduled item in Item Master Maintenance (1.4.1) or Item Planning Maintenance (1.4.7). Master Schedule. Yes. Plan Orders. No. Order Policy. Any option other than blank. Time Fence. The cumulative item lead time. Selective Materials Plan Selective Materials Plan (23.3) lets you plan master scheduled items separately from MRP items. If you use the computer-assisted approach to master scheduling, you may want to run Selective Materials Plan as follows. 1 Run Selective Materials Plan for master schedule items only. 2 Adjust the master schedule and rerun Selective Materials Plan as needed. 3 Run Selective Materials Plan for MRP-scheduled items only.
Available-to-Promise FORECASTING/MASTER SCHEDULE PLANNING 231 Available-to-promise (ATP) is the uncommitted portion of inventory or planned production which is available to be promised to new sales orders. The system displays ATP quantities on master schedule reports and inquiries. ATP can be used to verify whether a sales order can be filled within a specific time frame given other demands and currently scheduled supply orders. The system calculates ATP by time period by deducting real demand from real supply. Real demand includes requirements for work order components, sales orders, and required ship schedules, but excludes forecast and production forecast. Real supply includes quantity on hand, purchase orders, work orders, and repetitive schedules. A net decrease in demand increases ATP, while a net increase in demand decreases ATP. Note The system regards seasonal build quantities as real demand. The system performs the following calculation for each date when a Master Scheduled receipt is due or a seasonal build quantity is made available, causing a net increase in supply. It takes into account all sales order and required ship schedule demand and gross requirements up to the next increase in available supply. Master Scheduled Receipt – Sales Orders and Required Ship Schedules – Gross Item Requirements – Seasonal Build Net Increases + Seasonal Build Net Decreases = ATP. If demand exceeds supply, ATP for that period is zero, and the excess demand is applied as real demand against the ATP quantity for previous periods until all excess demand is eliminated or the ATP quantities for previous periods are exhausted. If the latter occurs, the system displays a negative ATP quantity for first period. ATP and the master schedule are bucketless because they are calculated using dates rather than fixed periods. However, master schedule report functions let you report ATP quantities in monthly, weekly, daily, or GL calendar period buckets. Ï See page 235. Ï See “Generating Master Schedule Reports” on page 237.
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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
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• Batches can overlap and visibil
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Setting Up Advanced Repetitive Repe
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• PO Shipper Receipt (5.5.5.5) Wh
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production lines. To set up multipl
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is 700 units per shift. If a second
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Milestone and Non-Milestone Operati
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In the first, there is a primary st
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Whenever you create or modify a seq
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Creating Repetitive Schedules A rep
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The schedule explodes automatically
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The Net Available is the material a
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Transfer the Inventory Use Repetiti
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• Cumulative Order Close (18.22.1
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Processing Steps Cumulative Order C
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Common Transaction Data All repetit
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Rate Variance All transactions cons
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Repetitive Transaction Programs The
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The component backflush logic looks
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Scrap Transaction Use Backflush Tra
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cumulative order. The amounts to po
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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
Page 241: Fully Automatic Scheduling FORECAST
Page 249 and 250: Generating Master Schedule Reports
Page 251 and 252: CHAPTER 12 Material Requirements Pl
Page 253 and 254: Sources of Demand MRP considers the
Page 255 and 256: Item Planning Data MATERIAL REQUIRE
Page 257 and 258: Order Policy Description Order Modi
Page 259 and 260: Time Fence MATERIAL REQUIREMENTS PL
Page 261 and 262: Component Effective Dates MATERIAL
Page 263 and 264: MRP Pegged Requirements MATERIAL RE
Page 265 and 266: MATERIAL REQUIREMENTS PLANNING 253
Page 267 and 268: Message Meaning Shipment Past Due I
Page 269 and 270: CHAPTER 13 Capacity Requirements Pl
Page 271 and 272: CAPACITY REQUIREMENTS PLANNING 259
Page 273 and 274: Generating Load Reports You can gen
Page 275 and 276: Adjusting Capacity and Load If a wo
Page 277 and 278: Numerics 1.1.5 58 1.1.13 57 1.2.1 5
Page 279 and 280: A Account Code Maintenance co-produ
Page 281 and 282: defined 53 demand for 77 material r
Page 283 and 284: Formula Maintenance 45 co-products/
Page 285 and 286: MPS. See master production scheduli
Page 287 and 288: epetitive 154, 183-189 completions
Page 289 and 290: sources for MRP 241 System/Account
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