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

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270 MFG/PRO USER GUIDE — MANUFACTURING cyclical pattern 210 D date work order 103 delete/archive forecast detail 223 quality orders 200 work orders 123 demand patterns sales history 210 Department Maintenance 29 departments account codes 28 accounts 28 capacity 258 labor capacity 28 labor feedback by 127 work center 28 destructive testing 204 Detail Forecast Delete/Archive 223 Detail Forecast Maintenance 215 modifying results 215 dispatching work orders 120 Down Time by Reason Report shop floor control 131 Down Time Report 131 Down Time Transaction 171 downtime 129 due dates work order 103 E effective dates product structures 18 efficiency 133 employee 127 Employee Maintenance 127 labor rate 127 employees efficiency 127 labor feedback 126 End Eff Days field 142 engineering change orders 23 engineering effectivity 23 expense work orders 96 expensed items 20 exploded work orders 100 explosion advanced repetitive schedules 154 F FAS. See final assembly (FAS) feature codes configured product 18 final assembly (FAS) work orders 96 firm planned work orders 99 first article inspections 203 fixed order quantity (FOQ) 244 floor stock 20 expensed items vs 20 FOQ (Fixed Order Quantity) 244 Forecast Maintenance 224 Forecast Worksheet Maintenance 224 forecasting 205–228 adding methods 213 alpha factor 212 calculating forecasts 214 combining criteria templates 219 consumption 225 forward and backward 226 copying criteria templates 219 forecasts 217 results 219 creating detail records 214 creating forecasts 206 creating forecasts manually 215 criteria templates 208, 214 detail records loading into summary forecast file 222 loading methods 223 horizon 207 material requirements planning (MRP) 222 methods 211 best fit 211 classic decomposition 212 creating custom 213 double exponential smoothing 211 double moving average 211 simple regression 212 Winter’s linear exponential smoothing 211 modifying results 215 multiplicative factors 217 net forecast calculation 226 new items 220 rolling forecasts 207 simulations 207 single items 220 summary forecast file 222 Formula Code Maintenance 14, 46 Formula Copy 47
Formula Maintenance 45 co-products/by-products 63 lead time offset 109 work order 102 formulas 43–47 batch size 46 batch type 46 co-product/by-product 47 copying 47 defining 45 defining BOM/Formula code 46 MRP use of 248 setup for 44 used for multiple items 14 freezing costs by-products 67 G general ledger (GL) period end 122 H horizon forecasting 207 horizontal pattern 210 I Input/Output Inquiry 261 Input/Output Report 133, 261 Integrate with SA field effect on forecasting 208 inventory audits 202 Inventory Control File picking logic 107 work order 109 Inventory Detail Report auditing items 203 inventory sampling 197 Issues–Unplanned floor stock 20 issuing work order components 110 Item Cost Maintenance co-products/by-products 68 Item Master Maintenance 154 base process item 58 co-products/by-products 59, 68 planning parameters 243 Item Planning Maintenance BOM code 14 co-products/by-products 59 MRP use of 243 phantoms 16 Pur/Mfg code 97 routing code 36 Item Specification Maintenance 195 Item Status Code Maintenance 58 co-products/by-products 58 Item Substitution Maintenance 21 co-products/by-products 65, 84 items expensed 20 key 108 master scheduled 228, 243 planning parameters 243 specifications for 195 Item-Site Cost Maintenance co-products/by-products 68 Item-Site Planning Maintenance 154 BOM code 14 co-products/by-products 58, 59 MRP use of 243 phantoms 16 routing code 36 J joint order sets 78 printing 81 releasing 81 reviewing 81 K key items work orders 108 L labor 31 advanced repetitive transactions 171 backflushing automatically 147 nonproductive 130 reporting feedback 126 reports 132 down time 133 input/output 133 transactions 132 utilization and efficiency 133 labor feedback departments 127 employees 126 item quantities 127 test results 201 work centers 127 Labor Feedback by Employee 126 Labor Feedback by Work Center 126 INDEX 271
Page 1 and 2:
User Guide Volume 3 MANUFACTURING P
Page 3 and 4:
Contents ABOUT THIS GUIDE . . . . .
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CONTENTS V Defining Processes . . .
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CONTENTS VII Lead Time Calculations
Page 9 and 10:
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
Page 31 and 32:
equired, consider changing the comp
Page 33 and 34:
Relationship with Configured Produc
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Assembly or Component Lead Time Sun
Page 37 and 38:
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
Page 87 and 88:
ecord for its base process. This de
Page 89 and 90:
When a planned purchase order is ap
Page 91 and 92:
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
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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
Page 119 and 120:
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
Page 125 and 126:
Subcontract Operations Work orders
Page 127 and 128:
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
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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
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
Page 191 and 192:
Using Scheduled Orders You can hand
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If there is no WIP item number ente
Page 195 and 196:
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
Page 213 and 214:
Conducting Process Inspections When
Page 215 and 216:
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
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Page 227 and 228:
Page 229 and 230:
Copying and Combining Forecasts FOR
Page 231 and 232: FORECASTING/MASTER SCHEDULE PLANNIN
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 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: defined 53 demand for 77 material r
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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