Maintaining Production Orders and Production Schedules

This chapter provides an overview of production orders (IDs) and production schedules, and discusses how to:

• Create production IDs.

• Generate production ID splits.

• Create production schedules.

• View production transaction history.

• Reschedule production.

Understanding Production IDs and Production Schedules

PeopleSoft Manufacturing's flexible model enables you to define, maintain, and track production by discrete batches or by production schedules. Production IDs can be used when it's necessary to track information using discrete orders or batches. Production schedules can be used when you want to manage production by day or shift. Alternatively, you can simply backflush an item within a production area even though a schedule has not been previously established, and the system automatically creates the supporting production schedule for you.

You can also use production IDs to create rework orders to track material, machine, and labor costs associated with the rework production. Teardown orders use production IDs to track costs associated with tearing down an end item into its component parts.

When you defined the production areas for the manufacturing items, you indicated whether you wanted to track production at a detailed level using production IDs, or at a summary level using production schedules. Production IDs also enable you to report intermediate completions at various operations in an item's manufacturing process. In addition, production IDs enable you set up any operation on the item's routing as a subcontracted operation.

If you use production schedules, you can create multiple schedule quantities per shift. You enter quantities for each day of the week, and the system determines the start date when the production schedule is added. This enables you to sequence production throughout the day.

If you are using PeopleSoft Supply Planning, you'll generate production ID and production schedule recommendations for regular production when you create the plan and schedule production. PeopleSoft Supply Planning sends recommendations to PeopleSoft Manufacturing in the form of messages.

You can accept and process recommendations (planning messages) to add new production or to apply changes to existing production. The planning messages that recommend changes to existing production include:

Important! PeopleSoft Supply Planning does not recommend creating rework or teardown production. Create rework and teardown production IDs manually using PeopleSoft Manufacturing.

Before you create production IDs and production schedules, you need to determine the type of production. The following sections review production types and provide an overview of the production creation process—from generating planned production to scheduling production IDs and production schedules.

See Also

Completing Operations and Recording Scrap

Production Types

When you manufacture items, you may need to perform additional work on a completed end item that has already been moved out of production and into stock. You might need to do this to correct a defect in the end item, convert the end item to a different end item, implement an engineering change, tear down an end item into its component parts, or for any purpose other than the normal build of an end item from its production bill of material (BOM).

PeopleSoft Manufacturing provides three production types:

Production Statuses

Every production ID and production schedule has a status that indicates where the production ID or production schedule is in the production cycle. These statuses are used throughout PeopleSoft Manufacturing.

Entered

The system recognizes a production ID's quantity, start date, and due date, but the order has no operation list or component list. In addition, the system creates a display-only output list for production with the status Entered. If production is for a single output item, an output list is generated with the end item listed as the primary item.

You can:

• Change the production order's status from Entered to Firmed or Released using the Production ID Maintenance component, the Production ID Status Change page, or the Production Schedule Status Change page.

• Record end item completions and scrap for Entered orders if you release production using the Record Completions/Scrap component.

• Select an option at the business unit level to release production IDs automatically, to prompt you when releasing production IDs, or to not release production IDs automatically.

Firmed

A Firmed production ID or production schedule has a quantity, start date, and due date, but the BOM and routing are frozen and the component and operation lists exist. In addition, the output list also exists and can be changed. You cannot generate a picking plan for a Firmed order.

You can:

• Change the production status from Firmed to Released using the either the Production ID Maintenance component, the Production Schedule Maintenance component, the Production ID Status Change page, or the Production Schedule Status Change pages.

• Change the order from Firmed to Entered using the same pages.

  Record end item completions and scrap for Firmed orders if you release production using the Record Completions/Scrap component.

• Select an option at the business unit level to release production IDs automatically, to prompt you when releasing production IDs, or to not release production IDs automatically.

If you change the production start quantity or the production end quantity, the system recalculates the component requirements accordingly. If the production ID or production schedule contains multiple outputs such as primary items, co-products and by-products, the system also recalculates new output quantities.

In addition, if you're using operation yield, the system then readjusts starting or ending quantities for single output and multiple output production.

You can enter either a new start quantity or a new end quantity, but not both.

If a new routing code or revision is specified or the due date of production is changed, you can recreate the component and operation lists based on the new information associated with the production ID.

If a rework production ID is added and a rework BOM and routing have been defined, the routing is copied to create an operation list. Additionally, the item to be reworked is added automatically to the component list with the kit issue method. An output list is created with the rework item as the primary output.

If a teardown production ID is added, a component list is created with the teardown item as the component. The system assigns the kit issue method to the item to be torn down. If there are any additional components, the system issues them using the issue method set for each item on the production area and item level. If you have previously defined a teardown routing, it is copied to create an operation list. An output list is created based on either the component list of another production ID or the teardown components designated on the item's production BOM.

Released

In the Released status, the production has a component list, an operation list, and an output. All of these can be modified. Additionally, each operation's start date, due date, and time are determined. Once released, changing a production ID can result in the deletion of the existing component list and operation list. The lists are then re-added, based on the new information associated with the production ID.

If you change the production start quantity or production end quantity, the system recalculates the component requirements accordingly. If the production ID or production schedule contains multiple outputs (primary items, co-products and by-products), the system recalculates new output quantities.

For rework production IDs, the system creates a component list with the reworked end item as a component. The scheduled quantity is the same as the production ID quantity.

If you have created a rework BOM for the item, the system copies that to the component list as well. If additional material is needed to complete the rework, you can manually add the items to the component list. The system issues the additional components using the issue method set for each item at the production area and item level.

If you have created a rework routing, the system copies it to the operation list. If there is no rework routing, the system does not create an operation list for rework production, but you can manually create one. An output list is created with the rework item as the only output.

You can:

• Generate a picking plan.

• Record completions and scrap.

• Modify the production start quantity or production end quantity.

• Add or change by-products for production.

• Change the status from Released to Firmed or Entered, except for a production ID with subcontracted operations if a purchase order has been generated against the production ID.

In Process

When you have recorded production transactions such as issuing or consuming components and recording completions, scrap, or actual hours, the system automatically changes the production status to In Process. You can only change the text, the scheduling method, the production quantity, and the production ID's start or due date and time, depending on the scheduling method.

