2 Overview to Process Manufacturing
This chapter contains these topics:
2.1 Objectives
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To understand the structure of a work order
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To understand co-products, by-products, and intermediates
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To understand the different ways you can reclassify an item
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To understand how availability is calculated
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To understand how to blend and split lots
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To understand the difference between backflush and super backflush
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To prioritize work at each work center or cell
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To understand how the Shop Floor Control system interfaces with the Payroll system
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To learn how to record completions and release backorders
2.2 About Process Manufacturing
Process manufacturing produces products, such as liquids, fibers, powders, or gasses. Pharmaceuticals, foodstuffs, and beverages are typical examples of process products and represent a significant share of the manufacturing market. Products such as these are usually manufactured by a two-step process:
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Mixing or blending
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Filling or packaging
Intermediate steps, such as curing, baking, or additional preparation, can also occur.
Process manufacturing uses recipes or formulas and resources or ingredients. These resources can either be consumed or produced during the manufacturing process. The products that the process produces are called co-products and by-products. In a process recipe or formula, the quantity of a component can vary according to its grade or potency.
The different types of processing in process manufacturing are:
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Batch
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Continuous
In batch processing, a product is usually made in a standard run or lot size determined by vessel size, line rates, or standard run length. Items made this way are typically scheduled in short production runs due to the life cycle of the product after its completion. Typical items might be pharmaceuticals, foods, inks, glues, oil or chemical products, or paints. Co-products and by-products might be generated during batch processing.
In the continuous or flow environment, production is typically of an extended period, utilizing dedicated equipment that produces one product or product line with slight variations. This method of manufacture is characterized by the difficulty of planning and controlling quantity and quality yield variances. Typical items might be petroleum-based products or distilled sea water. Co-products and by-products are generally more prevalent in continuous processing than in batch processing.
In addition, strategies similar to discrete manufacturing, such as repetitive or any of the "to-orders," might be employed to drive the process. Usually, both batch and continuous processing methods require extensive record keeping and recording of quality and tolerance values during the process, as well as strict adherence to lot tracing and tracking.
Process manufacturing consists of the following:
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Understanding work orders
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Creating work orders
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Processing work orders
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Understanding commitments
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Working with commitments
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Understanding grade and potency
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Understanding lot processing
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Entering lot information
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Working with lot availability
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Viewing lot transactions
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Reclassifying lots (optional)
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Reviewing availability and shortages (optional)
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Understanding issue transactions
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Issuing ingredients
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Scheduling work orders
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Working with hours and quantities
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Completing work orders
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Revising the status of a work order
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Reviewing information (optional)
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Processing kanbans (optional)
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Printing ingredient and operation reports (optional)
2.2.1 Blending, Filling, and Packaging
JD Edwards World has enhanced the Manufacturing systems to manage the manufacturing of bulk blended and filled products. These enhancements include accounting for gains and losses, recording ambient and standard quantity variations, and the reconciliation of bulk products in tanks.
2.2.2 How Are Units of Measure Used?
Not all processes are planned, scheduled, or produced in their primary unit of measure. To accommodate this, full unit of measure capabilities are allowed throughout the Shop Floor Control system.
Most entry programs have a unit of measure next to the quantity fields, and the unit of measure is stored in the database tables, along with the quantities. The system uses three fields in the Item Master table, Component Unit of Measure, Production Unit of Measure, and Primary Unit of Measure, throughout shop floor as defaults in entry forms. The Primary Unit of Measure must be the smallest of the three units of measure. In addition, if intermediates exist for an operation, the intermediate can be any valid unit of measure as long as the conversion is set up.
2.2.3 Transactions in Shop Floor Control
The following graphic illustrates the transactions throughout the Shop Floor Control system. You will see this graphic throughout this guide, with different areas highlighted, to indicate where you are in the process.
Figure 2-1 Shopr Floor Control System Transactions
Description of "Figure 2-1 Shopr Floor Control System Transactions"