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Contents
List of Figures
Title and Copyright Information
Preface
Audience
Documentation Accessibility
Related Documents
Conventions
1
Overview to Shop Floor Control - Process Guide
1.1
System Integration
1.2
Features
1.3
Process Flow
1.4
Tables for Shop Floor Control
1.5
Types of Manufacturing
1.6
Enterprise Requirements Planning and Execution System
1.7
Sales Order Management System
1.7.1
Features of Sales Order Management
1.7.1.1
Simplicity
1.7.1.2
Flexibility
1.7.1.3
Adaptability
1.8
Procurement System
1.8.1
Features of Procurement
1.8.1.1
Simplicity
1.8.1.2
Flexibility
1.8.1.3
Adaptability
Part I Process Manufacturing
2
Overview to Process Manufacturing
2.1
Objectives
2.2
About Process Manufacturing
2.2.1
Blending, Filling, and Packaging
2.2.2
How Are Units of Measure Used?
2.2.3
Transactions in Shop Floor Control
3
Understand Work Orders
3.1
Overview
3.2
What Happens When You Attach an Ingredients List?
3.2.1
Intermediate Items
3.3
When Do You Attach Routing Instructions?
3.3.1
Outside Operations
3.4
When Do You Attach Co-/By-Products and Intermediates?
3.5
How Does the System Calculate the Start Date?
3.5.1
Fixed Lead Time
3.5.2
Variable Lead Time
3.6
What Is Shop Paperwork?
3.7
What Is Backscheduling?
3.8
Blending, Filling, and Packaging
4
Create Work Orders
4.1
Entering Work Order Headers
4.1.1
Processing Options
4.2
Attaching the Ingredients List Interactively
4.2.1
What You Should Know About
4.3
Attaching the Routing Instructions Interactively
4.3.1
Before You Begin
4.3.2
What You Should Know About
4.4
Attaching Co-Products and By-Products
4.4.1
What You Should Know About
4.4.2
Example: Feature Cost Percent
4.5
Attaching the Intermediate Items
4.6
Assigning Serial Numbers
4.6.1
Before You Begin
4.6.2
What You Should Know About
5
Process Work Orders
5.1
Overview
5.2
Run Order Processing
5.3
Printing a Summary of Process Orders
6
Understand Commitments
6.1
Understanding Commitments
7
Work with Commitments
7.1
Defining Commitment Rules
7.2
Defining Commitments at a Work Center Location
7.2.1
What You Should Know About
7.3
Managing Commitments for Grade and Potency Controlled Items
7.4
Creating Commitments for Potent Units
7.4.1
Processing Options
7.5
Reposting Work Order Commitments
7.5.1
Before You Begin
7.5.2
What You Should Know About
7.5.3
Processing Options
8
Understand Grade and Potency
8.1
About Grade and Potency
8.2
Grade and Potency Control
8.3
Lot Control Items
9
Understand Lot Processing
9.1
Overview
9.2
Creating Lots
9.3
Lot Status
10
Enter Lot Information
10.1
Overview
10.2
Entering Lot Information for Items
10.3
Entering Information for Lots
10.3.1
What You Should Know About
10.3.2
Processing Options
11
Work with Lot Availability
11.1
Viewing Lot Availability
11.1.1
What You Should Know About
11.1.2
Processing Options
11.2
Working with Lot Quantities
11.2.1
What You Should Know About
11.3
Working with Lot Activity Dates
11.4
Working With Lot Statuses (Release A9.3 Update)
11.4.1
What You Should Know About
12
View Lot Transactions
12.1
Overview
12.2
Printing Trace and Track Reports
12.3
Reviewing Trace and Track Information
12.3.1
What You Should Know About
12.3.2
Processing Options
12.4
Setting up Trace and Track Inclusion Rules
12.4.1
What You Should Know About
13
Reclassify Lots
13.1
Reclassifying Lots
13.2
Example: Types of Reclassifications
13.2.1
Before You Begin
13.2.2
What You Should Know About
13.2.3
Processing Options
14
Review Availability and Shortages
14.1
Overview
14.1.1
What You Should Know About
14.2
Defining Availability Calculations for a Branch
14.3
Reviewing Availability
14.3.1
Processing Options
14.4
Managing Shortage Information
14.4.1
Processing Options
14.5
Printing Shortages
14.5.1
What You Should Know About
14.5.2
Printing Ingredient Shortages
14.5.3
Printing All Shortages
15
Understand Issue Transactions
15.1
When Do You Issue Inventory?
15.2
How Do You Issue Inventory?
15.3
From Where Is Inventory Issued?
15.4
What Tables Store Data when Issuing Ingredients?
15.5
Where in the Process Do You Issue Inventory?