You can modify the production start quantity or production end quantity for a production ID or production schedule in the In Process status after production has been started.

• If you increase or decrease the production start or production end quantity, the system recalculates the component requirements accordingly.

  If the production ID or production schedule contains multiple outputs (primary items, co-products and by-products), the system recalculates new output quantities.

• If you decrease the production start or production end quantity, the system verifies that you are not decreasing the order quantity to less than what has already been reported as completed or scrapped.

  You receive warning messages if components have been over-issued or over-consumed based on the new order quantity.

In either case, the system adjusts the component scheduled quantities to reflect the new order quantity and marks the production ID as changed so that PeopleSoft Supply Planning reschedules the operations during the next planning run.

You can also:

• Generate production ID splits for production IDs with a status of In Process.

• Change In Process orders back to Released or another prior status if any completion quantities (at an operation or to stock) have been completely reversed.

  To do this, you must reverse all end item completions and scrap, return components to stock, and reverse all actual hour recordings to correct completions or actual hours errors that have been reported against a particular production ID.

You cannot modify operation yields once the order is in process.

Note. You cannot change the production quantity if the production ID has a subcontracted operation and you've generated a purchase order for the ID.

Pending Complete

The Pending Complete status indicates that the scheduled production start or production end quantity has been completed or production for the day and shift has been completed, and you have selected the Production Completed check box on the Complete Production page in the Record Completions/Scrap component.

Complete

To change production to the Complete status, the scheduled quantity must be finished and you must have run the Close Production process to close the production ID or production schedule to any material movement. After an order is in the Complete status, you cannot record any operation or end item completions or any additional component consumption or scrap.

Note. Production must be in the In Process or Pending Complete status before you can change it to Complete.

Closed for Labor

The system sets the Closed for Labor status when you run the Close Production process to close the production ID or production schedule to any additional actual labor or machine hour recording. You can change the production status Closed for Labor from In Process, Pending Complete, or Complete.

Closed for Accounting

When you run the Close Production process to accounting, the system sets the production status to Closed for Accounting, which closes the production ID to all transactions and records the variances associated with production.

Canceled

The Canceled status cancels existing production quantities associated with a production ID. You can cancel production if the production status is Entered, Firmed or Released. You cannot cancel a production ID with subcontracted operations if a purchase order has been generated against the production ID.

See Also

Setting Up Manufacturing Business Unit Options

Releasing Production and Changing Production Statuses

Completing Operations and Recording Scrap

Closing Production

Production Status Changes

When the status on the production ID or production schedule is changed, these actions occur:

Rework Production

Rework production works in a manner similar to regular production, but with several exceptions. Add rework production IDs for current production in the Released status. The system automatically creates the component list using the rework BOM for rework production IDs, and it copies the end item to be reworked to the component list. The system assigns the kit issue method to the end item to be reworked when the component list is created and uses the issue method set at the production area and item level for each additional component. The default issue method is set on the Define Business Unit Item - Manufacturing page and can be overridden on the Production Area - Item Detail page. If the item has a rework routing defined, the system copies the routing to the operation list. Create rework production IDs with the Firmed status for production scheduled for future dates. The system creates frozen rework component lists and operation lists.

Teardown Production

You cannot create teardown production IDs in the Entered status; you must create them with a status of Firmed or Released. The system assigns the kit issue method to the end item to be torn down when the component list is created and uses the issue method set at the production area and item level for each additional component. The default issue method is set on the Define Business Unit Item - Manufacturing page and can be overridden on the Production Area - Item Detail page. The system creates the teardown output list, either by copying the components on the original production ID or by using the teardown components designated on the BOM.

Effect of Serial Genealogy on Rework or Teardown Production

If you're using serial genealogy, the serial association occurs when the assembly item is issued to the production through kit issues or the picking process. You are prompted to enter the serial ID that is issued to the rework or teardown production ID.

See Also

Releasing Production and Changing Production Statuses

Creation of New Production IDs or Production Schedules

Create production IDs or production schedules by:

• Automatically creating production IDs or production schedules based on recommendations generated by PeopleSoft Supply Planning.

• Manually adding production IDs by using PeopleSoft Manufacturing pages.

• Manually adding production schedules by using PeopleSoft Manufacturing pages.

Note. Use the PeopleSoft Supply Planning solvers to manage and schedule the shop floor.

Actual Dates and Production Due Dates

All production IDs and production schedules maintain production date and shift information, as well as actual date and time information.

Production date and shift information is defined as the working day and shift (or manufacturing day and shift) during which component and production scheduling may be done. Define the production dates and shifts through the business unit's production calendar or the work center calendars. For example, on the production calendar for the month of March, you specify that you are working three shifts on 3/29/07. You just defined a production date of 3/29/07 with three production shifts: 1, 2, and 3. In this example, shift 1 runs from 7 a.m. to 3:30 p.m. When the start date and time or due date and time is determined, the time is converted to the appropriate shift. In this example, a start time of 2 p.m. would equate to shift 1.

Actual date and time is defined as the actual date and time the production is scheduled to begin or end based on the standard calendar. In most cases, the production dates and actual dates are the same. If you have production shifts that span multiple standard calendar dates, the actual date for production may be different than the production date. The system determines the actual date by the actual time that the production is scheduled to start or end within the production shift and the operation start quantity.

These examples explain and illustrate the differences between how PeopleSoft Manufacturing determines production date and shift information as well as actual date and time information when a shift:

• Begins and ends on the same calendar date.

• Spans multiple calendar dates.

Shift That Begins and Ends on the Same Standard Calendar Date

Suppose that a company runs seven days a week with one shift that starts at 7 a.m. and ends at 4 p.m. A production schedule can now be defined for a production due date and due shift. In the example, the actual due date is 3/25/07 and the due time is 3:30 p.m. Because this shift does not span multiple standard calendar dates, the production due date and shift for the production is 3/25/07, shift 1.

Shift That Spans Multiple Calendar Dates

For shifts that span multiple dates, define whether the start time or end time of the shift is associated with the manufacturing production dates. Define this option when setting up the shift codes using the Shift Codes page. Associate this shift code with a manufacturing production date and shift when maintaining production or work center calendars.

Based on whether you want the start time or end time of the shift to be associated with the manufacturing production date, the system first determines the actual date and time information and then the production date and shift information. These examples illustrate how the system determines the production date and shift based on whether you want the start time or end time of the shift to be associated with the manufacturing production date.

