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Contents
List of Figures
Title and Copyright Information
Preface
Audience
Documentation Accessibility
Related Documents
Conventions
1
Overview to Shop Floor Control - Discrete
1.1
System Integration
1.2
Features
1.3
Process Flow
1.4
Tables for Shop Floor Control
1.5
Types of Manufacturing
1.6
Enterprise Requirements Planning and Execution System
1.7
Sales Order Management System
1.7.1
Features of Sales Order Management
1.7.1.1
Simplicity
1.7.1.2
Flexibility
1.7.1.3
Adaptability
1.8
Procurement System
1.8.1
Features of Procurement
1.8.1.1
Simplicity
1.8.1.2
Flexibility
1.8.1.3
Adaptability
Part I Discrete Manufacturing
2
Overview to Discrete Manufacturing
2.1
Objectives
2.2
About Discrete Manufacturing
2.2.1
Blending, Filling, and Packaging
2.2.2
How Are Units of Measure Used?
2.2.3
Transactions in Shop Floor Control
3
Understand Work Orders
3.1
About Work Orders
3.2
What Happens When You Attach a Parts List?
3.2.1
Phantom Items
3.3
When Do You Attach Routing Instructions?
3.3.1
Outside Operations
3.4
How Does the System Calculate the Start Date?
3.4.1
Fixed Leadtime
3.4.2
Variable Leadtime
3.5
What Is Shop Paperwork?
3.6
What Is Backscheduling?
3.7
Blending, Filling, and Packaging
4
Create Work Orders
4.1
Entering Work Order Headers
4.2
Attaching the Parts List Interactively
4.3
Attaching the Routing Instructions Interactively
4.4
Assigning Serial Numbers
5
Process Work Orders
5.1
Processing Work Orders
5.2
Run Order Processing
5.2.1
Printing a Summary of Work Orders
6
Understand Commitments
6.1
About Commitments
6.1.1
What Is a Soft Commitment?
6.1.1.1
What Is a Hard Commitment?
6.1.2
Where in the Process Do You Commit Inventory?
7
Work with Commitments
7.1
What You Should Know About
7.2
Defining the Commitment Rules
7.3
Defining Commitments at a Work Center Location
7.4
Managing Commitments for Grade and Potency Controlled Items
7.5
Creating Commitments for Potent Units
7.6
Reposting Work Order Commitments
8
Understand Grade and Potency
8.1
Grade and Potency Control
8.2
Lot Control Items
9
Understand Lot Processing
9.1
Overview
9.1.1
Creating Lots
9.1.2
Lot Status
10
Enter Lot Information
10.1
Entering Lot Information
10.2
Entering Lot Information for Items
10.3
Entering Information for Lots
11
Work with Lot Availability
11.1
Working with Lot Availability
11.2
Viewing Lot Availability
11.3
Working with Lot Quantities
11.4
Working with Lot Activity Dates
11.5
Working with Lot Statuses (Release A9.3 Update)
12
View Lot Transactions
12.1
Viewing Lot Transactions
12.2
Printing Trace and Track Reports
12.3
Reviewing Trace and Track Information
12.4
Setting up Trace and Track Inclusion Rules
13
Reclassify Lots
13.1
Reclassifying Lots
13.1.1
Example: Types of Reclassifications
14
Review Availability and Shortages
14.1
Reviewing Availability and Shortages
14.2
Defining Availability Calculations for a Branch
14.3
Reviewing Availability
14.4
Managing Shortage Information
14.5
Printing Shortages
14.5.1
Printing Component Shortages
14.5.2
Printing All Shortages
15
Understand Issue Transactions
15.1
When Do You Issue Inventory?
15.2
How Do You Issue Inventory?
15.3
From Where is Inventory Issued?
15.4
What Tables Store Data when Issuing Inventory?
15.5
Where in the Process Do You Issue Inventory?
