This chapter contains the following topics:
Section 9.3, "Entering Work Order Headers for Production Controlled Items"
Section 9.4, "Attaching Parts Lists for Production Controlled Items"
Section 9.5, "Attaching Routing Instructions for Production Controlled Items"
Section 9.6, "Processing Work Orders for Production Controlled Items"
Section 9.7, "Issuing Material Manually for Production Controlled Items"
Section 9.8, "Completing Work Orders for Production Controlled Items"
After you enter production controlled items, bills of material, and routings, you can use programs in the JD Edwards EnterpriseOne Shop Floor Management system to complete the manufacture of production controlled items. The JD Edwards EnterpriseOne Shop Floor Management system enables you to manage and track manufacturing work orders.
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Note: The JD Edwards EnterpriseOne Shop Floor Management system supports discrete manufacturing only for production controlled items. |
The JD Edwards EnterpriseOne Shop Floor Management system integrates with JD Edwards EnterpriseOne Project Manufacturing to support production controlled items.
The process flow for Shop Floor Management for Project Manufacturing uses many of the same programs as JD Edwards EnterpriseOne Shop Floor Management. The process flow consists of these steps:
Enter work order (P48013).
Attach routing instructions and parts list (R31410).
Perform work order commitment processing.
Check availability (P30200).
Issue inventory (P31113).
Schedule work.
Record hours and quantities (P311221).
Post completions to inventory (P31114).
The JD Edwards EnterpriseOne Shop Floor Management system does not support the following functionality for production controlled items:
Rate schedules.
Process manufacturing.
Cost details.
The system does not provide cost detail inquiry by production number.
Projects in the JD Edwards EnterpriseOne Engineer to Order system.
Before you work with production controlled items in JD Edwards EnterpriseOne Shop Floor Management, you must ensure that appropriate JD Edwards EnterpriseOne Shop Floor Management system setups are in place to support production controlled items.
This section provides an overview of work order header entry for production controlled items, lists a prerequisite, and discusses how to enter work order headers for production controlled items.
To enter a work order header, you identify an item, its branch/plant and quantity, and the requested date for the work order. You use the Manufacturing Work Order Processing program (P48013) to create and manage work orders.
The Production Number field and Query by Example (QBE) line appear in the detail grid of the Work With Manufacturing Work Orders form. The Production Number field also appears on the Addl Details 1 tab of the Work Order Details form. You can modify the production number on a work order only from the Manufacturing Work Order Processing program.
The system does not support a negative order quantity on a work order for a production controlled item.
The system enables changing the production number in a work order header. When revising a production number for a work order, the system checks for an attached parts list, attached routing, material issues, processed time entry records, and a partial or full completion. The system provides a warning message if any of these activities have occurred.
You can change the production number on a work order at any work order status, even a closed or completed work order.
When you copy a work order, the production number on the existing work order becomes the default production number on the new work order. When you copy a discrete work order, you can change both the item number and the production number on the new work order.
Work orders created from sales orders with a W line type contain the production number information from the sales order detail line. If you change the production number in the sales order detail line, the system does not update the production number on the related work order. Likewise, a change to the production number on a work order does not update the production number in the sales order detail line.
The system supports configured and kit items. The Production Number field is editable in the Manufacturing Work Order Processing program when you attempt to change the work order. For configured items, the system persists the production number to all related orders, both parent and child orders. You use the Production Number Workbench program (P34403) because the work order may be a child work order within a kit or configured item.
The production number is accessible to the Work Order Parts List (P3111), Work Order Routing (P3112), Work Order Completions (P31114), Work Order Print (R31415), and Super Backflush (P31123) programs. The system does not carry production number information forward to any other programs or functionality in the JD Edwards EnterpriseOne Shop Floor Management system.
Production number information from the work order header passes to inventory for maintaining the on-hand quantity in the Item Location Tag File table (F41021T).
You can use the Work Order Mass Update program (P48714) to change the status of discrete manufacturing work orders that contain production controlled items. The Work Order Mass Update program does not include the Production Number field, so you cannot search by or update production numbers. You can use the Production Number Reassignment program (P34404) to update production numbers on work orders.