Example 1: Production Date Time Set to Start Time

Suppose that a company runs three shifts and the third shift starts at 8 p.m. and ends at 2 a.m. This shift is defined with the start time associated with the production date. A production schedule can now be defined for a production due date and due shift. In the present example, production is due to end on 3/26/07 at 1:30 a.m. Because the shift in which production takes place actually begins on 3/25/07 at 8 p.m., the production date and shift is recorded as 3/25/07, shift 3. The actual date and time appears as 3/26/07 at 1:30 a.m.

Example 2: Production Date Time Set to End Time

Suppose that a company runs three shifts, and the first shift starts at 10 p.m. and ends at 6 a.m. This shift is defined with the end time associated with the production date. A production schedule can now be defined for a production due date and due shift. In the present example, production is due to end on 3/27/07 at 5:30 a.m. Because the shift ends at 6 a.m. and the flag indicates the production date is set to the shift's end time, the production due date and shift is 3/27/07, shift 1. The actual due date and time appears as 3/27/07 at 5:30 a.m.

When defining production IDs, you specify the actual date and time information, and the system determines the corresponding production date and shift information. When defining production schedules, you specify the production date and shift information, and the system determines the corresponding actual date and time. For production schedules, you can specify the actual time within the production shift. In this case, the system determines the actual date.

Regular Production Scheduling

For each production ID or production schedule that you create, a scheduling method (forward or backward) is defined either automatically or manually, depending on how the production ID or production schedule is created.

Production IDs and Production Schedules Using PeopleSoft Supply Planning

PeopleSoft Supply Planning analyzes supply and demand and determines whether new planned production needs to be generated. If new production is required, the system generates a planning message to recommend creation of a new production ID or production schedule. When a planned manufacturing order is generated within PeopleSoft Supply Planning, it is always backward scheduled based on the required delivery date and the routing or item's lead times to determine the start date of production.

If you are using the PeopleSoft Supply Planning solvers to schedule and reschedule production:

• Freeze production within PeopleSoft Supply Planning and apply the frozen requirement to the production within PeopleSoft Manufacturing.

  For example, PeopleSoft Supply Planning sends a planning message for a new production ID back to PeopleSoft Manufacturing with the requirement that production is frozen.

• Using PeopleSoft Manufacturing, convert the recommendation into a production ID with an Entered, Firmed, or Released status.

  If you are using the Production ID Maintenance component to change any information on the production ID that affects scheduling, the system displays a warning message that indicates production is frozen and any of the changes result in rescheduling the production. You can override the frozen status by proceeding and changing the information, or you can cancel the changes.

Within PeopleSoft Manufacturing, you can manually freeze production. Do this by selecting Frozen Production on the Planning Attribute page for production IDs or by selecting the Frozen check box on the Production by Area Details page for production schedules.

PeopleSoft Supply Planning uses planning lead times or routing times when scheduling production, and it takes into account the following factors that affect the actual start date and time and actual due date and time of each operation:

• Capacity and material availability.

• Planning labor or machine setup, run, and fixed run times or run rates.

• Operation overlap, based on an overlap percentage or send-ahead quantity.

• Operation intensity, based on machine, labor, cumulative, or longest.

• Operation yield.

• The work center calendar, if one exists.

• The production calendar, if one exists.

• The five-day work week calendar, when no other calendar exists.

Reviewing, Approving, and Applying Production Messages

Once a plan has been created and recommendations are made, planning messages are returned to the transactional system using the Post Updates process (PL_POST). Once the messages are received, you can:

• Review and approve the production messages using the Approve Production Updates component.

  Use this component to select the messages that you want to review, then look at the production details, status details, and configuration code information to select which messages you want to approve.

• Review any exception messages generated when the production messages are applied by using the Review Post Errors component.

  Use this component to select the exceptions that you want to review, then look at the exception details, dates and quantities, and configuration code information.

• Apply the production messages to PeopleSoft Manufacturing to take action on the recommendations made by PeopleSoft Supply Planning by using the Apply Production Updates page.

See Also

Using Planning Attributes

Production IDs and Production Schedules Using PeopleSoft Manufacturing

You can use PeopleSoft Manufacturing to create production IDs and production schedules.

Creating Production IDs

You can use the Production ID Maintenance component to add or maintain a production ID one at a time. When you manually add a production ID, determine whether production is forward or backward scheduled. The selection is based on whether you know when you want to start production or when the item is due:

• If the production ID is based on the completion date and time, or due date and time, it is backward scheduled, and the system calculates the actual start date and time.

• If the production ID is based on the start date, it is forward scheduled, and the system determines when the assemblies will be completed.

Automatic calculation of the opposing date and time applies only if you specify a routing for the production ID. In addition, the system calculates the production start date and shift as well as the production due date and shift associated with both the actual start date and time and due date and time.

If a production ID is added in the Firmed or Released status, the actual start dates and times and due dates and times for each operation in the manufacturing process are also calculated.

You can also add or maintain production ID information one week at a time using the Production by Area pages. This gives you a one-week view of all production taking place in a selected production area. By navigating to the details by day, you can view daily production ID and production schedule information. When adding production IDs, you select the date on which production will be completed and the system automatically backward schedules the production ID to determine the start date of production.

Creating Production Schedules

Production schedules are always entered with a quantity due for a day of the week, and the system determines the production start date and production start shift using backward scheduling.

Note. Because production schedules are always backward scheduled, you enter the production end quantity, and the system calculates the required production start quantity.

When you manually add a production schedule in the Entered status, the system:

• Determines the production start date and shift when the production due date and shift are entered.

• Determines the actual start date and time as well as the actual due date and time for the production start date and shift and production due date and shift, respectively.

When you add a schedule in the Firmed status or release a production schedule, the system must:

• Calculate an actual start date and time or due date and time.

• Calculate actual start dates and times and due dates and times for each operation in the manufacturing process.

Calculating Start and Due Dates for Production IDs and Production Schedules in PeopleSoft Manufacturing

PeopleSoft Manufacturing calculates start and due dates based on the production item's routing, and does not include other production that uses the required work centers or resources. If capacity and material availability are concerns, manually add a production ID or production schedule using PeopleSoft Manufacturing. When you add the production, estimate start and due dates and then schedule the actual start and due dates for the production ID or production schedule using PeopleSoft Supply Planning.