16
Issue Materials
16.1
Overview
16.2
Issuing Materials by Preflushing
16.3
Issuing Materials Manually
16.4
Recording Component Scrap
17
Work with Hours and Quantities
17.1
Overview
17.2
Where in the Process Do You Enter Hours and Quantities?
17.3
Entering Hours and Quantities Manually
17.4
Entering Hours and Quantities through Payroll Time Entry
17.4.1
Processing Options
17.5
Updating Hours and Quantities
17.6
Reviewing Hours and Quantities Transactions
17.6.1
Reviewing the Status of Hours, Quantities, and Operation Quantities
17.6.2
Reviewing the Hours and Quantities Report
18
Schedule Work Orders
18.1
Overview
18.2
Where in the Process Do You Schedule Work?
18.3
Reviewing Work Order Information
18.4
Revising Work Order Information
18.5
Printing Scheduling Information for Work Centers
19
Complete Work Orders
19.1
Overview
19.2
Completing a Work Order without Backflushing
19.3
Completing a Work Order through Backflush
19.4
Completing Partial Quantities on Work Orders
19.5
Processing Work Orders through Super Backflush
19.6
Processing Work Orders Using Quantity at Operation
19.7
Completing a Work Order with Serialized Components
19.8
Lot Status Processing at Work Order Completion
19.8.1
Full Completion/First Partial Completion:
19.8.2
Subsequent Completions:
20
Revise the Status of a Work Order
20.1
Revising the Status of a Work Order
20.2
Changing the Status of a Work Order to "Closed"
20.3
Purging a Work Order
21
Enter Rates
21.1
Entering Rates
22
Process Kanbans
22.1
Overview
22.1.1
One-Phase
22.1.2
Two-Phase
22.1.2.1
Inventoried Items Processing
22.1.2.2
Manufactured Processing
22.1.2.3
Manufactured Processing - Phantom Item
22.1.2.4
Externally Supplied Processing
22.2
Processing Kanban Consumption by Item
22.3
Processing Kanban Supply by Item
22.4
Processing Kanban Status Override
23
Review Information for Discrete Manufacturing
23.1
Reviewing Material Information
23.2
Reviewing Item Ledger Information
23.3
Reviewing Work Order Status
23.4
Reviewing Parts List Comparison
24
Print Material and Operation Reports
24.1
Printing Discrete Manufacturing Reports
Part II Repetitive Manufacturing
25
Overview to Repetitive Manufacturing
25.1
Objectives
25.2
About Repetitive Manufacturing
26
Schedule Rates
26.1
Scheduling Rates
26.2
Scheduling Items on a Production Line
26.3
Sequencing Rates by Classification Scheme or Manually
26.4
Reviewing Production Across Lines
27
Complete Rates
27.1
Completing Rates
28
Review Information for Repetitive Manufacturing
28.1
Reviewing Production Status
28.2
Reviewing Production History
28.3
Reviewing Line Dispatch List
29
Process Kanbans
29.1
Processing Kanbans
29.1.1
One-Phase
29.1.2
Two-Phase
29.1.2.1
Inventoried Items Processing
29.1.2.2
Manufactured Processing
29.1.2.3
Manufactured Processing - Phantom Item
29.1.2.4
Externally Supplied Processing
29.2
Processing Kanban Consumption by Item
29.3
Processing Kanban Supply by Item
29.4
Processing Kanban Status Override
30
Close Rates
30.1
Closing Rates
31
Orderless Processing
31.1
Processing Orderless Completion
31.2
Orderless Completion Inquiry
31.3
Orderless Manufacturing Accounting
Part III System Setup
32
Overview to System Setup
32.1
Objectives
32.2
About System Setup
33
Set Up Work Order Codes
33.1
Setting Up Work Order Codes
34
Set Up Manufacturing Information
34.1
