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

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246 MFG/PRO USER GUIDE — MANUFACTURING Order Modifier Description Yield % The percentage of an order expected to be in usable condition. If Yield % is less than 100%, MRP plans orders for more than needed. For example, if the net requirement is 100 and the item Yield % is 50%, then the planned order quantity will be 200. You can enter this value manually or use Routing Cost Roll-Up (14.13.13) to calculate yield percent based on the yield percentages at each operation in the item routing. If an item’s Yield % is less than 100%, MRP may generate planned orders for fractional quantities. To prevent this, set Order Minimum or Order Multiple to 1, or any whole number. Scrap % The percentage of a component item expected to be scrapped during manufacture of the parent item.This value increases the component requirements for planned orders for that component-parent pair. Specify scrap % values for components in Product Structure Maintenance (13.5). When scrap percentage is greater than zero, MRP may calculate fractional component quantities, even if the component is a discrete item. For example, if one housing is required to build an item and the scrap factor is 5%, the system will calculate a requirement for 105.2631 housings to make 100 units. To prevent MRP from generating planned orders for fractional quantities, set Order Minimum or Order Multiple to 1, or any whole number. Lead Times Lead time determines when MRP planned orders are due—manufacturing lead time for manufactured items, and purchasing lead time plus inspection lead time for purchased items. For both purchased and manufactured items, if the lead time varies, you can define a safety time. MRP then calculates the planned order due date by adding safety time to the lead time.
Time Fence MATERIAL REQUIREMENTS PLANNING 247 Lead Time Description Manufacturing Lead Time The number of working days it takes to manufacture an item, including the time it takes to process paperwork, issue components, inspect the finished product, and receive it into stock. For DRP items, enter DRP transit and order time in this field so that this value is included in the cumulative lead time for this item. Purchasing Lead Time The number of calendar days it takes to complete a purchasing cycle for an item, from the date the need for a purchase is recognized to the date the item is received. Inspection Lead Time The number of working days it takes to inspect a purchased item after it is received. Safety Lead Time The number of working days early that MRP plans to receive orders for an item, to allow for late deliveries. Cumulative Lead Time The longest number of calendar days it takes to obtain an item, assuming that neither it nor any of its components are in stock. The system calculates this value, by converting manufacturing, inspection, and safety lead time to calendar days. The time fence is the number of calendar days inside of which MRP will not generate or adjust any planned orders, even if there are net requirements within that period. MRP still deletes a planned order, even if it is inside the time fence, if no demand is generated for that item. Time fences are often used with master scheduled items and are usually set to greater than or equal to the manufacturing lead time. MRP Required The MRP Required flag is set by the system to indicate whether this item has had changes made against it and will be replanned the next time you run net change MRP. Yes indicates that the item will be replanned; No indicates that it will not. Table 12.3 Lead Times Ï See “Net Change Materials Plan” on page 252.
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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
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Defining Control File Settings Sett
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Operation Reporting The reporting o
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• If the remainder is positive, t
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CHAPTER 10 Quality Management MFG/P
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Setting Up Quality Management Befor
Page 207 and 208: A comparative symbol (, =) and a nu
Page 209 and 210: Defining Sampling Patterns Define s
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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
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: Order Policy Description Order Modi
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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