If you are using PeopleSoft Manufacturing to schedule production, there are several factors that affect the actual start date and time and actual due date and time of each operation in addition to the planning lead times:

• Operation overlap, based on a percentage or send-ahead quantity.

• Setup that can occur during queue time (or at any time once production begins).

• Setup time that is included in scheduling the operation.

• Operation intensity.

• Work center calendar, if one exists.

• Production calendar, if one exists.

• Five-day work week calendar.

• Operation yield.

Define these factors when you set up manufacturing data for each business unit, item, work center, or routing. Once the system creates the operation list for the production ID or production schedule, it reschedules each operation any time that the operation list is modified.

See Also

Production IDs and Production Schedules Using PeopleSoft Supply Planning

Understanding Scheduling Operations

Production IDs Using PeopleSoft Product Configurator

The production configuration process:

• Takes the detailed configuration information captured in PeopleSoft Order Management and sends requirements to PeopleSoft Manufacturing.

  The production configuration rules enable you to dynamically specify component and operation list elements without having to have standard BOMs or routings for each specific configuration.

• Generates configured production IDs, component lists, operation lists, and configured costs.

  You can manually create a production ID for a configured item, and create the operation list and component list.

See Also

Using PeopleSoft Enterprise Product Configurator

Rework and Teardown Production

You can use PeopleSoft Manufacturing to manually create rework and teardown production IDs, or create an operation list:

• Manually create rework and teardown production IDs using PeopleSoft Manufacturing.

  The process of creating rework or teardown production IDs is the same as for regular production. However, because the use of an operation list is optional for rework or teardown production, PeopleSoft Manufacturing does not automatically determine the actual start date and time or actual due date and time for rework or teardown production, unless you have previously created a rework or teardown routing that is then copied to the operation list.

• Manually create an operation list if a rework or teardown routing has not previously been defined.

  If you create an operation list for the rework or teardown production, the tasks and work centers associated with it are used for scheduling. If an operation list does not exist, manually enter the scheduling information, indicating the actual start date and time and due date and time for production IDs.

Once the production ID is created:

• Modify the appropriate start and due dates manually.

• If capacity and material availability are concerns and you've created a component list and operation list for the rework or teardown production, schedule the production ID using PeopleSoft Supply Planning.

  PeopleSoft Supply Planning treats rework and teardown requirements for a resource in the same manner as regular production.

Note. You cannot create rework or teardown production IDs using PeopleSoft Supply Planning. However, you can schedule rework or teardown production IDs to repair capacity restraints using PeopleSoft Supply Planning.

See Also

Regular Production Scheduling

Production ID Splits

Occasionally, during the production process you may need to to split a single production ID into two or more production orders. With PeopleSoft Manufacturing, you can split production when:

• A portion of the production quantity needs to be split out because of a change in processing steps.

• A portion of the production quantity must be split due to material shortages or capacity issues.

  This enables you to complete what you can and close out the order. The remaining quantities requiring material or resources remain on an open order.

• Production variations occur, such as unplanned outputs that need to be completed separately and put away using a different item number.

Perform production ID splits for this type of production orders:

• Production

• Rework

• Teardown

You can:

• Split configured production IDs; however, you can only split the configured order to a new configured production ID.

• Split production IDs that have subcontracted operations; however, you must perform the production split before running the Select Subcontract Prdn for PO process (SFS5000).

  Assign a new item number to the new production order if the final end item produced differs from the original item.

• Manually adjust operation lists for production that has not started.

  Material, earned conversion costs and actual conversion hours are split across the From and To orders on an operation-by-operation basis. Scrap costs remain with the original production ID.

• Correct and modify the component material split across orders even after the order has been split by using the PID to PID Component Transfers (production-ID to production-ID component transfers) page.

• Split multiple outputs—primary items, co-products, by-products—to the new (To) production ID if there are still remaining quantities.

  In addition, the system copies any resources, attachments, text, or documents to the new (To) production ID. The system maintains the split history at the production header level, and you can view the history by using the Production ID Split History inquiry page.

• Make manual changes to the components by using the Production ID Comp Transfer page after a production ID split.

You cannot perform production ID splits under these circumstances:

• Production IDs that have subcontracted operations in process cannot be split.

• Co-products cannot be split to primary items.

• Splits across production types—production to teardown, rework to production, or teardown to rework—are not allowed.

Note. Production schedules cannot be split.

When splitting production IDs being tracked by serial genealogy, you are prompted for the assembly serial IDs that are being split. These serial IDs will be associated with the new production ID. In addition, the component genealogy associated with the serial assemblies being split is moved to the new production ID.

Production order splits are permanent, and after they're created, the production orders cannot be rejoined at a later operation. Each production ID becomes a separate entity that must be closed and the costs must be reported independently. If more than two production IDs are required, the split must be run multiple times. When the entire quantity of a production ID is moved to one or more new production IDs, the status of the original production ID is set to Canceled.

Both the original (From) and the new (To) production IDs can be rescheduled in PeopleSoft Supply Planning.

See Also

Recording Completed Operations and Scrap for Subcontracted Operations

Generating Production ID Splits

Frozen Production

If you are maintaining production that was scheduled using PeopleSoft Supply Planning, the production ID may have a frozen status. The frozen status indicates that a decision was made to hold or firm up the due date and that changes to these production IDs or production schedules within PeopleSoft Manufacturing could result in a change to the schedule created by PeopleSoft Supply Planning.

• Set a default at the manufacturing business unit level to create all new rework or teardown orders with a frozen status, indicating that you do not want PeopleSoft Supply Planning to reschedule those orders.

• Override this default using the Planning Attribute page, which is available from the Production ID Maintenance component and the Production by Area Details component.

• If the production ID or production schedule has a frozen status and you change information that affects the actual start or due dates and times, PeopleSoft Manufacturing displays a warning message indicating that the production is frozen.

• You can continue, or you can cancel the changes.

  If you proceed with changing the production ID or production schedule, the production ID or production schedule is no longer frozen.