The system supports creating and updating work orders for production controlled items through electronic data interchange (EDI). The system uses the Outbound Work Order Header table (F4801Z1).
Before you enter work order headers for production controlled items, you must set the processing options for your version of the Manufacturing Work Order Processing program.
This section provides an overview of attachment of parts lists for production controlled items, lists a prerequisite, and discusses how to attach parts lists for production controlled items.
You attach a parts list after you enter a work order header. You use the Work Order Parts List program (P3111) to enter parts lists manually.
The Production Number field appears in the header of the Work Order Parts List form. The system does not store the production number in the Work Order Parts List table (F3111).
You create a parts list from the beginning on the Work Order Parts List form. You can attach a parts list to a work order using the Copy BOM and Copy From WO options in the Form menu of the Work Order Parts List form.
The system assigns each item in the work order parts list the same production number as that of the work order.
You use the Prod No. Location option in the Row menu of the Work Order Parts List form to access the Production Number On Hand form and review parts information stored in the F41021T table. You can select the row of on-hand quantity by production number, lot, and location. The system returns only the selected location and lot to the work order parts list. The system does not automatically enter or control the quantities of the items selected on the Production Number On Hand form. You must enter the correct order quantity on the Work Order Parts List form.
The JD Edwards EnterpriseOne Shop Floor Management system does not support substitute items for production number control. A production number is associated with a specific end item. Consequently, selecting a substitute item requires that you associate a different production number to the substitute item number. Substitute items must have production numbers designated that differ from the production number of the original item.
Before you attach parts lists for production controlled items, you must set the processing options for your version of the Work Order Parts List program.
Access the Work Order Parts List form.
To attach parts lists for production controlled items:
Enter the parts list information required for the order.
Ensure a value exists in the Order Quantity field.
Select a row for an item.
Select the Prod No. Location option from the Row menu.
Select an available component for the parts list and click Select.
Click OK on the Work Order Parts List form.
This section provides an overview of attachment of routing instructions for production controlled items, lists a prerequisite, and discusses how to attach routing instructions for production controlled items.
You attach routing instructions after you enter a work order header. You use the Work Order Routing program (P3112) to enter routing instructions manually.
The Production Number field appears in the header of the Work Order Routing form. The system does not store the production number in the Work Order Routing table (F3112).
You create routing instructions from the beginning on the Work Order Routing form. You can also attach routing instructions to a work order using the Copy by Item and Copy By WO options in the Form menu of the Work Order Routing form.
Before you attach routing instructions for production controlled items, you must set the processing options for your version of the Work Order Routing program.
This section provides overviews of work order processing for production controlled items, parts availability information for production controlled items, and work order commitment processing for production controlled items, lists a prerequisite, and discusses how to run the order processing program for production controlled items.
After you enter a work order header, you can use the Order Processing batch program (R31410) to attach the parts list and routing instructions for each work order header. If you attach the parts list and routing instructions interactively, you can use the Order Processing batch program to generate and print the shop paperwork.
When you run the Order Processing program to attach a parts list and routing, the system may also create a purchase order for outsourcing. You can manually revise the system-generated parts list.
The system does not support the consolidation of work orders based on production numbers. You can consolidate work orders for general inventory with demand from other sales orders.
The JD Edwards EnterpriseOne Shop Floor Management system does not support substitute items for production number control. A production number is associated with a specific end item. Consequently, selecting a substitute item requires that you associate a different production number with the substitute item number. Substitute items must have production numbers designated that differ from the production number of the original item.
When you copy a work order, the production number of the existing work order becomes the default production number of the new work order. When you copy a discrete work order, you can change both the item number and the production number of the new work order.
The system stores the production number in the Work Order Master Tag File table (F4801T). The Order Processing program contains the Production Number field in the data selection so that you can run order processing by production number.
The Work Order Print program (R31415) contains the production number from the work order header.