16
Issue Ingredients
16.1
Issuing Ingredients by Preflushing
16.1.1
Before You Begin
16.1.2
What You Should Know About
16.2
Issuing Ingredients Manually
16.2.1
What You Should Know About
16.2.2
Processing Options
16.3
Recording Ingredient Scrap
16.3.1
What You Should Know About
16.3.2
Processing Options
17
Schedule Work Orders
17.1
Overview
17.2
Where in the Process Do You Schedule Work Orders
17.3
Reviewing Work Order Information
17.4
Revising Work Order Information
17.4.1
Processing Options
17.5
Printing Scheduling Information for a Work Center
18
Work with Hours and Quantities
18.1
Overview
18.2
Where in the Process Do You Enter Hours and Quantities
18.3
Entering Hours and Quantities Manually
18.3.1
Processing Options
18.4
Entering Hours and Quantities through Payroll Time Entry
18.4.1
Before You Begin
18.4.2
What You Should Know About
18.4.3
Processing Options
18.5
Updating Hours and Quantities
18.5.1
Before You Begin
18.5.2
What You Should Know About
18.6
Reviewing Hours and Quantities Transactions
19
Complete Work Orders
19.1
Overview
19.2
Completing Work Orders without Backflushing
19.2.1
Processing Options
19.3
Completing a Work Order through Backflush
19.3.1
Example: Feature Cost Percent
19.3.2
Before You Begin
19.3.3
What You Should Know About
19.3.4
Processing Options
19.4
Completing Partial Quantities on a Work Order
19.4.1
What You Should Know About
19.5
Processing Work Orders through Super Backflush
19.5.1
What You Should Know About
19.5.2
Processing Options
19.6
Processing a Work Order Using Quantity at Operation
19.6.1
What You Should Know About
19.7
Completing a Work Order with Serialized Components
19.7.1
What You Should Know About
20
Work with Shop Floor Workbench
20.1
Overview
20.2
Performing a Super Backflush from within Shop Floor Workbench
20.2.1
Processing Options
21
Revise the Status of a Work Order
21.1
Overview
21.1.1
What You Should Know About
21.2
Changing the Status of a Work Order to "Closed"
21.2.1
Processing Options
21.3
Purging a Work Order
21.3.1
Before You Begin
21.3.2
What You Should Know About
21.3.3
Processing Options
22
Review Information
22.1
Reviewing Ingredient Information
22.1.1
Before You Begin
22.1.2
What You Should Know About
22.1.3
Processing Options
22.2
Reviewing Cost Information
22.2.1
What You Should Know About
22.2.2
Processing Options
22.3
Reviewing Work Order Status
22.4
Reviewing Process Orders
22.5
Reviewing Ingredient Comparison
22.5.1
Before You Begin
22.5.2
What You Should Know About
23
Process Kanbans
23.1
Overview
23.1.1
One-Phase
23.1.2
Two-Phase
23.1.2.1
Inventoried Items Processing
23.1.2.2
Manufactured Processing
23.1.2.3
Manufactured Processing - Phantom Item
23.1.2.4
Externally Supplied Processing
23.2
Processing Kanban Consumption by Item
23.2.1
Processing Options
23.3
Processing Kanban Supply by Item
23.3.1
Processing Options
23.4
Processing Kanban Status Override
23.4.1
Processing Options
24
Print Ingredient and Operation Reports
24.1
Overview
24.1.1
What You Should Know About
Part II Repetitive Manufacturing
25
Overview to Repetitive Manufacturing
25.1
Objectives
25.2
About Repetitive Manufacturing
26
Enter Rates
26.1
Entering Rates
26.1.1
Before You Begin
26.1.2
What You Should Know About
26.1.3
Processing Options
27
Schedule Rates
27.1
Scheduling Items on a Production Line
27.1.1
Processing Options
27.2
Sequencing Rates by Classification Scheme or Manually
27.2.1
Processing Options
27.3
Reviewing Production Across Lines
27.3.1
Processing Options
28
Complete Rates
28.1
Completing Rates
28.1.1
Before You Begin
28.1.2
What You Should Know About
28.1.3
Processing Options
29
Review Information
29.1
Reviewing Production Status
29.1.1
Processing Options
29.2
Reviewing Production History
29.2.1
Processing Options
29.3
Reviewing Line Dispatch List
29.3.1
Processing Options
30
Process Kanbans
30.1
Overview
30.1.1
One-Phase
30.1.2
Two-Phase
30.1.2.1
Inventoried Items Processing
