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

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58 MFG/PRO USER GUIDE — MANUFACTURING Tip Item status codes are created and maintained in Item Status Code Maintenance (1.1.5). Setting Up Work Centers A work center is a production facility capable of performing a certain task. A work center might be a place, a machine or group of machines, a person or group of people. In MFG/PRO, work centers are the most basic units used for operation scheduling, capacity requirements planning, and cost determinations for GL transactions. In Work Center Maintenance (14.5), set up work centers by entering for each a unique work center code and a unique machine code. Setting Up Product Lines A product line is a group of similar items or products. At many companies, sales and operations are planned, reported, and analyzed by product line rather than by individual item or product. To establish a product line, use Product Line Maintenance (1.2.1). Setting Up Item Status Codes for the Base Process Base process items are never stocked in inventory. As a result, although base processes are entered as regular items, they are not processed as inventory items. Use item status codes to prevent any inventory transactions related to base process items. Only two transactions should be allowed for the base item: • ADD-PS, which occurs when the item is added to a product structure. • ADD-WO, which occurs when the item is added to a work order. Setting Up an Item for the Base Process 1 Create a base process item in Item Master Maintenance (1.4.1). Enter the unit of measure for each batch. Assign an item status that restricts inventory transactions. 2 Enter the following information in the Item Planning Data frame. Batch Qty. This is established in Formula Code Maintenance (15.1) or Process/Formula Maintenance (15.18). Plan Orders. Enter Yes.
Order Policy. Enter POQ or FOQ. MRP does not use LFL or OTO for base processes. Pur/Mfg Code. Enter M (manufactured) or leave blank. BOM/Formula. Leave blank. A base process item cannot refer to another BOM/Formula. Phantom. Enter No. Setting Up Items for Co-products and By-products Create items for co-products and by-products using standard procedures. For co-products, it is important to set the BOM/Formula field equal to a base process item number. In Item Master Maintenance (1.4.1), Item Planning Maintenance (1.4.7), or Item-Site Planning Maintenance (1.4.17), enter the following for each co-product and by-product of a given base process. Item Number. Enter an item number for the co-product or by-product. Planning Parameters. Normally, you accept default values for these fields. MRP does not use planning parameters for co-products. Instead, it uses the parameters of the base process. MRP does not plan the base process to satisfy demand for a by-product. Rather, it plans by-products using the conventional method. Pur/Mfg. Leave blank or enter M (manufactured) for co-products. Enter any value for by-products. BOM/Formula. Enter the item number for the base process normally used to produce this co-product or by-product. This field is used for planning, work orders, and cost roll-up. An item can be a by-product and have a normal BOM/Formula code. Note For items that are always by-products, BOM/Formula codes are optional. Entering the base process item number as the BOM/Formula code for by-products and co-products enables you to sort MRP Summary and Detail Reports by BOM/Formula code. Routing Code. This should be left blank in most cases. If a co-product has a preferred routing different from the base process routing, enter CO-PRODUCTS/BY-PRODUCTS 59
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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
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: Setting Up Mix Variance Accounts If
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
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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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