Setting Up Standard Procedures
34.2
Setting Up Employee Labor Rates
34.3
Setting Up the Shop Floor Calendar
34.4
Setting Up Manufacturing Constants
34.5
Setting Up Work Order Activity Rules
34.6
Setting Up Work Centers
34.7
Setting Up Resource Units
34.8
Setting Up Line and Item Relationships
Part IV Processing Options
35
Discrete Manufacturing Processing Options
35.1
Manufacturing Work Order Entry (P48013)
35.2
Generate and Print Work Orders (P31410)
35.3
General User-Defined Codes (P0005A)
35.4
Work Order Repost (P3190)
35.5
Lot Master Revisions (P4108)
35.6
Lot Availability (P41280)
35.7
Lot Tracing and Tracking (P41203)
35.8
Item Reclassifications (P4116)
35.9
Part/Ingredient Availability (P30205)
35.10
Parts List Inquiry (P3121)
35.11
Item Shortage Workbench (P3128)
35.12
Shortage Revisions (P3118)
35.13
Work Order Component Shortage List (P31418)
35.14
Work Order Inventory Issues (P31113)
35.15
Component Scrap Transactions (P31116)
35.16
Manufacturing Scheduling Workbench (P31225)
35.17
Work Order Time Entry (P311221)
35.18
Manufacturing/Payroll Time Entry (P061181)
35.19
Production Status (P31226)
35.20
Work Order Completion - Full (P31114)
35.21
Release Backorders (P42117)
35.22
Super Backflush (P31123)
35.23
Work Order Purge (P4801P)
35.24
Kanban Consumption/Supply (P3157)
35.25
Kanban Status Override (P3163)
35.26
Co-/By-Products Produced by Process (P30201)
35.27
Item Availability (P41202)
35.28
Supply & Demand (P4021)
35.29
Item Ledger - Costs (P4111)
35.30
Parts List Comparison (P31117)
36
Repetitive Manufacturing Processing Options
36.1
Enter/Change Rate Schedule (P3109)
36.2
Line Scheduling Workbench (P3153)
36.3
Line Sequencing Workbench (P3156)
36.4
Schedule Review (P3152)
36.5
Rate Transactions Workbench (P3119)
36.6
Super Backflush (P31123)
36.7
Work Order Time Entry (P311221)
36.8
Production Status (P31226)
36.9
Production History (P31227)
36.10
Line Dispatch List (P3159)
36.11
Kanban Consumption/Supply (P3157)
36.12
Kanban Status Override (P3163)
36.13
Batch Rate Close by Date (P3191)
36.14
MFG Accounting for Orderless Completion (P31862)
37
System Setup Processing Options
37.1
General User-Defined Codes (P0005A)
37.2
Generic Rate/Message Records Program (P00191)
37.3
Work Center Resource Units Refresh (P3007G)
37.4
Kanban Size Calculation (P30450)
38
Z File Processing Options
38.1
Work Center Information - Z File (P3006Z)
38.2
Routing Information - Z File (P3003Z)
38.3
Work Order Parts List - Z File (P3111Z)
38.4
Work Order Hours and Qty - Z File (P311221Z)
38.5
Work Order Routing - Z File (P3112Z)
38.6
Manufacturing Work Order Entry - Z File (P48013Z)
A
Flash Messages in Shop Floor Control
A.1
W.O. Scheduling
A.2
Operation Scheduling
A.3
Urgent
B
Lead Times
B.1
Introduction to Lead Times
B.2
Work Order Start Dates
B.2.1
Fixed Lead Time
B.2.2
Variable Lead Time
B.3
Operation Start and Due Dates
B.3.1
Fixed Lead Time
B.3.2
Variable Lead Time
B.4
Overlapping Operations
B.5
Overlapping and Concurrent Operations
B.6
Calculating Lead Times
B.6.1
Level Lead Time
B.6.1.1
Calculation
B.6.1.2
Calculation
B.6.2
Cumulative Lead Time
B.6.2.1
Calculation
B.6.3
Per Unit Lead Time
B.6.3.1
Calculation
C
Functional Servers
C.1
About Functional Servers
D
Import Mass Data into Manufacturing Systems
Index
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