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

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272 MFG/PRO USER GUIDE — MANUFACTURING Labor Feedback by Work Order 126 test results 201 lead times 246 changing 40 composite 22 co-products/by-products 73 cumulative 22 manufacturing 40 move 38 operation 38 queue 37 run 38 scheduling production lines 151 setup 37 subcontract 38 wait 38 Line Allocation Inquiry 143 Line Allocation Maintenance 143 Line Changeover Maintenance 145 Line Schedule Maintenance co-products/by-products 87 Line Schedule Workbench 149 deleting sequence records 152 lead times 151 multiples 150 production quantities 151 sequence numbers 150 Line Utilization Report 152 lines production 142 load reporting 261 Lot Actual Bill Inquiry co-products/by-products 85 lot control co-products/by-products 85 Lot Where-Used Inquiry co-products/by-products 85 Low Level Code Update 251 M manufacturing lead time 37, 40 yield 41 master specifications 194 master production scheduling (MPS) 228–237 available-to-promise (ATP) 231 computer-assisted scheduling 230 creating schedule 228 fully automatic 229 fully manual scheduling 229 items for 228, 243 master schedule orders 234 MRP use of 240 multilevel 232 multilevel scheduling techniques 233 planning bills 232 production forecast 233 repetitive schedules 234 seasonality 235 Master Schedule Detail Inquiry 237 Master Schedule Detail Report 237 Master Schedule Order Maintenance 93, 229, 234 Master Specification Maintenance 194 material requirements planning (MRP) 239–256 action messages 253 by-products 74 co-products/by-products 59, 74 action messages 76 base processes 74, 75 co-products 74, 77 planned order reports 77 planned work orders 76 summary reports 77 demand 240 demand sources 241 forecasting 222 item planning data 243 items not seen by 248 lead times and 246 Line Schedule Workbench 151 multiple base processes 74 output 253 past due forecasts 227 pegged requirements 251 repetitive explosion 155 scrap factor in 18 shop calendar 255 substitute items 21 supply 240 supply sources 241 yield 41 messages advanced repetitive warnings 166 MRP action 253 method change variance (MCV) 168 milestones operations 33, 147 mix variance accounts co-products/by-products 57, 81 modifying work order bill 106 work order routings 107 work orders 106
MPS. See master production scheduling (MPS) MRP Control File 242 MRP Detail Inquiry 251 MRP Detail Report 251 co-products/by-products 59, 77 MRP Summary Report co-products/by-products 59 MRP. See material requirements planning (MRP) Multiple Work Order Release/Print 97, 107 co-products/by-products 81 Multiple Work Order Status Change co-products/by-products 76 multiplicative factors forecasting 217 N Net Change MRP 252 non-milestone backflushing 138 nonproductive labor 130 Non-Productive Labor Feedback 130 Non-productive Labor Feedback 171 O one time only (OTO) 245 Operation Complete Transaction 131 operation status 129 Operation Cost Calculation 189 Operation Cost Inquiry 189 Operation Cost Report 189 Operation Move Transaction queue status 129 Operation Transaction Inquiry 177 operations automatic completion 131 capacity 33 changes to 32 lead time 38 lead time calculation 38 load 261 milestone 33, 147 product structure 19 scheduling 105, 258 standard 32 status 129 complete 129 hold 130 queue 129 running 129 setup 129 subcontract 40 yield 41 order modifiers 245 order pegging 251 order policies MRP use of 244 OTO 245 P parent items product structures 12 performance efficiency 133 productivity 133 utilization 133 period order quantity (POQ) 244 phantoms 15 global 16 identifying 16 local 16 products evolving into 16 use-up logic 16 picklists processing flow 155 repetitive 155 reprinting 109 work order 109 plan orders parameter 243 Planned Order Reports co-products/by-products 77 Planned Purchase Order Approval 255 Planned Repetitive Schedule Approval 255 Planned Work Order Approval 255 co-products/by-products 76 planned work orders 99, 255 planning bills for 232 capacity requirements 257 master production schedule (MPS) 228 material requirements 239 POQ 244 Post Accumulated Usage Variances 174 printing picklists 158 Procedure Maintenance 196 Process Definition Copy 48 Process Definition Maintenance 34, 47 co-products/by-products 61 run time 38 process inspection 201 Process/Formula Maintenance 48 co-products/by-products 60, 66, 83 processes 47–49 batch quantity 48 copying 48 INDEX 273
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User Guide Volume 3 MANUFACTURING P
Page 3 and 4:
Contents ABOUT THIS GUIDE . . . . .
Page 5 and 6:
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
Page 13 and 14:
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
Page 19 and 20:
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
Page 27 and 28:
Alternate Structures/Formulas An it
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
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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
Page 47 and 48:
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
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
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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
Page 163 and 164:
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
Page 179 and 180:
Rate Variance All transactions cons
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Repetitive Transaction Programs The
Page 183 and 184:
The component backflush logic looks
Page 185 and 186:
Scrap Transaction Use Backflush Tra
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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
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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
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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
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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: FORECASTING/MASTER SCHEDULE PLANNIN
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 and 282: defined 53 demand for 77 material r
Page 283: Formula Maintenance 45 co-products/
Page 287 and 288: epetitive 154, 183-189 completions
Page 289 and 290: sources for MRP 241 System/Account
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