Changes to the production that affect the actual start date and time or actual due date and time include:

• Item ID

• Status

• Production quantity

• Production type

• Actual start date and time

• Actual due date and time

• Production start date and shift

• Production due date and shift

• Routing code

• Operation yield

• Revision

See Also

Setting Up Manufacturing Business Unit Options

Using Planning Attributes

Manufacturing Execution System Integration

If you're using PeopleSoft Manufacturing with a Manufacturing Execution System (MES), the system publishes messages for the MES when you add or modify production IDs or production schedules. The system publishes production order messages when you:

• Change the production status of a production ID or production schedule to Released.

• Modify a released production ID or production schedule.

• Change the production status of a production ID or production schedule from Released to an earlier status.

• Change a component list or operation list.

• Change an output list.

• Split a production ID.

When the system publishes a production order for the MES:

• The system includes the component list and operation list, with attachments and documents, as well as the output list for the production ID or production schedule.

• You release production IDs or production schedules in either PeopleSoft Manufacturing or the MES.

• You perform detailed production scheduling, production monitoring, and reporting in the MES.

See Also

Integrating with Third-Party Systems

Prerequisites

Before you create production IDs and production schedules, make sure that:

• Items have been defined in PeopleSoft Inventory.

• BOMs have been created for the assembly item.

• Production areas are defined.

• The items you'll be manufacturing, tearing down, or reworking are linked to a production area by using the production Area Maintenance component or the Production Option Maintenance component.

  The production area and item relationship must have an Active status.

• All items you'll be tracking using production IDs have the MA ID (maintain production IDs) check box selected on the production Area Maintenance Summary page.

• The production calendar is defined.

• The five-day work week is defined for the business unit if you are not using production calendars.

Optionally, you can define:

• A primary routing or alternate routing for the items you'll be manufacturing.

  For reworking assemblies, you can also define rework BOMs or rework routings.

• If you typically tear down finished end items into their component parts, define a teardown routing, defining the operations necessary in the teardown process.

  Additionally, indicate on the production BOM which components are outputs from a teardown process.

• Any revisions for revision-controlled items that you manufacture.

• Any work center calendars.

Common Elements Used in This Chapter

Creating Production IDs

The first step in defining a discrete manufacturing order is to create a production ID. Once you've generated a production plan, manually enter any discrete production or rework orders for those items that were not included in the new production recommendations from PeopleSoft Supply Planning.

When you change any information on an existing production ID, the system optionally sends the Production ID Change workflow notification to selected roles that you defined. These roles could include a planner, buyer, or a production control manager.

You can create production IDs for production, rework, or teardown orders.

If you want to automatically create operation and component lists, you must define BOMs and routings for the end item.

This section discusses how to:

• Create and maintain production IDs.

• View production start date and shift information and production due date and shift information.

• Locate the original production ID used to create teardown item.

• Use planning attributes.

• Display production ID detail.

• Maintain production ID output information.

See Also

Enterprise PeopleTools 8.48 PeopleBook: Workflow Technology

Integrating with Third-Party Systems

Maintaining Bills of Material

Structuring Routings

Delivered Workflows for PeopleSoft Manufacturing

Common Elements Used in This Section

Pages Used to Define and Maintain Production IDs

See Also

Maintaining Production ID Output Information

SFS2003 - Production Documents

SFS2004 - Production Report

Adding and Maintaining a Single Production ID

Access the Production ID Maintenance page.

Status

You can add a production ID with a production type of Production in either the Entered, Firmed, or Released status. You can add a rework or teardown production ID with a Firmed or Released status only.

Note. Pend Cmpl (pending complete), Completed, Clsd/Labor (closed for labor), and Clsd/Acctg (closed for accounting) are used when tracking and closing production, but they are not used when creating or maintaining a production ID.

Maintaining Production ID Information

Note. Whether the quantity is a whole number or a decimal depends on the item's unit of measure and quantity precision combination defined in PeopleSoft Inventory.

Note. The production start quantity and production end quantity may not be the same due to operation yield allowances.

Once you add the production ID, keep these points in mind when you change the production start or production end quantity:

• If the production ID is Firmed or Released, the system recalculates the component's scheduled quantities.

• If the production ID is In Process and you increase or decrease the order quantity, the system adjusts the component's scheduled quantities to reflect the new order quantity and marks the production ID as changed so that PeopleSoft Supply Planning reschedules the operations during the next planning run.

• If you have decreased the production quantity and have already issued components, you might have a surplus of components at the WIP location.

• If you have decreased the production start or production end quantity and already kitted material to the production ID, a usage variance results at accounting close time if the excess material is not returned to stock.

• If you change the production quantity and the production ID is released and backward scheduled, the system automatically recalculates the actual start date and time.

• If you change the production start or production end quantity and the production ID is released and forward scheduled, the system automatically recalculates the actual due date and time.

  In this case, the system prompts you to delete the existing component list.

  • If you select Yes to the Component List for Production ID prompt, the system deletes the component list and then creates a new component list for the production ID, based on the BOM in effect on the new production due date.

  • If you select No, the system uses the existing component list for production.

• If you change the production quantity, and the production ID is Firmed or Released, and subcontracted purchase orders have been created, the system sends a purchase order change request to PeopleSoft Purchasing, indicating a change in production start or production end quantity.

  Note. If a subcontracted operation has more than one purchase order, the system will not automatically create change requests. You will need to manually create the change requests.

• You cannot decrease the production quantity to a quantity less than the quantity that has already been completed to stock.

Warning! A warning is issued if you decrease the production start quantity to a quantity less than the number of serial IDs associated.

Note. Effectivity dates apply only if you use the Production Option Maintenance component to define the valid BOM and routing combinations.

BOM and routing combinations can be viewed in the Production Option Maintenance component.

Select valid production options (predefined BOM and routing combinations) for the item. If you select the Valid Production Options only option on the Item Attributes by Unit - Manufacturing page, then only the predefined combinations can be entered or selected.

Note. If you create a component list and there are operations linked to the components that do not exist on the routing, the system treats those components as linked to the first operation sequence. This is similar to how the system handles a component with a 0 operation sequence. Unmatched output by-products, on the other hand, are linked to the last operation.

Once you add the production ID, keep these points in mind if you make any changes to the routing code:

• The system recalculates the production ID's actual start or due date and time based on the new routing's lead times and scheduling parameters.

• If the production ID is in the Firmed or Released status, changing the routing code also deletes the existing operation list.

