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

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IV MFG/PRO USER GUIDE — MANUFACTURING CHAPTER 2 PRODUCT STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BOM Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alternate Structures/Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Phantoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Simulated BOM Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Setting Up a Product Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Related Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Floor Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Relationship with Configured Products . . . . . . . . . . . . . . . . . . . . . . . . . 21 Component Substitutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cumulative Lead Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engineering Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CHAPTER 3 ROUTINGS/WORK CENTERS . . . . . . . . . . . . . . . . . . . . . . . . . 25 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Work Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Work Center Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Standard Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Operation Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Routings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Alternate Routings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Work Center Routing Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Routing Cost Roll-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lead Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Operation Lead Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Manufacturing Lead Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Subcontract Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Yield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 CHAPTER 4 FORMULA/PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Defining Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CONTENTS V Defining Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Process/Formula Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 CHAPTER 5 CO-PRODUCTS/BY-PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . 51 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 More About Co-products and By-products . . . . . . . . . . . . . . . . . . . . . . 55 Co-product/By-product Work Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Setting Up a Co/By-product Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Setting Up Mix Variance Accounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Setting Up Sites and Locations for the Base Process . . . . . . . . . . . . . . 57 Setting Up Work Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Setting Up Product Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Setting Up Item Status Codes for the Base Process . . . . . . . . . . . . . . . 58 Setting Up an Item for the Base Process . . . . . . . . . . . . . . . . . . . . . . . . 58 Setting Up Items for Co-products and By-products . . . . . . . . . . . . . . . 59 Setting Up a Co/By-product Structure . . . . . . . . . . . . . . . . . . . . . . . . . 60 Setting Up Structures for Recyclable By-products . . . . . . . . . . . . . . . . 62 Setting Up Unit of Measure Conversion Factors . . . . . . . . . . . . . . . . . 64 Setting Up Alternate Base Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Setting Up Alternate Base Process Routings . . . . . . . . . . . . . . . . . . . . 64 Setting Up Definitions for Valid Substitute Items . . . . . . . . . . . . . . . . 65 Calculating Costs and Lead Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Allocating Costs to Co-products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Entering By-product Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Freezing By-product Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Rolling Up Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Calculating Average Costs for Co-products . . . . . . . . . . . . . . . . . . . . . 69 Defining the Average Cost Allocation Methods . . . . . . . . . . . . . . . . . . 70 Average Cost Accounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Rolling Up Lead Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Reviewing Product Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 MRP for Co-products/By-products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Planning for By-products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Page 1 and 2: User Guide Volume 3 MANUFACTURING P
Page 3: Contents ABOUT THIS GUIDE . . . . .
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
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Overview A base process is a manufa
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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
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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
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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
Page 101 and 102:
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
Page 107 and 108:
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
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.
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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
Page 137 and 138:
CHAPTER 7 Shop Floor Control The Sh
Page 139 and 140:
You can calculate employee efficien
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Times You can enter setup times, ru
Page 143 and 144:
You can review recorded downtime us
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Downtime Review recorded downtime b
Page 147 and 148:
CHAPTER 8 Advanced Repetitive Repet
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• Batches can overlap and visibil
Page 151 and 152:
Setting Up Advanced Repetitive Repe
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• 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
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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
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
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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
Page 199 and 200:
Operation Reporting The reporting o
Page 201 and 202:
• 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
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
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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
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Page 237 and 238:
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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
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
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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
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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
Page 289 and 290:
sources for MRP 241 System/Account
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