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

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274 MFG/PRO USER GUIDE — MANUFACTURING defining 47 manufacturing 17 product definition 7 Product Line Maintenance co-products/by-products 58 product lines co-products/by-products 58 Product Structure Code Maintenance 14 Product Structure Cost Report co-products/by-products 74 Product Structure Cost Roll-Up co-products/by-products 69 product structure Op field 20 Product Structure Maintenance co-products/by-products 61 lead time offset 109 planning bills 232 work order BOM 102 product structures 11–24 alternate 15 alternate routings 15 BOM codes 14 component quantities 17 configured products 18, 21 effective dates in 18 MRP use of 248 operation codes 19 phantoms 15 reference codes 17 repetitive 154 scrap 18 substitutions 21 type codes 19 used for multiple items 14 Production Line Maintenance 142 production lines 142 changeover time 145 schedules 149 shifts 144 productivity 133 profit margin forecasting 221 Pur/Mfg code MRP use of 244 Purchase Order Maintenance co-products/by-products 86 Purchase Order Receipts co-products/by-products 86 Q quality management 191–204 Certificate of Analysis Print 204 destructive testing 204 first article inspections 203 inspection 198 inspection site 193 inventory audits 202 inventory sampling 197 item specification 195 master specifications 194 procedures 196 process inspection 201 process validation 203 quality orders 197 quarantine 192 specifications 193 values for 194 test results 202 Test Results Maintenance 201 Quality Management Control File 193 Quality Order Delete/Archive 200 Quality Order Maintenance 198 Quality Order Results Entry 200 destructive testing 204 quality orders creating 198 deleting 200 entering results 200 inspection 198 quarantine 192 queues lead time component 37 operation input 164 output 164 reject 164 operation status 129 R rate variance advanced repetitive 167 Reason Codes Maintenance nonproductive labor 130 Recalculate Capacity Plan 258 effect on operation schedules 105 recyclable by-products 62 reference codes product structures 17 Regenerate Materials Plan 252 Reject Analysis Report 177 Reject Transaction 171 released work orders 101 releasing work orders 107
epetitive 154, 183–189 completions 188 consume forward/backward 185 contrast with advanced repetitive 136 cumulative orders 186 differences from advanced repetitive 184 milestone operations 187 picklists 155 calculation 156 setting up 184 transactions 186 reporting 187 scrap cost 189 Repetitive Control File 185 advanced 139 consume forward and backward 185 Next Picklist field 157 Repetitive Labor Transaction 188 test results 201 Repetitive module co-products/by-products 87 Repetitive Operations Accounting Report 189 Repetitive Picklist Calculation 155, 156 troubleshooting 157 Repetitive Picklist Delete 158 Repetitive Picklist Print 158 product structure Op field 20 Repetitive Picklist Transfer 155, 159 Repetitive Picklist Undo 158 repetitive picklists deleting 158 inventory transfer 159 printing 158 Repetitive Schedule Explosion co-products/by-products 87 Repetitive Schedule Maintenance co-products/by-products 87 Repetitive Schedule Update 153 repetitive schedules master production scheduling (MPS) 234 Repetitive Scrap Transaction 189 repetitive. See also advanced repetitive reports labor 132 reprinting picklists 109 Rework Analysis Report 177 Rework Transaction 172 rework work orders 95 rolling forecasts 207 routable work orders 97 Routing Cost Roll-Up 37 co-products/by-products 68 product structure Op field 20 yield totals 41 Routing Maintenance 34 co-products/by-products 61 overlap units 105 quality operations 201 run time 38 Routing Maintenance (Rate Based) run time 34, 38 Routing Update applying changes 32 routings 34–37 advanced repetitive requirements 146 alternate 36 co-products/by-products 81 defaults 36 defining 34 lead times and 27 quality management 201 site-specific defaults 36 uses of 26 work orders 101 Run Labor Transaction 171 run time 129 S safety stock 245 safety time MRP use of 247 sales history demand patterns cyclical 210 horizontal 210 seasonal 210 trend 210 forecasting use of 210 underlying patterns 210 Sales Order Control File Consume Forward field 226 Integrate with SA field 208 Sales Order Maintenance abnormal demand 225 consuming forecast 225 sales orders abnormal demand 225 demand 225 Sample by Expire Days Inquiry 197 Sample by Lot Interval Inquiry 197 Sampling Pattern Maintenance 197 Days to Expire field 197 lot interval 197 INDEX 275
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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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FORECASTING/MASTER SCHEDULE PLANNIN
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Forecast Methods FORECASTING/MASTER
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Copying and Combining Forecasts FOR
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Generating Reports FORECASTING/MAST
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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 and 284: Formula Maintenance 45 co-products/
Page 285: MPS. See master production scheduli
Page 289 and 290: sources for MRP 241 System/Account
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