  The system creates a new operation list for the production ID using the routing code specified.

• If the production ID is in the Firmed or Released status, you can change the routing code only if a subcontracted purchase order has not been generated against the production ID.

• If the production ID is forward scheduled and the due date and time for production has changed based on the new routing, the system prompts you to delete the existing component list.

  If you select Yes to the Component List for Production ID prompt, the system deletes the component list and creates a new one based on the BOM in effect on the new due date.

Adding and Maintaining Production IDs Using a Weekly View

You can also maintain and view production IDs by using the Production by Area pages.

See Adding and Maintaining Production Schedules.

Viewing Production Start Date and Shift Information and Production Due Date and Shift Information

Access the Production Start Date/Shift or Production Due Date/Shift page.

The first or last minute of the production shift is based on these scenarios:

• For Forward scheduling, the system uses the work center calendar for the routing's first operation, if one exists.

• For Backward scheduling, the system uses the work center calendar for the routing's last operation, if one exists.

• If work center calendars do not exist for the routing's first or last operation's work center, the system uses the production calendar, if one exists.

• If a production calendar does not exist, the shift's start or end time specified for the five-day work week is used.

• If you are changing the due date and time and a routing is specified, the system recalculates the start date and time.

  Conversely, if you are changing the start date and time, the system recalculates the due date and time. The production start date and shift and the production due date and shift associated with the start date and time and due date and time are also determined.

• If the production ID is in the Firmed or Released status and you replace the start date and time or due date and time, the system updates the operation list with each operation's new start and due dates and times.

• If you are changing the due date or the due date changes as a result of a change in start date, the system prompts you to delete the existing component list.

  If you select Yes to the Component List for Production ID prompt, the system deletes the component list and adds a new one based on the BOM in effect on the new due date.

• If the production ID is in the Firmed or Released status and a subcontracted purchase order has been generated against the production ID, any changes that result in a change to the start date and time or due date and time may affect the purchase order due date.

  The system displays a warning message when changes occur that result in a change to the start dates and times and the due dates and times.

Using the Teardown Production ID Search Page

Access the Teardown Original Production ID Search page.

Note. If the production type is Teardown, the output list is based on the components used on a previous production ID or on the components designed as teardown outputs on the item's BOM.

Select Completion History, and if the serial ID and lot ID exist for the original order, select values.

You can also select a production due date range or configuration code from the available options. After you make the selections, click Search for a list of production IDs. If multiple production IDs were used to create the item, the system generates a list of production IDs, but it only selects production IDs with a status of In Process or later status with a production type of Production.

Production Tab

Select the check box next to the original production ID that you're tearing down.

Using Planning Attributes

Access the Planning Attribute page.

See Also

Setting Up Manufacturing Business Unit Production Options

Defining Production Options

Structuring Routings

Maintaining Production ID Output Information

Issuing Material to Production

Working With Configuration Codes

Displaying Production ID Detail

Access the Production ID Detail page.

Frozen Production	Indicates whether a decision was made to hold or firm up the due date for this production ID by PeopleSoft Supply Planning. Change production information using the Production ID Maintenance page. If you change production information and the status is Yes, the system displays a warning message indicating that the production ID has been frozen by PeopleSoft Supply Planning and the change results in the production ID being rescheduled. You can continue or cancel the changes. If you change this information, the production ID is no longer frozen and the status changes to No.
Frozen Substitutes	Indicates whether the system has frozen substitutes in the PeopleSoft Supply Planning system. This means that when you sent this production ID to PeopleSoft Supply Planning, the Planning engine did not include substitute components.
OM Business Unit (Order Management business unit), Sales Order No and Configuration Code	These fields display sales order information if the production ID results from a sales order configured in PeopleSoft Order Management.
Print Count	Indicates the number of times that production documents have been printed for the production ID.
Prdn Doc Status (production document status)	Indicates whether production documents have been printed.
Completed Qty (completed production start or production end quantity)	Indicates whether assemblies have been completed to stock, routed to another WIP location, or issued directly to another production ID.
Scrapped Qty (scrapped quantity)	Indicates the number of assemblies that have been scrapped in process.

Maintaining Production ID Output Information

Access the Production ID Outputs page.

Output List

See Pegging Supply and Demand.

Adding Unplanned By-Products

Important! Only by-products such as recycle or waste products can be added or changed. You cannot change or add primary items or co-products.

If you are maintaining a rework production ID, the output page lists only the reworked item as the end item. You cannot define co-products or by-products with rework.

Generating Production ID Splits

When required, you can split a single production ID into two or more production orders.

You can only split production with a status of In Process. Quantities can be split by operation based on the quantity that still exists at the original production ID operation sequence. You can also split a batch production ID order that has at least one co-product or by-product in addition to the primary item. You can split the entire production quantity to a new production ID, item ID or production area. All new production IDs will also have a production status of In Process.

You can only split production IDs. You cannot split production schedules.

Note. You cannot split an In Process production ID if there are pending pick plans, pending bar code transactions, or subcontracted operations that are also in process.

If you want to split a Pending Complete production ID, change the production status to In Process. You must reopen production to change the status back to In Process.

If you split a production ID that is being traced using serial genealogy, be aware of these issues:

• You select the assembly serial IDs to split.

  These serial IDs become disassociated from the original production ID and become associated with the new production ID. Any components associated with split assembly serial IDs are automatically transferred to the new production ID.

• If the new (To) item is not using serial genealogy, you will no longer be able to track genealogy information.

  In this scenario, the new production ID will not have any historical genealogy information.

• You can use the associate serial commands to associate additional serial numbers with the new production ID.

• You cannot transfer components to another production ID if they have been previously associated with a production ID using serial genealogy, unless those components are associated to an assembly serial that is being split.

  In that case, they are automatically transferred. You cannot make serial associations when transferring components during the production ID split process.

This section lists common elements and discusses how to:

• Define production ID split information.

• Enter production ID split quantities.

• Edit components to be transferred.

• Correct errors after a production ID split and transfer components between production IDs.

See Also

Production ID Splits

Common Elements Used in This Section

Pages Used to Generate Production ID Splits

Defining Production ID Split Information

Access the Production ID Split - Header page.

