Understanding Shop Floor Management

This chapter provides and overview of JD Edwards EnterpriseOne Shop Floor Management features and discusses:

Tables for JD Edwards EnterpriseOne Shop Floor Management.
Types of manufacturing.

Shop Floor Management Features

This section discusses:

Hours and quantities tracking.
Reporting.
Material tracking.
Manufacturing accounting.
Production scheduling and tracking.
Work order and rate schedule creation.
Process or routing instructions.
Parts list.

Hours and Quantities Tracking

You use the hours and quantities tracking features to:

Enter and track time and quantity completed and quantity scrapped by work order and by employee.
Allocate and track resource usage by work center per calendar month.
Review and analyze work order reports with detail information when you use standard versus actual values for:
Setup, labor, and machine time.
Charging actual hours and quantities to a work order as each manufacturing step is completed.

Reporting

You use the reporting features to:

Generate reports that compare actual values with planned values and indicate the variance between the two.
Generate shortage reports by item or work order to identify potential manufacturing constraints due to a lack of required components.
Print shop floor paperwork, such as work orders, parts lists, and routing instructions for items.
Review daily work lists to monitor job status, identify queue problems at work centers, and flag other areas, such as engineering changes or lost material.

Material Tracking

You use the material tracking features to:

Create a parts list automatically when you run the Order Processing program (R31410).
Attach the parts list and routing instructions to the work order and print shop floor paperwork.
Check the availability of the components required to manufacture a parent item and generate a shortage list.
Issue the parts to a work order using a manual, preflush, or backflush method.
Backflush quantities of components issued to a work order and the labor expended with pay point operations.
Signal material movement with kanban processing from inventory, work orders, or purchase orders.
Enter and track completions to inventory when parent items are completed.
Track where lots are used, and split and trace where lots originate with advanced lot control.
Maintain and monitor work orders created from the JD Edwards EnterpriseOne Configurator system for configured items.
Process work orders that produce co-products or by-products.
Enter issue transactions for inventory items associated with a work order.
Generate a picking request in the JD Edwards EnterpriseOne Warehouse Management system to select a location and move the inventory. This task occurs after the system creates a parts list without a work center attached, and checks availability. You must have JD Edwards EnterpriseOne Warehouse Management installed to take this step.

Manufacturing Accounting

You use the manufacturing accounting features to:

Plan and track costs for setup, labor, material, and overhead.
Compare planned costs to actual costs and calculate a variance amount.
Create journal entries in the general ledger to charge actual costs and variance costs to a work order or rate schedule.
Use feature cost percent for co-product and by-product costing.

Production Scheduling and Tracking

You use the production scheduling and tracking features to:

Schedule work center production for work orders, rate schedules, or both.
Track and compare planned production schedules with actual schedules.
Use the online scheduling workbench to review, dispatch, and update production scheduling information in real time.
Calculate start and completion dates for each work order by operation.
Maintain the rate schedule after using rate-based Material Requirements Planning (MPS) or Master Production Scheduling (MPS).

Work Order and Rate Schedule Creation

You use the work order and rate schedule creation features to:

Enter work orders or rate schedules manually.
Create work orders and rate schedules automatically from MPS or MRP by answering action messages.
Create work orders from the Sales Order Entry program (P4210), in which you can select kits for assemble-to-order products.
Generate shop floor paperwork for rate schedules, including standard parts lists and routing instructions.
Differentiate work orders and rate schedules by type, priority, and status.
Group work orders by a parent number. For example, you can create job numbers that contain many work order numbers.
Generate purchase orders for subcontracted operations on the routing instructions for work orders and rate schedules by running the Order Processing program (R31410).

Process or Routing Instructions

You use the process or routing instructions features to:

Generate routing instructions automatically when you run the Order Processing program (R31410).
Use master routings or nonstandard routing instructions for items and indicate when to use each item.
Change the work centers and procedures for each operation on the routing instructions.
Modify the sequence and status of each operation on the routing instructions.
Make realtime modifications to routing instructions.
Review quantity ordered, completed, and scrapped for each operation in the Production Status program (P31226) or the Production History program (P31227).

Parts List

You use the parts list features to:

Generate a parts list automatically when you run the Order Processing program (R31410)
Copy an existing bill of material for the items required by a new work order and attach the parts list to the new work order.
Copy a parts list from an existing work order and attach it to a new work order.
Specify or change a substitute item or quantities from different locations.
Select defined substitute items and their quantities on-hand when a component shortage exists.

