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

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72 MFG/PRO USER GUIDE — MANUFACTURING Table 5.3 Co-product Costs Allocated by Price and Receipt Quantity Table 5.3 shows how costs are allocated by receipt quantity and price. Rcpt Rcpt Qty Price Price Price/Rcpt Item UM Conv Qty (KG) Price (KG) Qty Allocation P1 KG 1.00 50.00 50.00 2.00 2.00 100 38.48% P2 KG 1.00 30.00 30.00 4.00 4.00 120 48.15% P3 LT 0.50 40.00 20.00 1.00 2.00 40 15.38% Average Cost Accounting WIP costs are the sum of component costs and shop floor control costs, and are reduced by the cost of co-products and by-products received plus reject quantity. These transactions do not update GL or current costs. Costs are averaged by taking the costs accumulated in WIP and adjusting the costs of items in inventory received from WIP. MFG/PRO does this in two steps. 1 Co-products and by-products are received from work orders into inventory using their current average costs. 2 Average GL costs and average current costs are re-averaged based on the costs accumulated for an item’s work order when the work order is closed. Co-product costs are re-averaged based on any WIP costs accumulated by this process. Costs can be accumulated when the Work Order Accounting Close program closes any work order operations that have not been closed. Costs are not re-averaged for quantities received to sites other than the work order (WIP) site. Receipts are handled in two ways depending on whether the work order status is closed or not closed. • Not closed. Co-product costs are not re-averaged. Items are received to the work order WIP site using current average costs. These costs are deducted from WIP. If quantities are received at a different site, they are received at the work order WIP site using current average costs, then transferred to the indicated site.
• Closed. Co-product costs are re-averaged. Items are received to the work order WIP site using current average costs. These costs are deducted from WIP. The re-averaging process takes into account quantities received during previous receipt transactions for the same work order. If quantities are received to a different site than the work order WIP site, it is likely that the inventory quantity on hand is less than the quantity received. This increases the chance that some of the costs cannot be allocated and re-averaged at the WIP site and that costs will be booked to the discrepancy account for the base process. To maximize the accuracy of average costs and reduce costs booked to discrepancy accounts, the following should be emphasized. • Complete reporting of co-product and by-product quantities when all quantities for all items are completed. • Setting of work order status to Closed when receipt quantities are reported. • Running of Work Order Accounting Close on a regular basis to process recently closed work orders. The cost change taken to inventory is bounded as follows. • Upper limit. Greater of the existing average cost or calculated work order unit cost. • Lower limit. Lesser of the existing average cost or calculated work order unit cost. Rolling Up Lead Times The lead time to produce the co-products resulting from a base process is the same as the lead time for the base process. Cumulative Lead Time Roll-Up (13.12.14) copies the manufacturing lead time and the cumulative lead time for a base process to its co-products. Typically, the roll-up program is run for all items, not just those involved in co-product/ by-product structures. By-product lead times are not derived from the base process, but from roll-ups of regular product structures and routings. Enter by-product lead times in Item Planning Maintenance (1.4.7) or Item-Site Planning Maintenance (1.4.17). CO-PRODUCTS/BY-PRODUCTS 73 Tip Re-averaging of co-product costs is time-sensitive. The greater the time between receipt and close, the greater the probability that some of the products produced have been consumed.
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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
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CHAPTER 1 Introduction to Manufactu
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Formula/Process The Formula/Process
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CHAPTER 2 Product Structures This c
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If a single company manufactures th
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Alternate Structures/Formulas An it
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Setting Up a Product Structure Defi
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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: Allocation by Price The percentage
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
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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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MFG/PRO 9.0 User Guide Volume 3: Manufacturing - QAD.com

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