As you process work orders, the system does not change the production number associated with any previous activity. For example, you issue material for a work order with production number PMPN1. If you change the production number of the work order to PMPN2, the system does not change the production number of the material issue related to production number PMPN1. Any additional material issues related to the work order reduce the inventory associated with production number PMPN2.
You can determine the availability of the parts that are required to make a certain quantity of a parent item before you create a work order. Use the Part Availability program (P30200) to determine the availability of the parts.
The Part Availability program only shows a summary of what is available. If you must review parts availability by production number, use the Production Number Workbench program.
A commitment is a reservation for the parts that are needed by a work order. You can define commitments by branch or work center. You can change commitments manually or through a batch program.
When you attach a parts list to a work order header, the system creates commitments for the required quantity of each component. The commitment reserves the material for a particular work order. The type of commitment that the program creates (hard or soft) depends on which commitment option you specified in the Manufacturing Constants program (P3009).
When you run the Order Processing program, the system performs commitments specific to the work order. Production controlled items have no commitment-based functionality in the JD Edwards EnterpriseOne Shop Floor Management system. The system supports the standard process for commitments. The production number is used only to label inventory.
Although the system recommends inventory allocation based on production controlled inventory, with no visibility to individual project commitments, the system can overcommit and make the wrong recommendations.
Work order scheduling does not contain any specific functionality for production controlled items.
This section provides an overview of the manual issue of material for production controlled items, lists prerequisites, and discusses how to issue material manually for production controlled items.
You use the Work Order Inventory Issues program (P31113) to manually issue material that is associated with a work order.
The Production Number field and Query by Example (QBE) line appear in the detail grid of the Work With Work Order Inventory Issue form. The Production Number field also appears in the header of the Inventory Issue Revisions form.
Before issuing inventory, you can review on-hand availability of production controlled items by item number, production number, branch/plant, location, and lot serial number. To access the Production Number On Hand form, select the Prod No. Location option from the Row menu of the Inventory Issue Revisions form. The Production Number On Hand form displays relevant information from the F41021T table.
During work order inventory issues, the production number is an attribute of the inventory and not an attribute of the order. The production number is an attribute of the work order when submitting direct inventory transactions.
When you issue inventory for production controlled items, the system restricts you from issuing production controlled inventory in excess of what is currently on hand for a location in the F41021T table.
You use production number related inventory when issuing production controlled inventory to the work order. When the required quantity of the specific production controlled or generic inventory is not available, the system enables you to consume the remaining required quantity from another production number. You consume the remaining required inventory for production controlled items using either blind or interactive mode.
You set the Production Number On Hand Consumption processing option for the Work Order Inventory Issues program to blank to activate blind inventory issues.
When the Work Order Inventory Issues program is run to issue inventory blindly for production controlled items, the algorithm:
Allocates generic inventory.
Generic inventory is inventory for items that are not production controlled and, therefore, are not associated with a production number.
Allocates inactive production numbers.
These are production controlled items that have the Production Number Status set to I in the Production Number Master File table (F34401).
Allocates orphaned production numbers.
These are production controlled items that are no longer associated with a supply or demand.
Allocates production number by end item demand date.
This is the demand date of a production controlled item that is the farthest in the future. The system then replans the end item to meet the demand.
If you set the Production Number On Hand Consumption processing option to a value of 1 to interactively issue inventory, then the system displays the Select Inventory for Consumption form. You select the specific inventory and quantity to consume.
You must complete the Secondary Quantity field if the item you are issuing is set up with dual units of measure in the item master record.
After you select the inventory to consume, you can access the Select Inventory to Consume form to review or redistribute inventory. You must have a value in the Issues field to access the Prod No. Consumption option in the Row menu.
During inventory issues, the system passes production number information only to component items that are set up as production number controlled in the Item Master (P4101) or Item Branch (P41026) programs. If you issue a non-production controlled component item to the work order, the system does not label the item with the production number.
The system uses the production number from the work order to maintain the on-hand quantity in the F41021T table. The system also updates the Item Ledger File table (F4111) with corresponding production numbers for transactions.
If the system is set up to perform work order blind issues using backflush or the Super Backflush program (P31123). The system then follows the blind consumption logic by default.