30.1.2.2
Manufactured Processing
30.1.2.3
Manufactured Processing - Phantom Item
30.1.2.4
Externally Supplied Processing
30.2
Processing Kanban Consumption by Item
30.2.1
Processing Options
30.3
Processing Kanban Supply by Item
30.3.1
Processing Options
30.4
Processing Kanban Status Override
30.4.1
Processing Options
31
Close Rates
31.1
Closing Rates
Part III System Setup
32
Overview to System Setup
32.1
Objectives
32.2
About System Setup
32.2.1
Before You Begin
33
Set Up Work Order Codes
33.1
Setting Up Work Order Codes
33.1.1
Processing Options
34
Set Up Manufacturing Information
34.1
Setting Up Standard Procedures
34.1.1
What You Should Know About
34.1.2
Processing Options
34.2
Setting Up Employee Labor Rates
34.2.1
Processing Options
34.3
Setting Up the Shop Floor Calendar
34.3.1
What You Should Know About
34.4
Setting Up Manufacturing Constants
34.5
Setting Up Work Order Activity Rules
34.6
Setting Up Work Centers
34.6.1
Before You Begin
34.6.2
What You Should Know About
34.7
Setting Up Resource Units
34.7.1
Before You Begin
34.7.2
What You Should Know About
34.7.3
Processing Options
34.8
Setting Up Line and Item Relationships
Part IV Processing Options
35
Process Manufacturing Processing Options
35.1
Manufacturing Work Order Entry (P48013)
35.2
Generate and Print Work Orders (P31410)
35.3
User-Defined Code Entry (P41092)
35.4
Work Order Repost (P3190)
35.5
Lot Master Revisions (P4108)
35.6
Lot Availability (P41280)
35.7
Lot Tracing and Tracking (P41203)
35.8
Item Reclassifications (P4116)
35.9
Part/Ingredient Availability (P30205)
35.10
Parts List Inquiry (P3121)
35.11
Item Shortage Workbench (P3128)
35.12
Shortage Revisions (P3118)
35.13
Work Order Component Shortage List (P31418)
35.14
Work Order Inventory Issues (P31113)
35.15
Component Scrap Transactions (P31116)
35.16
Manufacturing Scheduling Workbench (P31225)
35.17
Work Order Time Entry (P311221)
35.18
Manufacturing/Payroll Time Entry (P061181)
35.19
Work Order Completion - Full (P31114)
35.20
Release Backorders (P42117)
35.21
Super Backflush (P31123)
35.22
Manufacturing Scheduling Workbench (P31225)
35.23
Work Order Purge (P4801P)
35.24
Where Used Inquiry (P30201)
35.25
Item Availability (P41202)
35.26
Supply & Demand (P4021)
35.27
Item Ledger - Costs (P4111)
35.28
Kanban Consumption/Supply (P3157)
35.29
Kanban Status Override (P3163)
35.30
Work Order Activity Rules - Equipment (P4826)
35.31
Work Center Information - Z File (P3006Z)
35.32
Work Order Hours and Quantity - Z File (P311221Z)
36
Repetitive Manufacturing Processing Options
36.1
Enter/Change Rate Schedule (P3109)
36.2
Line Scheduling Workbench (P3153)
36.3
Line Sequencing Workbench (P3156)
36.4
Schedule Review (P3152)
36.5
Rate Transactions Workbench (P3119)
36.6
Super Backflush (P31123)
36.7
Work Order Time Entry (P311221)
36.8
Production Status (P31226)
36.9
Production History (P31227)
36.10
Line Dispatch List (P3159)
36.11
Kanban Consumption/Supply (P3157)
36.12
Kanban Status Override (P3163)
36.13
Batch Rate Close by Date (P3191)
37
System Setup Processing Options
37.1
User-Defined Code Entry (P41092)
37.2
Generic Rate/Message Records Program (P00191)
37.3
Generic Rate/Message Records Program (P00191)
37.4
Work Center Resource Units (P3007)
37.5
Kanban Size Calculation (P30450)
A
Appendix A - Lead Times
A.1
Introduction to Lead Times
A.2
Work Order Start Dates
A.2.1
Fixed Lead Time
A.2.2
Variable Lead Time
A.3
Operation Start and Due Dates
A.3.1
Fixed Lead Time
A.3.2
Variable Lead Time
A.4
Overlapping Operations
A.5
Overlapping and Concurrent Operations
A.6
Calculating Lead Times
A.6.1
Level Lead Time
A.6.1.1
Calculation
A.6.2
Manufacturing Lead Time
A.6.2.1
Calculation
A.6.3
Cumulative Lead Time
A.6.3.1
Calculation
A.6.4
Per Unit Lead Time
A.6.4.1
Calculation
B
Appendix B - Functional Servers
B.1
Overview
C
Import Mass Data into Manufacturing Systems
Index
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