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

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14 MFG/PRO USER GUIDE — MANUFACTURING Tip The system automatically creates BOM codes for parent items that exist in the item master file when adding product structures and formulas. BOM Codes Sometimes, a single product structure or formula can produce more than one kind of product. Example A company uses the same formula for a beverage or a cheese, but depending on how it is processed and aged, different products result. In this case, it does not make sense to define the formula with respect to one specific product. In another case, one product can be produced with several different product structures or formulas. Example A computer workstation is assembled in different countries around the world. Several different product structures use slightly different components produced by different manufacturers. No matter which product structure is used, the end product is functionally equivalent. Depending on where the product is manufactured, one structure may be more favorable as a result of cost differences due to price and/or tax considerations. In both cases, enter product structures and formulas by using a product structure/formula—or bill of material (BOM)—code as the parent item instead of an item number. Use two programs to set up BOM codes. • Product Structure Code Maintenance (13.1) • Formula Code Maintenance (15.1) BOM codes and item numbers are entirely independent. You can use the same product structure or formula for multiple items, and any one of several product structures or formulas to make the same item. When an item number and its BOM code are the same, they are automatically linked. If an item’s BOM code is blank, the item number is used as the BOM code. When they are different, you can change the BOM code in Item Planning Maintenance (1.4.7) or Item-Site Planning Maintenance (1.4.17).
Alternate Structures/Formulas An item can use a product structure that is defined for a BOM code different from the item number. After you have defined a BOM code and a product structure or formula, link it to an item based on how it will be used. • If the structure/formula should be the default for an item, update the BOM code in Item Master Maintenance (1.4.1) or Item Planning Maintenance (1.4.7). The system uses this BOM code for MRP, work orders, repetitive manufacturing, and costing. • If the structure/formula should be the default for an item at a particular site, update the BOM code in Item-Site Planning Maintenance (1.4.17). The system uses this BOM code for MRP, work orders, repetitive manufacturing, and costing for an item at a site. This overrides the BOM code set up at the item level. • If the structure/formula should be available as an alternate for an item at any site, use Alternate Structure Maintenance (13.15) to link the BOM code with an item. You can then change the BOM code on a work order to this alternate structure/formula. • If the structure/formula should be available as an alternate for an item at a specific site when a specific routing is used, use Alternate Routing Maintenance (14.15.1) to link a BOM code and routing code to an item-site. You can then change the BOM code on a work order to this alternate structure/formula when using the specified routing code. Phantoms Sometimes engineering drawings and bills define transient product items that exist independently for a relatively short time and are not stocked. Instead, they are immediately consumed by higher-level products. These are called phantom structures. PRODUCT STRUCTURES 15
Page 1 and 2: User Guide Volume 3 MANUFACTURING P
Page 3 and 4: Contents ABOUT THIS GUIDE . . . . .
Page 5 and 6: CONTENTS V Defining Processes . . .
Page 7 and 8: CONTENTS VII Lead Time Calculations
Page 9 and 10: CONTENTS IX Common Transaction Data
Page 11 and 12: CONTENTS XI Maintaining Master Sche
Page 13 and 14: What Is in This Guide? 2 Windows Ke
Page 15 and 16: QAD Web Site or MFG/PRO users with
Page 17 and 18: Navigation Commands User Menu F6 Ct
Page 19 and 20: CHAPTER 1 Introduction to Manufactu
Page 21 and 22: Formula/Process The Formula/Process
Page 23 and 24: CHAPTER 2 Product Structures This c
Page 25: If a single company manufactures th
Page 29 and 30: Setting Up a Product Structure Defi
Page 31 and 32: equired, consider changing the comp
Page 33 and 34: Relationship with Configured Produc
Page 35 and 36: Assembly or Component Lead Time Sun
Page 37 and 38: CHAPTER 3 Routings/Work Centers Thi
Page 39 and 40: Some of these capabilities are espe
Page 41 and 42: Account Type Use Burden Usage Var E
Page 43 and 44: Machines. Enter the number of machi
Page 45 and 46: Yield %. Enter the order percentage
Page 47 and 48: Planning Maintenance (1.4.7) or Ite
Page 49 and 50: Work Center Routing Standards Somet
Page 51 and 52: If you examine this formula, severa
Page 53 and 54: Set the work center labor and burde
Page 55 and 56: CHAPTER 4 Formula/Process The Formu
Page 57 and 58: The Formula/Process module works in
Page 59 and 60: BOM/Formula as an alternate using A
Page 61 and 62: Use this frame to specify which scr
Page 63 and 64: CHAPTER 5 Co-products/ By-products
Page 65 and 66: Overview A base process is a manufa
Page 67 and 68: More About Co-products and By-produ
Page 69 and 70: Setting Up Mix Variance Accounts If
Page 71 and 72: Order Policy. Enter POQ or FOQ. MRP
Page 73 and 74: Qty Type. Enter B for batch, P for
Page 75 and 76: To set up a structure for a recycla
Page 77 and 78:
Only a base process can have altern
Page 79 and 80:
Although prune juice is a significa
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Rolling Up Costs Roll up lower-leve
Page 83 and 84:
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
Page 89 and 90:
When a planned purchase order is ap
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Accessing and Modifying Joint Order
Page 93 and 94:
Mix Variance Acct. Enter the accoun
Page 95 and 96:
Backflush Calculation Methods Speci
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Receiving Unplanned Items Use Unpla
Page 99 and 100:
(Supplier) Schedule Update from MRP
Page 101 and 102:
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
Page 109 and 110:
Scheduled Work Orders Scheduled wor
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Planned Bills Bill created Routings
Page 113 and 114:
Released A released order is like a
Page 115 and 116:
• 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
Page 121 and 122:
Creating Picklists After you releas
Page 123 and 124:
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
Page 133 and 134:
Closing Work Orders To close a work
Page 135 and 136:
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
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
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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
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
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Defining Sampling Patterns Define s
Page 211 and 212:
Type. Specify the type of testing t
Page 213 and 214:
Conducting Process Inspections When
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Use inventory sampling patterns to
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CHAPTER 11 Forecasting/Master Sched
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6 Load the detail forecast records
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FORECASTING/MASTER SCHEDULE PLANNIN
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Forecast Methods FORECASTING/MASTER
Page 225 and 226:
Page 227 and 228:
Page 229 and 230:
Copying and Combining Forecasts FOR
Page 231 and 232:
Page 233 and 234:
Generating Reports FORECASTING/MAST
Page 235 and 236:
Page 237 and 238:
Page 239 and 240:
Page 241 and 242:
Fully Automatic Scheduling FORECAST
Page 243 and 244:
Available-to-Promise FORECASTING/MA
Page 245 and 246:
Page 247 and 248:
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
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CHAPTER 13 Capacity Requirements Pl
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CAPACITY REQUIREMENTS PLANNING 259
Page 273 and 274:
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
Page 287 and 288:
epetitive 154, 183-189 completions
Page 289 and 290:
sources for MRP 241 System/Account
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