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

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This document contains proprietary information that is protected by copyright. No part of this document may be photocopied, reproduced, or translated without the prior written consent of QAD Inc. The information contained in this document is subject to change without notice. QAD Inc. provides this material as is and makes no warranty of any kind, expressed or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. QAD Inc. shall not be liable for errors contained herein or for incidental or consequential damages (including lost profits) in connection with the furnishing, performance, or use of this material whether based on warranty, contract, or other legal theory. Some states do not allow the exclusion of implied warranties or the limitation or exclusion of liability for incidental or consequential damages, so the above limitations and exclusion may not be applicable. PROGRESS ® is a registered trademark of Progress Software Corporation. Windows is a trademark of Microsoft Corporation. MFG/PRO ® is a registered trademark of QAD Inc. Copyright © 1999 by QAD Inc. 78-0449A QAD Inc. 6450 Via Real Carpinteria, California 93013 Phone (805) 684-6614 Fax (805) 684-1890
Contents ABOUT THIS GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 What Is in This Guide? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Other 9.0 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Online Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 QAD Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Windows Keyboard Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Character Keyboard Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CHAPTER 1 INTRODUCTION TO MANUFACTURING. . . . . . . . . . . . . . . . . . . . 7 Product Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Routings/Work Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Formula/Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Co-products/By-products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Work Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Shop Floor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Advanced Repetitive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Repetitive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Quality Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Forecasting/Master Schedule Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Material Requirements Planning (MRP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Capacity Requirements Planning (CRP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Page 1: User Guide Volume 3 MANUFACTURING P
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 and 26: 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
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
Page 81 and 82:
Rolling Up Costs Roll up lower-leve
Page 83 and 84:
Allocation by Price The percentage
Page 85 and 86:
• 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
Page 97 and 98:
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
Page 103 and 104:
• Schedule operations with Capaci
Page 105 and 106:
Creating Work Orders Work orders ar
Page 107 and 108:
Table 6.2 lists work order type cod
Page 109 and 110:
Scheduled Work Orders Scheduled wor
Page 111 and 112:
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
Page 117 and 118:
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
Page 129 and 130:
Example Ten phantoms are in stock.
Page 131 and 132:
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
Page 137 and 138:
CHAPTER 7 Shop Floor Control The Sh
Page 139 and 140:
You can calculate employee efficien
Page 141 and 142:
Times You can enter setup times, ru
Page 143 and 144:
You can review recorded downtime us
Page 145 and 146:
Downtime Review recorded downtime b
Page 147 and 148:
CHAPTER 8 Advanced Repetitive Repet
Page 149 and 150:
• Batches can overlap and visibil
Page 151 and 152:
Setting Up Advanced Repetitive Repe
Page 153 and 154:
• PO Shipper Receipt (5.5.5.5) Wh
Page 155 and 156:
production lines. To set up multipl
Page 157 and 158:
is 700 units per shift. If a second
Page 159 and 160:
Milestone and Non-Milestone Operati
Page 161 and 162:
In the first, there is a primary st
Page 163 and 164:
Whenever you create or modify a seq
Page 165 and 166:
Creating Repetitive Schedules A rep
Page 167 and 168:
The schedule explodes automatically
Page 169 and 170:
The Net Available is the material a
Page 171 and 172:
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
Page 191 and 192:
Using Scheduled Orders You can hand
Page 193 and 194:
If there is no WIP item number ente
Page 195 and 196:
CHAPTER 9 Repetitive The Repetitive
Page 197 and 198:
Defining Control File Settings Sett
Page 199 and 200:
Operation Reporting The reporting o
Page 201 and 202:
• 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
Page 209 and 210:
Defining Sampling Patterns Define s
Page 211 and 212:
Type. Specify the type of testing t
Page 213 and 214:
Conducting Process Inspections When
Page 215 and 216:
Use inventory sampling patterns to
Page 217 and 218:
CHAPTER 11 Forecasting/Master Sched
Page 219 and 220:
6 Load the detail forecast records
Page 221 and 222:
FORECASTING/MASTER SCHEDULE PLANNIN
Page 223 and 224:
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
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 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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