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

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236 MFG/PRO USER GUIDE — MANUFACTURING Fig. 11.11 Seasonal Build Maintenance (22.9) Ï See “Availableto-Promise” on page 231. Example 600 snowmobiles are scheduled to be completed in July due to a seasonal build requirement. A rush order for 200 snowmobiles arrives from Australia for shipment in July. The current production of snowmobiles would not be promised to that order, since it would be excluded from the ATP calculation. MRP plans for the target inventory levels set by seasonal build requirements. Specifying seasonal build requirements causes MRP to plan orders to satisfy those requirements and prevents it from issuing action messages to cancel or delay orders for seasonal build items when their demand is not yet apparent. Use Seasonal Build Maintenance (22.9) to create seasonal build forecasts for items by site. You must define an end date by which you need items in inventory and a seasonal inventory quantity needed by that end date. Example If you need 600 snowmobiles available in inventory by December 1st, you may decide to build them during the previous three months at a rate of 200 per month. You would then enter the following values. Date Seasonal Inventory 09/30/99 200 10/31/99 400 11/30/99 600 12/1/99 1 Setting the seasonal inventory quantity to zero (0) for December 1st indicates to MFG/PRO that the seasonal build requirement is complete. This means that the item is now included in ATP calculations and is considered a source of supply by MRP.
Generating Master Schedule Reports FORECASTING/MASTER SCHEDULE PLANNING 237 The Master Schedule Summary Inquiry and Report (22.18 and 22.19) and Master Schedule Detail Inquiry and Report (22.21 and 22.22) functions display the following information. Production Forecast. System-calculated forecast used in multilevel master scheduling. Forecast. Forecast quantity for an item, either loaded into forecast summary files using Simulation to Summarized Forecast (22.7.13) or manually entered using Forecast Maintenance (22.1) or Forecast Worksheet Maintenance (22.2). Sales Orders. Demand derived from confirmed sales orders and required ship schedules. Gross Requirements. The sum of an item’s requirements from forecasts, higher-level products, confirmed sales orders, required ship schedules, service items, and intersite orders generated by DRP. Gross requirements do not take into account inventory on hand or scheduled receipts. Master Scheduled Receipts. Total scheduled receipts for an item from work orders, repetitive schedules, purchase orders, and distribution orders. Projected QOH. Projected item quantity on hand, calculated by the system. This is a projection by period of an item’s on-hand balance plus scheduled receipts minus gross requirements. Available-to-Promise. The uncommitted portion of inventory or planned production, calculated by deducting real demand from real supply. Seasonal Build. Seasonal build quantity in inventory for that period, not included in the ATP quantity. The Master Schedule Detail Inquiry and Report functions (22.21 and 22.22) display the same information as the Master Schedule Summary Inquiry and Report, sequenced by due date. They also include source-todemand pegging details, allowing you to identify the actual work order or sales order generating a particular item requirement. Ï See page 232. Ï See page 225. Ï See Chapter 12. Ï See page 231. Ï See page 235.
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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
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Using Scheduled Orders You can hand
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If there is no WIP item number ente
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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 and 242: Fully Automatic Scheduling FORECAST
Page 243 and 244: Available-to-Promise FORECASTING/MA
Page 247: FORECASTING/MASTER SCHEDULE PLANNIN
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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