From Production	Displays the production header data from the production ID that you are going to split.
Split Qty (split quantity)	If the production ID that you want to split has no operation list, enter the total quantity that you want to split from the original production ID. Whether you can enter a whole number or a decimal depends on the unit of measure and quantity precision combination that was defined for the item in PeopleSoft Inventory. For example, if item ID A0007 has a unit of measure of EA and a natural round, whole number combination, then you can only enter whole numbers. If you enter an incorrect number format, you'll receive an error message. If this field is unavailable, enter the split quantity on the Operation List page because there may be several operation steps with quantities that can be split. Note. You cannot split a higher quantity than what is remaining at the operation sequence. For example, suppose that there is a quantity of 20 at operation sequence 10. Then you cannot split more than 20. If you enter a higher split quantity than the quantity that is available, you receive an error message.
View Trace Info	Click to access the Traceability page, where you can view the assembly serial IDs that have been associated with this production ID.
To Prdn ID (to production ID)	Enter a value for the new production ID if you are not using automatic numbering. If you are using automatic numbering, retain NEXT as the value.
New Rev (new revision)	Enter a value if the item is revision-controlled and this new production ID represents a new revision for the end item. Note. Changes to the revision on the To item ID as reflected on the To production ID header only. Components copied during the production ID split process are based on the From production ID's component list and are not based on the revision number entered in the New Rev field.
To Prdn Area (to production area)	Select the area where the new production ID is processed. The production area for the To production ID can differ from the production area of the From production ID, but the end item must be assigned to the production area where you are moving the split quantities. If you select an area that has a WIP storage location that differs from the From production area, you receive a warning message indicating that any material issued in WIP is not automatically transferred to the new area's WIP location. Use the EZ Transfer page or the Material Release page to move the components to the new WIP location.
To Item ID	You can split the original production ID to the same item or to a different item. However, you cannot split a primary item to a batch item—that is, an item that has at least one co-product. If you're splitting a batch item to a different batch item, then the new item inherits the by-products from the original item ID as long as they are not fully completed on the from Production ID. In that case, they are not copied. Note. If the To item ID in a production ID split has an item status of Hold or Discontinue, you receive a warning message; however, the warning message does not prevent you from performing the action. These situations cannot exist when selecting a value: The To item ID cannot exist as a component on the parent component list. The To item ID cannot exist on the parent output list as a by-product because the To item ID would be the end item as a primary item and a by-product. The To item ID cannot be changed on rework or teardown orders.
Config Code (configuration code)	Select or enter a value if the item is configured: If the From item ID and the To item ID are identical, you can change the configuration code for the To production ID. If you split to a different item, the system prompts you to select a new configuration code for the To item ID. If the configuration code changes during the split process, you can change the sales order for the new To production ID.

See Also

Making Stock Location Transfers Online

Issuing Material to the Shop Floor

Managing Inventory by Item Status

Entering Production ID Split Quantities

Access the Production ID Split - Operation List page.

To Production

Operation List

This information appears for the From production ID, and is used to split operation data to the new production ID:

See Also

Maintaining Tasks

Enterprise PeopleTools 8.48 PeopleBook: PeopleSoft Process Scheduler

Transferring Components

Access the PID Split Component page.

Issue Quantities Tab

Pending Quantities tab

Note. If you are splitting the entire production quantity, all the material, actual labor and machine hours, earned conversion costs, actual conversion costs, and scrap costs are copied to the To production ID. The production status of the original production ID is set to Canceled, and it has a production quantity of 0.

Note. You can make manual changes to the To production ID by using the Production ID Maintenance, Component List Maintenance, or Operation List Maintenance pages. Make changes to the production start or production end quantity, BOM code, scheduling method, start date and time, or due date and time.

See Also

Adding and Maintaining a Single Production ID

Understanding Recording Completions and Scrap

Making Production ID Split Component Transfer Adjustments and Transferring Components Between Production IDs

Access the Production ID Comp Transfer page.

Note. You can only perform component transfers on production orders with a status of In Process. In addition, only production ID materials that have actually been issued from the original production ID can be transferred to the To production ID.

Click the Detail link to view production details for either the From production ID or the To production ID.

Component List

Creating Production Schedules

After fine-tuning the production plan, you may need to use the Production Schedule pages to manually enter or maintain production that you want to track by day and shift.

Important! Both production IDs and production schedules can be created and maintained by using these pages.

Production schedules can be created and maintained for each production area and item combination. You can add a schedule for production quantities that are in the Entered status at the summary level. Because you define production quantities due on a specific production due date and shift, production schedules are always backward scheduled. You also can maintain multiple production schedules per shift, and you can set the due time as well as the due date.

Note. You cannot use production schedules to track rework, teardown production, or regular production using the kit issue method. Rework BOMs and routings and teardown routings are not available for production schedules.

When you change any information on an existing production schedule, you can have the system send the Production ID Change workflow notification to selected roles that you define. These roles might include a planner or buyer or a production control manager.

This section lists common element and discusses how to:

• Add and maintain production schedules.

• Define and view production details.

• View the production output list.

See Also

Delivered Workflows for PeopleSoft Manufacturing

Common Elements Used in This Section

Pages Used to Create Production Schedules

See Also

SFS2007 - Production Schedule by Area Report

Adding and Maintaining Production Schedules

Access the Production by Area Summary page.

Date Query	Enter the production due date to add or view production for the appropriate workweek. After you enter a date, the system displays the corresponding day of the week.
	Click the Fetch button to retrieve the production information, to add a new production schedule or production ID, or to make changes to existing production.
Due Shift (production due shift)	The system displays the shift when the production start quantity will be completed. The system also displays the schedule quantity due for each day of the week.
	Click the Production Detail button to select one of these links: Details: Click to access the Production by Area Details page to make changes to the production quantities by day. Shift Total: Click to access the Total by Production Area, Shift page to view additional production information.
	Click Insert to add a production quantity for an item in the selected area. Note. Click the Insert Row button to enter a row on this page. To delete a production start or production end quantity, use the Production by Area Details page.
	Click the Reset Selection button to clear the information that appears in the grid and select a new area or date.
Due Shift	Enter a production due shift for the item and scheduled quantity.
Item	Enter an item value. You can maintain production quantities for items that are manufactured using either production schedules or IDs. The only restriction is that the item must be defined for the production area selected. Once you save the information, you cannot change the item; you can only delete the schedule.

