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

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26 MFG/PRO USER GUIDE — MANUFACTURING Tip Routings are required if you use the Repetitive module. Introduction To manufacture an item or product, it is always necessary to complete one or more activities or operations. The listing of required operations is called a routing, which basically defines the process needed to make the item. If a product structure is the list of ingredients in a recipe, a routing is the directions. The routing operations indicate the machines, expected times, and instructions for completing specific tasks. For example, in manufacturing sunglass lenses, there might be a routing with four operations with instructions to grind, polish, tint, and coat the lenses. These would be separate operations because they involve different machines, tools, skills, and tasks. In the Shop Floor Control and Repetitive modules, you record actual statistics on what happens during production. This might include how long it takes to produce items, what quantities are produced and by whom, whether there was downtime or some other interruption to production, and so on. These statistics are always recorded against a routing operation. In addition to providing manufacturing instructions, routings contain data used as a standard for evaluating production, operation times, yield percentages, the number of machines normally needed, and so on. The department and work center codes associated with routing operations link actual production results with capacity planning, cost accounting, payroll, and other programs. Specifically, routings can be used to: • Calculate the cost of producing an item • Calculate the time it takes to manufacture an item • Schedule operations for work orders and repetitive schedules • Backflush components in the Repetitive module • Calculate work center and department load • Print routings for work orders • Obtain operation feedback using programs in Shop Floor Control and Repetitive
Some of these capabilities are especially important when there is a combination of medium to long operation lead times, a significant labor component of cost, many operations, and bottleneck operations. Routing operations may not be necessary when: • Item lead times are very short. • Total item costs consist mostly of material and overhead and the labor component is relatively small. • Capacity can be easily managed. • Repetitive module is not used. Figure 3.1 summarizes the steps required to set up routings. Set Set up up shop shop calendar. calendar. Define Define departments. departments. Define Define work work centers. centers. Define Define standard standard operations. operations. Set Set up up routings. routings. Important Work centers and operations work in conjunction with the shop calendar, which determines the work days and hours for the plant. Use Calendar Maintenance (36.3.5) to add work center-specific calendars. Before you begin defining the elements needed to create routings, make sure you set up the shop calendar. ROUTINGS/WORK CENTERS 27 Fig. 3.1 Routing Setup Work Flow Ï See User Guide Volume 11: Manager Functions for more information on calendars.
Page 1 and 2: User Guide Volume 3 MANUFACTURING P
Page 3 and 4: Contents ABOUT THIS GUIDE . . . . .
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: CHAPTER 3 Routings/Work Centers Thi
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
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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
Page 109 and 110:
Scheduled Work Orders Scheduled wor
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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
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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
Page 129 and 130:
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
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
Page 173 and 174:
• Cumulative Order Close (18.22.1
Page 175 and 176:
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
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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
Page 199 and 200:
Operation Reporting The reporting o
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• 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
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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
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
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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
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Page 247 and 248:
Page 249 and 250:
Generating Master Schedule Reports
Page 251 and 252:
CHAPTER 12 Material Requirements Pl
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Sources of Demand MRP considers the
Page 255 and 256:
Item Planning Data MATERIAL REQUIRE
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Order Policy Description Order Modi
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Time Fence MATERIAL REQUIREMENTS PL
Page 261 and 262:
Component Effective Dates MATERIAL
Page 263 and 264:
MRP Pegged Requirements MATERIAL RE
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MATERIAL REQUIREMENTS PLANNING 253
Page 267 and 268:
Message Meaning Shipment Past Due I
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CHAPTER 13 Capacity Requirements Pl
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CAPACITY REQUIREMENTS PLANNING 259
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Generating Load Reports You can gen
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Adjusting Capacity and Load If a wo
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Numerics 1.1.5 58 1.1.13 57 1.2.1 5
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A Account Code Maintenance co-produ
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defined 53 demand for 77 material r
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Formula Maintenance 45 co-products/
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MPS. See master production scheduli
Page 287 and 288:
epetitive 154, 183-189 completions
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sources for MRP 241 System/Account
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