9 Work with Work Centers

This chapter contains these topics:

9.1 Working with Work Centers

Work centers consist of people and machines. They are the specific production facilities on the shop floor where the routing operations occur. For each work center, you can define the following:

  • Work center number, description, and link to business unit

  • Queue and move times

  • Operator, machine, and hours per day capacity

  • Set up, labor, machine, and overhead rates

In discrete manufacturing, examples of work centers include:

  • Lathe

  • Drill

  • Heat treat

  • Mill

  • Cut-off

The system stores work center information in the Work Center Master table.

9.1.1 Before You Begin

9.2 Entering Work Centers

Navigation

From Daily Product Data Management (G30), choose Daily PDM Discrete

From Daily PDM Discrete (G3011), choose Enter/Change Work Center

Enter work center information that corresponds to the facilities on your shop floor.

Complete the following tasks:

  • Enter a work center

  • Enter work center hours

Note:

This program supports Batch Export functionality. See JD Edwards World Technical Tools Guide for more information.

To enter a work center

On Enter/Change Work Center

Figure 9-1 Enter/Change Work Center screen

Description of Figure 9-1 follows
Description of "Figure 9-1 Enter/Change Work Center screen"

  1. To identify the work center, complete the following fields and click Add:

    • Work Center (required)

    • Dispatch Group

  2. To enter repetitive manufacturing information, complete the following fields:

    • Work Center Type

    • Calendar Name

    • Capacity Standard

    • Capacity UOM

    • Capacity Minimum

    • Capacity Maximum

    • Hours

    • Shift Code/Description

  3. Complete the following fields:

    • Pay Point Code

    • Prime Load Code

    • Critical Work Center

    • Crew Size

    • Number of Machines

    • Number of Employees

    • Resource Offset

    • Efficiency

    • Utilization

    • Location

    • Branch

Note:

To commit components to a work center, the Pay Point Code must be M (Backflush material only) or B (Backflush material and labor).
Field Explanation
Work Center An alphanumeric field that identifies a separate entity within a business for which you want to track costs. For example, a business unit might be a warehouse location, job, project, work center, or branch/plant.

You can assign a business unit to a voucher, invoice, fixed asset, and so on, for purposes of responsibility reporting. For example, the system provides reports of open accounts payable and accounts receivable by business units to track equipment by responsible department.

Security for this field can prevent you from locating business units for which you have no authority.
Dispatch Group A super category code to group work centers within an overall business unit. For example, you can group like machines operating out of several work centers that report to one business unit under a dispatch group.
Work Center Type Defines the type of work center. Possible values are:

Blank Stand alone work center

1 – Production line in a repetitive environment

2 – Reporting work station within a production line

Form-specific information

For repetitive manufacturing, the system verifies the value is not valid as a work center for an operation from the routing.
Calendar Name Enter the value of the calendar which corresponds to the calendar type. For example, if the calendar type is ROUTE, enter a valid route code to display the calendar for a particular route.
Capacity Std The standard capacity level at which a production line usually operates.
Capacity Min The lower limit capacity beyond which the production line should not operate. This value is decided by management based on efficiencies, costs, etc.
Capacity Max The upper limit capacity beyond which a production line can not produce.
Hours The number of work hours that the manufacturing plant operates per day.

Form-specific information

For repetitive manufacturing, identify the number of work hours per shift for the specified work center. Use the six corresponding shift fields to identify all production line shifts for the specified work center.
Shift Code / Description A user defined code (07/SH) that identifies daily work shifts. In payroll systems, you can use a shift code to add a percent or amount to the hourly rate on a timecard.

For payroll and time entry:

If an employee always works a shift for which a shift rate differential is applicable, enter that shift code on the employee's master record. When you enter the shift on the employee's master record, you do not need to enter the code on the timecard when you enter time.

If an employee occasionally works a different shift, you enter the shift code on each applicable timecard to override the default.
Pay Point Code A code that indicates if a work center will have labor, material, or both, backflushed through it when quantities are reported against operations occurring in the work center. The default value for this code is the routing sequence record unless overridden when the routing is defined. Valid codes are:

0 – Not a backflush work center

B – Backflush material and labor

M – Backflush material only

L – Backflush labor only

P – Preflush material only

If you leave this field blank, the system uses the value in the Enter/Change Routing table.
Prime Load Code This value determines if a work center is machine or labor intensive. These codes are also used in Resource Requirements Planning and Capacity Requirements Planning calculations to develop load profiles.

Valid codes are:

L Run labor hours only

M Machine hours only

B Run labor plus setup labor hours

C Machine plus setup hours

O Other (will not generate resource units)
Critical Work Center A code that identifies the work center as critical or not critical when the system calculates capacity. Valid values are:

N Not a critical work center

1 A critical work center in calculating resource requirement planning only

2 A critical work center in calculating capacity requirements planning only

3 A critical work center in calculating resource requirements planning and capacity requirements planning

4 Not a capacity work center (will not be generated in capacity planning)

Note: The system displays Type 3 work centers whenever type 1 or type 2 is selected in this field.
Crew Size The number of people who work in the specified work center or routing operation.

The system multiplies the Run Labor value in the Routing Master table (F3003) by crew size during costing to generate total labor dollars.

If the Prime Load Code is L or B, the system uses the total labor hours for backscheduling. If the Prime Load Code is C or M, the system uses the total machine hours for backscheduling without modification by crew size.