Note. When adding an assembly with item status of Hold, you will receive a warning message. The warning message does not prevent you from performing the action. The system also gives you the option to cancel at save time.

Production Quantity

Enter the quantity on the day the week that you want the production to be completed. If you have specified a rate quantity per shift for the area and item, you can view and select that rate by clicking the down arrow in the appropriate day column. For example, the day that you choose for the quantity is the production due date. Whether you can enter a whole number or a decimal may depend on the item's unit of measure and quantity precision combination defined in PeopleSoft Inventory. For example, suppose that item ID A0007 has a unit of measure of EA and a natural round, whole number combination. Then you can only enter whole numbers. If you enter an incorrect number format, you receive an error message.

The system automatically calculates the production start date and shift as well as the actual start date and time and actual due date and time once you click the Process button. In addition, when you enter a quantity for a day:

• The system adds the quantity on the date corresponding to the day of the week in which the quantity was entered.

  The time is set to the last hour of operation for the last work center on the item's routing.

• If you're using operation yield, the system calculates the production start quantity based on the production end quantity.

  Because production schedules are always backward scheduled, you enter the production end quantity.

• You can change the due time at the production detail level.

Important! You must click the Process button to save the schedule before you can access the Detail page.

You can change the due time for the scheduled production from the Detail page. ally, you can define and maintain multiple production quantities, each with a different due time.

All changes to quantities for a day must be done at the production detail level.

You cannot delete production quantities in the Production by Area Summary page. Navigate to the Production by Area Details page to delete quantities.

If a routing is not defined for the item and you've entered a quantity for a shift and a day on this page, you must define the production start date and production start shift on the Production by Area Details page. The system automatically changes the due time to the last hour of operation based on the production calendar. The start date and shift automatically changes to the due date and shift. The time automatically changes to the first hour of operation based on the production calendar. You can change the actual start date and time within the production start shift as well as the actual due time within the production due shift.

The system displays production due shift options based on these scenarios:

• The system uses the work center calendar for the routing's last operation, if one exists.

• If a work center calendar does not exist for the routing's last operation's work center, the system uses the production calendar, if one exists.

• If a production calendar does not exist, the shift for the five-day work week is available.

If you are adding production on the summary page, they are added in the Entered status. Access the Detail page to change the status or add production in the Firmed or Released statuses.

Click the Process button to save the production schedule or production ID. The system then calculates the production start date, time, and shift.

Note. If capacity and material availability are concerns, estimate the production start and production due dates and shifts when you create or maintain production using PeopleSoft Manufacturing, and then schedule the production schedule's or production ID's production start and production due dates and shifts using PeopleSoft Supply Planning.

The Process button uses Remote Call for three-tier processing. Remote Call is a PeopleCode API function that provides a means of calling a Tuxedo service from a PeopleSoft application. A typical use of Remote Call is to run data-intensive, performance-sensitive programs near or on the database server. If you experience a time-out or other error when adding or changing production information, use the Reschedule Production process (SFPCRSCH).

Production Status Change and Effects

If you are changing production information, the production status determines what changes you can make:

See Also

Establishing Production Calendars

Completing Operations and Recording Scrap

Managing Inventory by Item Status

Establishing Quantity Precision and Rounding Rules for Items

Enterprise PeopleTools 8.48 PeopleBook: PeopleCode Language Reference

Rescheduling Production

Defining and Viewing Production Details

Access the Production by Area Details page.

Prdn Due Date (production due date), Prdn Due Shift (production due shift), Item ID, Prdn Start Date, (production start date) and Prdn Start Shift (production start shift)	Enter values for these fields to retrieve production information.
Search	Click to display the selected production information.
Compl Qty (completed quantity)	Indicates whether assemblies have been completed to stock or routed to another production area.
Scrap Qty (scrapped quantity)	Displays the number of assemblies that have been scrapped in process.
	Click the Insert button to add new production quantities. Each quantity that you add on the Production by Area Details page has the same business unit, production area, item ID, routing, routing item, and production due date. The system calculates the total production quantity for the production due date or on the Production by Area Summary page. You can only add production in the Entered, Firmed, and Released statuses, and you can delete Entered, Firmed, and Released schedules.
Rtg Itm (routing item)	Displays the referenced item's routing. The end item can either have its own unique routing or reference another item's routing.
Due Time	The actual due date and time when production should be completed for the given production due date and production due shift.
Prdn Start Qty (production start quantity)	Displays the beginning quantity at the first operation of the manufacturing process. The system will adjust this quantity to account for any operation yield.
Prdn End Qty (production end quantity)	Displays the quantity expected at the end of the manufacturing process. The is the production quantity that you entered in the days of the week fields on the Production Area by Summary page.
	Click to Output List button to access the Production Output List page.

Production Status Change and Effects

See Also

Defining and Viewing Master Routings

Viewing the Production Output List

Access the Production Output List page.

Output List Tab

Note. You cannot change or add primary or co-products. However, you can change or add recycle and waste by-products.

Output Detail Tab

Viewing Production Transaction History

Use the Production History page to track material and labor transactions associated with the WIP as an end item is manufactured on the shop floor. View production transaction history based on a business unit, production ID, or schedule and a date range or see all transactions recorded by a particular user ID. Within PeopleSoft Manufacturing, each operation or end item completion transaction is recorded with the date and time stamp as the end item is produced on the shop floor.

You can review previously posted transactions and navigate to the details of each transaction. You can also see where the completed assemblies are routed—either to an inventory storage location or to another production ID.

Common Element Used in This Section

Pages Used to View Production Transaction History

Viewing Production Transaction History Details

Access the Production History page.

The type of production information that appears depends on the selection of inquiry values on the Production History page. You can view production transaction history for:

• Completions detail

• Component consumption

• Operation detail

Selection Criteria Options

There are several ways to view production information using the Production History page. Narrow the selection by entering a From date and time and To date and time range with any of these options. For example, to view a production ID for a specific date range, enter a beginning date and an ending date.

Rescheduling Production

Reschedule selected production IDs or production schedules with a status of Entered, Firmed, Released, or In Process.

Pages Used to Reschedule Production

Defining Production to Be Rescheduled

Access the Reschedule Production page.

Defining Additional Reschedule Production Criteria

Access the Reschedule Production - Production Selection page.

Report Request Parameters