Use the Select Multiple Locations form to select inventory by lot, location, and item branch/plant. You use the Select Multiple Locations form to split the required quantity for material issue between two or more locations based on availability.
In the case of unplanned issues, you cannot specify the production number during work order issues. The system uses the production number of the work order if the unplanned line is a production controlled item. If the unplanned line is for a nonproduction controlled item, then the system issues generic inventory.
For direct inventory transactions using the Inventory Issues (P4112), Inventory Adjustments (P4114), and Inventory Transfers (P4113) programs, a reversal of production-controlled inventory transactions increases or decreases the on-hand quantity of the production number used in the transactions. For inventory issues using the Work Order Inventory Issues program (P31113), a reversal of work order issues for a production-controlled item increases the on-hand quantity of the production number inventory in the F41021T table for the production number on the work order (Release 9.1 Update).
The on-hand quantity for production controlled inventory in the F41021T table goes to zero but does not go negative. All on-hand quantity for production controlled items must be consumed before the on-hand quantity of generic items goes negative.
If the Negative Quantity on Hand processing option on the Edits tab of the Work Order Inventory Issues program is set to blank to allow negative on-hand quantity for an item, then discrepancies may occur in the F41021T table because quantities do not go negative for production controlled items.
You can manage production number inventory through the Production Number Workbench program before issuing inventory.
Before you issue material manually for production controlled items, you must:
Set the processing options for your version of the Work Order Inventory Issues program.
Set the Production Number On Hand Consumption processing option on the Edits tab of the Work Order Inventory Issue program.
This section provides overviews of hours and quantities for production controlled items, work order completions for production controlled items, backflush for production controlled items, and super backflush for production controlled items, lists prerequisites, and discusses how to complete work orders for production controlled items.
As you produce the items on a work request, you must record the hours spent on production and the number of items that were completed in that time.
If the estimates are reasonably accurate, you can use the Super Backflush program (P31123) to have the system automatically enter the standard values at the pay point operations in the routing instructions. Otherwise, you can have all employees individually enter their time and the quantities that they completed. You use the Hours and Quantities program (P311221) to charge actual hours and quantities to a work order.
The actual hours and quantities you charge to a work order do not have associated production number information.
When you finish producing discrete items on the shop floor, you must record the completions to inventory. The completion transactions that you enter in the JD Edwards EnterpriseOne Shop Floor Management system update the item quantity records in the JD Edwards EnterpriseOne Inventory Management system.
You use the Work Order Completions (P31114) program to record completions. If you issued material for a work order manually, you perform a completion without backflush.
For production controlled items, you assign a production number to work order completions to track supply.
Before performing a full or partial work order completion, you can review the on-hand availability of production controlled items by item number, production number, branch/plant, location, and lot serial number. To access the Production Number On Hand form, select the Prod No. Location option from the Form menu of the Work Order Detail Completion form. The Production Number On Hand form displays relevant information from the F41021T table.
The Production Number field and QBE line appear in the detail grid on the Work With Work Order Completions form. The Production Number field also appears in the header of the Work Order Detail Completion form, but it is disabled.
Only component items with the Production Number Controlled option enabled on the Additional Info. tab of the Item/Branch Plant Info. form have the production number information passed to inventory during completions.
You can set the Work Order Lot and Location Defaults processing option on the Sales Orders tab of the Work Order Completions program to override the lot number with the production number during work order completions.
You can set the Memo Lot Field Defaults processing option on the Sales Orders tab of the Work Order Completions program to display the production number in the Memo Lot 1 field during work order completions. If you set the processing option to display the production number in the Memo Lot 1 field, then you can use the Lot field for a serial number during work order completions. (Release 9.1 Update)
To complete the work order quantity for multiple locations, access the Select Multiple Locations form (W42053B) from the Work Order Completion Detail form.
When reversing a work order completion, the system consumes the reversal quantity from the production number on the work order. The system issues an error if the production number quantity is not available. If generic inventory is not available during a completions reversal, the system uses blind or interactive consumption of production numbers to consume inventory.
