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

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260 MFG/PRO USER GUIDE — MANUFACTURING Ï See Chapter 12, “Material Requirements Planning,” on page 239. Tip Repetitive schedules are treated like Exploded orders. When manufacturing order operations overlap, the system smoothes the scheduled start and due dates to prevent the scheduled due date for one operation from occurring later than the due date for a subsequent operation. Schedule Discrepancies MRP calculates manufacturing order release dates using a manufacturing lead time that is based on an average order quantity defined in Item Planning Maintenance (1.4.7) or Item-Site Planning Maintenance (1.4.17). If the order quantities used in CRP calculations differ from this average quantity, CRP may schedule the start date for an order’s first operation before the release date for that order. When this occurs, a message displays to alert you of the conflict. You can resolve such conflicts by adjusting the order release or due date and rerunning CRP. Note Exceptions to the normal work week in the work center and shop calendars—for example, planned overtime—may also cause schedule discrepancies in CRP. CRP and Order Statuses CRP is normally executed for Planned and Firm Planned orders. For these orders, CRP explodes the standard item routing and schedules the operations to create work center/machine load. You can also choose to include orders with other statuses. For Exploded and Allocated orders, the work order routing is scheduled. For Released orders, only open operations are rescheduled. When you run CRP, all open operations for selected work orders are rescheduled. That means that if you have manually adjusted your operation start and stop dates, they will probably be changed unless you also adjusted the work order release and due date to match.
Generating Load Reports You can generate load reports by department, work center, or machine using the work center and department load inquiries and reports. CAPACITY REQUIREMENTS PLANNING 261 CRP determines load hours for a work center based on setup and run times. Queue, wait, and move times are excluded from load calculations. To include queue times in load calculations, set up separate operations for queue. CRP then considers these operations when calculating load. CRP determines the load an operation exerts on a work center using the following calculation: Operation Load = Setup Time + (Run Hours/Unit x Quantity Open) The quantity open for an operation is the order quantity minus any quantities reported complete. Note The system assigns the entire load for an operation to its scheduled start date. Even for operations with run times longer than one day, load is not spread between operation start and due dates. Reviewing Input and Output You can compare the planned input and output for a work center or machine with actual input and output using Input/Output Report (24.4) and Input/Output Inquiry (24.5). These functions help you evaluate a work center or machine’s response to planned loads. You can display planned and actual input and output in daily, weekly, or monthly periods. Planned Input Planned input is load on a work center or machine represented by work order operations scheduled to start in a reporting period. It is determined using the following calculation: Standard Setup + (Standard Run x Quantity Ordered)
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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
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A comparative symbol (, =) and a nu
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Defining Sampling Patterns Define s
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Type. Specify the type of testing t
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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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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 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: CAPACITY REQUIREMENTS PLANNING 259
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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