Tables for Shop Floor Management

This a list of the tables that are used throughout the JD Edwards EnterpriseOne Shop Floor Management system:

Table	Description
Business Unit Master table (F0006)	Stores branch, plant, warehouse, and business unit information, such as company, description, and category codes that are assigned to that entity.
Generic Message/Rates table (F00191)	Stores codes that correspond to a text message and the employee labor rate. In the JD Edwards EnterpriseOne Shop Floor Management system, these codes are used for the routing instructions text on a work order.
Account Master table (F0901)	Stores account definitions including numbers and descriptions.
Account Ledger table (F0911)	Stores detailed transactions in the general ledger.
Work Center Master File table (F30006)	Stores detailed information, such as efficiency, about all defined work centers.
Bill of Material Master File table (F3002)	Stores information at the business unit level about bills of materials, such as quantities of components, features, options, and levels of detail for each bill.
Lean Multi Level Bill of Material Header table (F300210)	Stores the end item and any related sub-assembly item information for lean manufacturing.
Lean Multi Level Bill of Material table (F300211)	Stores the component information for the end item and related sub-assembly items from the F300210 table. Used only by lean manufacturing.
Item Cost Component Add-Ons table (F30026)	Stores frozen standard costs for the creation of journal entries that are related to work orders.
Routing Master File table (F3003)	Stores information about routing instructions, including operation sequences; work centers; and run, setup, and machine time. The system uses this information to calculate labor, machine, and overhead costs.
Lean Multi Level Routing Detail File table (F300311)	Stores the routing information for the end item and sub-assemblies from the F300210 table. Used by lean manufacturing.
Work Center Resource Units table (F3007)	Stores the capacity information for work centers, such as business unit, month, shift, and efficiency.
Manufacturing Constants table (F3009)	Stores general branch/plant information, such as bill of material and routing instructions validation, commitment control, work hours per day, and costs.
Kanban Master table (F3016)	Stores the set of kanban cards that are associated with an item. Each kanban defines the supplying location, consuming location, quantity, and unit of measure. The system uses next numbers to control the kanban identification number. If the system obtains the item from an external source, the supplier's number is included.
Kanban Card Detail table (F30161)	Stores information related to the kanban, such as status, transaction quantity, and date updated.
Line Master table (F30L912)	Stores production line information used in JD Edwards EnterpriseOne Demand Flow® manufacturing.
Production Master table (FF31010)	Stores the daily plans for lean manufacturing. Contains the Production IDs that are used for tracking.
Transaction ID Master table (FF31011)	Stores the completion and scrap information when JD Edwards EnterpriseOne Demand Flow® completions are entered.
Production Cost table (F3102)	Stores the work order variance. Variance is the difference between actual costs and the standard costs that were defined at the beginning of the accounting period.
Work Order LSN table (F3105)	Stores the data that identifies work order assemblies with lot serial numbers.
Summarized WO Cross-Reference table (F3108)	Stores the cross-reference information for work orders, such as batch number and date, user, program ID, and workstation.
Line/Item Relationship Master table (F3109)	Stores the relationships between items and production lines. The system uses one of the records as the default rate generation rule.
Schedule Quantity Detail table (F31091)	Stores the daily quantities that make up a work order or a rate schedule. The system uses this table for scheduling and sequencing production lines and work centers.
Work Order Parts List table (F3111)	Stores the components required by a work order.
Work Order Routing table (F3112)	Stores the routing steps that are attached to a work order or rate schedule. It contains one record for each operation sequence number and work center.
Work Order Time Transactions table (F31122)	Stores the labor transactions reported on work orders and rate schedules.
Shortage Maintenance Master File table (F3118)	Stores component shortages for work orders.
Distribution/Manufacturing - AAI Values table (F4095)	Stores the AAIs for the JD Edwards EnterpriseOne Manufacturing systems.
Assembly Inclusion Rules table (F3293)	Stores the inclusion parameters for item numbers and business units.
MPS/MRP/DRP Message File table (F3411)	Stores the supply and demand relationship among the branches.
Forecast File table (F3460)	Stores the forecast data that Resource Requirements Planning (RRP) validates. The data is then used as input to MPS/MRP/DRP.
Inventory Constants table (F41001)	Stores the constants for the day-to-day transactions that occur within the JD Edwards EnterpriseOne Inventory Management system. Inventory constants direct the nature of certain integrated operations between JD Edwards EnterpriseOne Inventory Management and other systems, such as JD Edwards EnterpriseOne Sales Order Management, JD Edwards EnterpriseOne Procurement, and JD Edwards EnterpriseOne General Accounting.
Item Master table (F4101)	Stores basic information about each defined inventory item, such as item number, description, category codes and units of measure.
Item Branch File table (F4102)	Stores the warehouse or plant-level information for an item, such as costs, quantities, category codes, and physical locations.
Item Location File table (F41021)	Stores all inventory locations for an item.
Item Cross Reference File table (F4104)	Stores information that enables you to relate item numbers for a specific purpose.
Lot Master table (F4108)	Stores the potency of a lot.
Item Ledger File table (F4111)	Stores transaction history for all items.
Item History table (F4115)	Stores usage data for items that are optional in some transaction programs in the JD Edwards EnterpriseOne Shop Floor Management system.
Warehouse Requests table (F4600)	Stores putaway, picking, and replenishment requests.
Location Detail Information table (F4602)	Stores the information for locations, such as item, business unit, and lot.
Warehouse Suggestions table (F4611)	Stores putaway, pick, and replenishment suggestions for inventory movement
Work Order Master File table (F4801)	Stores the work order and rate schedule information, such as item numbers, quantities, dates, lots, locations, and shift codes.
Work Order Instructions File table (F4802)	Stores text and instructions for specific work orders that are identified by different record types.