You cannot use the Production Number Reassignment program (P34404) because the production controlled inventory is gone. A work order completions reversal updates the F41021T table for the related production number.
The system uses the production number from the work order to maintain the on-hand quantity in the F41021T table. The system also updates the F4111 table with corresponding production numbers for transactions.
When you complete a work order, the system labels inventory with the production number. When running commitments, the system looks at all inventory, both generic and production controlled, using the normal commitment process.
You can manage production number inventory through the Production Number Workbench program after you complete work orders.
If you did not manually issue material for a work order, you perform a completion with backflush. If you use backflushing, you report the issue transactions at completion or at operations that are defined as pay point operations for super backflush. For backflush to occur, an item must be set up with an issue code that enables the item to be backflushed.
You use the Work Order Completions (P31114) program to record completions with backflush.
The system enables you to consume the remaining required quantity from production controlled items only when the required quantity of generic inventory is not available. You consume the remaining required inventory using either blind or interactive mode.
You set the Production Number On Hand Consumption processing option on the Work Order Completions program to blank to activate blind inventory issues.
When the Work Order Completions program is run to issue inventory blindly for production controlled items, the algorithm:
Allocates generic inventory.
Generic inventory is inventory for items that are not production controlled and, therefore, are not associated with a production number.
Allocates inactive production numbers.
These are production controlled items that have the Production Number Status set to I in the Production Number Master File table (F34401).
Allocates orphaned production numbers.
These are production controlled items that are no longer associated with a supply or demand.
Allocates production number by end item demand date.
This is the demand date of a production controlled item that is the farthest in the future. The system then replans the end item to meet the demand.
If you set the Production Number On Hand Consumption processing option to a value of 1 to interactively complete work order issues through backflush, then the system displays the Select Inventory for Consumption form. You select the specific inventory and quantity to consume.
You must complete the Secondary Quantity field if the item you are completing through backflush is set up with dual units of measure in the item master record.
After you select the inventory to consume, you can access the Select Inventory to Consume form to review or redistribute inventory. You must have a value in the Quantity field to access the Prod No. Consumption option in the Row menu.
If the Backflush processing option on the Edits tab of the Work Order Completions program is set to perform blind work order issues, then the system follows the blind consumption logic by default.
The on-hand quantity for production controlled inventory in the F41021T table does not go negative. Therefore, if the on-hand quantity for the production controlled item is insufficient, then the F41021T table shows zero on-hand quantity and the Item Location File table (F41021) shows a negative on-hand quantity. All on-hand quantity for production controlled items must be consumed before the on-hand quantity of generic items goes negative.
If the Negative Quantity on Hand processing option on the Edits tab of the Work Order Completions program is set to blank to allow negative on-hand quantity for an item, then discrepancies may occur in the F41021T table because quantity does not go negative for production controlled items.
You can use the Super Backflush program (P31123) to enter completed and scrapped quantities by operation and employee.
The Production Number field and QBE line appear in the detail grid on the Work With Order Numbers form (W31123B). The Production Number field also appears in the header on the Super Backflush form (W31123A), but the field is disabled.
If the system is set up to perform work order blind issues using the Super Backflush program, then the system follows the blind consumption logic by default.
The system uses the production number from the work order to maintain the on-hand quantity in the F41021T table. The system also updates the F4111 table with corresponding production numbers for transactions.
Before you complete work orders for production controlled items, you must:
Set the processing options for your version of the Work Order Completions (P31114) program.
Set the Work Order Lot and Location Defaults processing option on the Sales Orders tab of the Work Order Completions program.
Set the Memo Lot Field Defaults processing option on the Sales Orders tab of the Work Order Completions program (Release 9.1 Update).
If you want to perform a completion with backflush for production controlled items, you must:
Set the Backflush processing option on the Edits tab of the Work Order Completions program.
Set the Production Number On Hand Consumption processing option on the Edits tab of the Work Order Completions program.
Set the Work Order Issues Version (P31113) processing option on the Versions tab of the Work Order Completions program.
If you want to perform a completion with super backflush for production controlled items, you must set the processing options for your version of the Super Backflush program (P31123).