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

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56 MFG/PRO USER GUIDE — MANUFACTURING Fig. 5.4 General Work Flow for Co-products/ By-products Fig. 5.5 Setting up for Co-products/ By-products Co-product/By-product Work Flow Figure 5.4 shows steps for setting up and managing a typical operation involving a base process with co-products and by-products. Set Set up up co-product/by-product co-product/by-product operation. operation. Enter Enter co-product co-product demand. demand. Run Run MRP. MRP. Generate Generate joint joint order order set. set. Perform Perform work work order order accounting accounting close. close. Receive Receive products. products. Make Make shop shop floor floor control control entries. entries. Setting Up a Co/By-product Operation Figure 5.5 shows steps for setting up a typical operation for co-products and by-products. Each step is discussed in detail in the following sections. Set Set up up mix mix variance variance accounts. accounts. Set Set up up sites, sites, locations, locations, and and work work centers centers for for the the base base process. process. Set Set up up product product lines. lines. Set Set up up item item status status codes codes and and items items for for base base process, process, cocoproducts,products, and and by-products. by-products. Set Set up up product product structures structures for for co-products, co-products, by-products, by-products, and and recyclable recyclable by-products. by-products. Set Set up up UM UM conversion conversion factors. factors. Set Set up up alternate alternate base base processes processes and and their their routings. routings. Set Set up up definitions definitions for for valid valid substitute substitute items. items. Set Set up up costs costs and and lead lead times. times.
Setting Up Mix Variance Accounts If the quantity of a co-product received to stock differs from the quantity expected, a variance occurs. To properly account for such variances, called mix variances, a mix variance account must be established. Even if you do not plan to use the co-product/by-product features, a mix variance account must be established before any work orders can be generated. Mix/yield variance is the costed difference between the quantity received and scrapped for a product and its expected (order) quantity. The formula is as follows: Mix Variance = [Order Qty – (Received Qty + Scrapped Qty)] x Unit Cost Mix/yield variances are always calculated as the result of unplanned receipts because the expected (order) quantity is zero. 1 Set up mix variance accounts in Account Code Maintenance (25.3.13). 2 Verify that mix variance account numbers appear in the variances frame of the System/Account Control File (36.1). Mix variance amounts (if any) are updated on the affected co/by-product work order, and subtracted from the work-in-process (WIP) amount of the base process work order. A general ledger (GL) transaction is created debiting the mix variance account specified on the co/by-product work order and crediting the WIP account specified on the base process work order. The work order close procedure can be performed more than once on a work order, and the work order amounts are cumulative. The GL transaction is additive. Setting Up Sites and Locations for the Base Process Establish sites for the base process in Site Maintenance (1.1.13). A location is an area within a site. A site can have an unlimited number of locations. You can use the same location code for different sites. Use Location Maintenance (1.1.18) to set up locations for the base process. CO-PRODUCTS/BY-PRODUCTS 57
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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
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: More About Co-products and By-produ
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
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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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Fully Automatic Scheduling FORECAST
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Available-to-Promise FORECASTING/MA
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Generating Master Schedule Reports
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CHAPTER 12 Material Requirements Pl
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Sources of Demand MRP considers the
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Item Planning Data MATERIAL REQUIRE
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Order Policy Description Order Modi
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Time Fence MATERIAL REQUIREMENTS PL
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Component Effective Dates MATERIAL
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MRP Pegged Requirements MATERIAL RE
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MATERIAL REQUIREMENTS PLANNING 253
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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
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epetitive 154, 183-189 completions
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sources for MRP 241 System/Account
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