Types of Manufacturing

Discrete, process, and repetitive manufacturing all use bills of material and routing instructions. The bills of material contain individual parts or components, such as nuts, bolts, wire, plastic, or metal parts of a fixed or variable quantity. Products can be broken down into subassemblies that go into various larger assemblies. The routing instructions include the operations to be performed, their sequence, the various work centers involved, and the standards for setting up and running the operations.

All types of manufacturing use the term item for both the raw materials and finished goods. Not all items are planned, scheduled, or produced in their primary unit of measure. To accommodate this fact, full unit of measure capabilities are allowed throughout JD Edwards EnterpriseOne Shop Floor Management. Most entry programs have a Unit of Measure field next to the quantity fields. The unit of measure is stored in the database tables with the quantities. Throughout JD Edwards EnterpriseOne Shop Floor Management, the system uses the values in these three fields in the Item Master table (F4101) as default values in entry forms:

Component Unit of Measure
Production Unit of Measure
Primary Unit of Measure

The value in the Primary Unit of Measure field must be the smallest of the three units of measure.

See Defining Default Units of Measure for Bulk Items in the JD Edwards EnterpriseOne Bulk Stock Management Implementation Guide, if the company uses or manufactures bulk product

Discrete Manufacturing

Discrete manufacturing is typically characterized by these conditions:

Work orders produce a specific quantity of a single item for a specific completion date.
Routing instructions are a series of independent operations.
Components can be manually issued with the release of the work order, backflushed at the completion of the work order, or both.

Discrete manufacturing is most often used in these manufacturing environments:

Make-to-stock, using either a highly repetitive or process order-based system.
Any of the to-order strategies, such as make-to-order, assemble-to-order, or engineer-to-order.
The one-off or job shop environment

Discrete manufacturing is used to produce items such as:

Cars
Furniture
Electronics
Airplanes

Process Manufacturing

Process manufacturing is typically characterized by these conditions:

Work orders produce multiple items, both co-products and by-products, for a specific completion date.
Routing instructions are a series of dependent operations that work together continuously.
Products are often produced in batches or with a continuous process.
Components or ingredients are often stated in terms of a recipe or formula.
Quantities of components or ingredients can vary according to their grade or potency.
Components or ingredients can be issued by preflushing with the release of the work order or backflushed at the completion of the work order.

Process manufacturing is most often used to produce:

Pharmaceuticals.
Foods and beverages.
Raw materials such as lumber, metals, and fluids.

The different types of processing in process manufacturing consist of:

Type of processing	Description
Batch processing	In batch processing, a product is usually made in a standard run or lot-size that is determined by vessel size, line rates, or a length of standard run. Items 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, and paints. A co-products and by-products list might be generated during batch processing.
Continuous processing	In continuous (or flow) processing, the production period is typically extended, using dedicated equipment that produces one product or product line with slight variations. This method of manufacturing is characterized by the difficulty of planning and controlling variances in quantity and quality yield. Typical items might be petroleum-based products or distilled seawater. Co-products and by-products are generally more prevalent in continuous processing than in batch processing.

Strategies that are similar to discrete manufacturing, including repetitive or any of the to-orders strategies (such as, make-to-order, assemble-to-order, or engineer-to-order) might be used to control the process. Usually, both batch and continuous processing methods require extensive record-keeping. You must track quality and tolerance values during the process, as well as strictly adhere to lot tracing and lot tracking. You use lot tracing to display the items that are assigned to a lot. You use lot tracking to display the items that are removed from a lot.

Repetitive Manufacturing

Repetitive manufacturing is typically characterized by these conditions:

Production lines are dedicated to a family of products.
Product families share similar components and routing instructions.
Products are often manufactured in a continuous process that requires less inventory movement to and from the production line.
Work center setup and changeover times between related products are minimized.
Production is defined in units per hour. The time spent at the operational level might or might not be important. Therefore, you must be able to set up line capacity and define routing instructions in units per hour at the line level. The fundamental basis for backscheduling and capacity planning is hours. To view information in units, the system uses a conversion factor defined at the work center level.
Visual cues, called kanbans, control material movement. Kanbans represent predetermined quantities of components at specified locations on the production line. They are designed to minimize work-in-process inventories.