Form-specific information

For Shop Floor Control:

If you leave the Hours field on the Routing Revisions form blank, the system uses the value entered in this field for lead time and scheduling calculations.
Number of Machines This represents the normal number of machines in this work center. When you run the Work Center Resource Units Refresh program, this number is multiplied by the number of work hours per day from the Manufacturing Constants table (F3009) to generate the total gross machine hours available in the work center each day.
Number of Employees This represents the normal number of employees in this work center. When you run the Work Center Resource Units Refresh program, the system multiplies this number by the Number of Work Hours Per Day from the Manufacturing Constants table (F3009) to generate the total gross labor hours available in the work center each day.
Resource Offset A value used in the Resource Profile table (F3303) to determine the number of days that the actual use of a work center resource should be offset from the forecasted need date.
Location - Issue A code that identifies inventory locations in a branch/plant. You define the format of the location identifier by branch/plant.

Form-specific information

This location and the backflush options in Manufacturing Constants (P3009) control the location from which a component is backflushed.
Location Branch This is the branch plant of the location associated with the work center.

To enter work center hours

On Enter/Change Work Center

Complete the following fields:

  • Queue Hours

  • Move Hours

  • Replenishment Hours

Field Explanation
Queue Hours The total time (in hours) that an order is expected to be in queue at work centers and moving between work centers.

The system stores this value in the Item Branch table (F4102). You can calculate this value using the Lead time Rollup program or you can enter it manually. When you run the Lead time Rollup program, the system overrides manual entries with calculated values.

Form-specific information

If the Routing Master values are blank, the default value comes from the work order routing. However, the system uses these values only for back scheduling variable lead time items.
Move Hours The planned time in hours that is required to move the order from this operation to the next operation in the same work center.

If the Routing Master values are blank, the default value comes from the work order routing. However, the system uses these values only for backscheduling variable lead time items.

Form-specific information

If you leave the Hours field on the Routing Revisions form blank, the system uses the value entered in this field for lead time and scheduling calculations.
Replenishment Hours - Standard The time required before a consuming work center will have a replacement container of goods available from this supplying work center.

This value is used only for KANBAN card processing in Shop Floor Control.

See Also:

9.3 Entering Costing and Accounting Information

Navigation

From Daily Product Data Management (G30), choose Daily PDM Discrete

From Daily PDM Discrete (G3011), choose Enter/Change Work Center

After you enter a work center, you can enter simulated rates for machine and labor hours. The Product Costing and Manufacturing Accounting systems use these values to generate reports, rollups, and journal entries. The Cost Rollup program uses all of these values to calculate the simulated cost.

You can update the simulated rates, but not the frozen values. The system updates frozen values when you run Frozen Update.

To enter costing and accounting information

On Enter/Change Work Center

  1. Choose the Work Center Rates function.

    Figure 9-2 Work Center Rate Revisions screen

    Description of Figure 9-2 follows
    Description of "Figure 9-2 Work Center Rate Revisions screen"

  2. On Enter/Change Work Center Rate, complete the following fields:

    • Cost Method

    • Direct Labor (Simulated)

    • Setup Labor (Simulated)

    • Labor Variable Overhead (Simulated)

    • Labor Fixed Overhead (Simulated)

    • Machine Run (Simulated)

    • Machine Variable Overhead (Simulated)

    • Machine Fixed Overhead (Simulated)

Field Explanation
Cost Method A user defined code (system 40, type CM) that identifies a cost method. Cost methods 01 through 08 are hard-coded.

Form-specific information

This code was entered on Branch/Plant Constants.
Direct Labor Simulated This rate, in cost per hour, is the rate used to calculate the current labor cost as of the last simulation and update.
Setup Labor Simulated This rate, in cost per hour, is the rate used to calculate the current setup labor cost as of the last simulation and update.
Labor Var. Overhead Simulated This rate, in cost per hour or percent of labor, is the rate used to calculate the current variable labor overhead cost as of the last simulation and update.
Labor Fixed Overhead Simulated This rate, in cost per hour or percent of labor, is the rate used to calculate the current fixed labor overhead cost as of the last simulation and update.
Machine Run Simulated This rate, in cost per hour, is the rate used to calculate the current machine cost as of the last simulation and update.
Machine Var. O/H Simulated This rate, in cost per hour or percent of labor, is the rate used to calculate the current variable machine overhead cost as of the last simulation and update.
Machine Fixed O/H Simulated This rate, in cost per hour or percent of labor, is the rate used to calculate the current fixed machine overhead cost as of the last simulation and update.

See Also:

9.4 Reviewing Operations by Work Center

Navigation

From Daily Product Data Management (G30), choose Daily PDM Discrete

From Daily PDM Discrete (G3011), choose Operations by Work Center

You can review operations by work center to:

  • Plan capacity, resource and manpower

  • Evaluate equipment needs

  • Display which items include routing operations at the work center

To review operations by work center

On Operations by Work Center

Figure 9-3 Operations by Work Center screen

Description of Figure 9-3 follows
Description of "Figure 9-3 Operations by Work Center screen"

Complete the following required fields:

  • Work Center

  • Branch/Plant

Work center hour information displays in the following fields:

  • Machine Hours

  • Labor Hours

Field Explanation
Run Hours Machine This is the standard machine hours expected to be incurred in the normal production of this item.
Run Hours Labor This is the standard hours of labor expected in the normal production of this item.

The run labor hours in the Routing Master table (F3003) are the total hours it takes the specified crew size to complete the operation. The hours are multiplied by the crew size during shop floor release and product costing.