4 Setting Up Shop Floor Management

This chapter contains the following topics:

4.1 Understanding Shop Floor Management Setup

This section provides an overview of JD Edwards EnterpriseOne Shop Floor Management setup, lists prerequisites, and discusses:

  • User-defined codes for work orders.

  • Work center setup.

  • Resource unit setup.

4.1.1 Overview of Shop Floor Management Setup

JD Edwards EnterpriseOne Shop Floor Management requires some setup before you can use the system. Setup for JD Edwards EnterpriseOne Shop Floor Management includes identifying the codes needed for work orders, such as priority, status, and category codes, and defining the information needed for discrete, process, and repetitive manufacturing, such as shop floor calendars, work centers, and so on.

You must also set up information that is necessary for manufacturing, such as generic messages, shop floor calendars, manufacturing constants, work centers, resource units, and item-to-line relationships.

4.1.2 Prerequisites

Before you set up JD Edwards EnterpriseOne Shop Floor Management, you must:

4.1.3 User-Defined Codes for Work Orders

Many fields throughout JD Edwards EnterpriseOne Shop Floor Management accept only user-defined codes (UDCs) for work orders. You need to define these UDCs for manufacturing work orders.

UDCs are stored in tables by system and code type. For example, system 31, type OS represents JD Edwards EnterpriseOne Shop Floor Management and a UDC called operation status. To set up operation status codes for work orders, use the User Defined Codes program (P0004A). If you enter an operation status code on another form that you did not identify as an operation status code in the User Defined Codes program, the system displays an error message. For example, in the Operation Status Code field, you can enter only those codes that exist in UDC 31/OS.

You can access all codes through a single user-defined code form. You can access the UDC form by entering UDC in the fast path. After you select a UDC from a menu, you can change the values in the System Code and User Defined Code fields to access another UDC table. The system stores UDCs in the User Defined Codes table (F0005).

This table describes the UDCs for work orders:

User-Defined Code Description
Work Order/ECO Type (00/TY) Work Order/Engineering Change Order (ECO) type codes indicate the classification of a work order. For example, rework orders might be type R, and design orders might be type D.
Work Order Priority Code (00/PR) Work order priority codes indicate the priority of a work order in relation to other work orders. These codes are for reference only and do not affect the scheduling or planning of work. Do not use these codes as the formal priority system.
Work Order Status Code (00/SS) Work order status codes describe the status of an order or the current step in the process of implementing a work order. You can prevent certain transactions from occurring, based on the status of a work order. For instance, the system can hold work orders for which the status indicates that they are pending approval or quality inspection, and release work orders that have status codes indicating that they have been approved or have passed quality inspection. You can also set up the system to automatically update the work order status code when you enter issue and completion transactions.
Phase and Matter Codes (00/W1) Phase and matter codes indicate the implementation phase of the work order. You can use phase and matter codes to group families of orders for project management, cost accounting, and inquiry purposes. For example, if inspection on the internal parts of a product is not possible beyond a certain point in its production, you can divide the routing into phases. You can then use the phase code to indicate the availability of the product for the next level of inspection.
Work Order Category Codes (00/W2 and 00/W3) Work order category codes can represent any category or description by which you want to group work orders for project management, cost accounting, or reviews. For example, you can set up one category code to represent types of problems that you might encounter during the work order implementation, such as improper startup or inadequate maintenance, and another code to represent locations in which the work is taking place.
Operation Status (31/OS) Work order operation status codes indicate the progress or status of an order during the steps that you follow in a particular operation. For example, you can set up codes to indicate whether materials have been received or work has begun at a particular operation. This code enables management to monitor the progress of operations that have longer run times, or shop floor personnel to indicate when items are ready to move to the next operation.
Document Type (00/DT) Document type codes categorize information throughout the JD Edwards EnterpriseOne systems. You can specify up to 12 document types to use for work orders and rates in supply and demand calculations by entering them in the processing options for the Supply/Demand Inclusion Rules program (P34004) in Material Planning. Manufacturing Accounting uses the document type to match the orders to the document types that are defined in the Automatic Accounting Instructions (AAIs) when you post journal entries to the general ledger. You can use the document type codes to categorize work orders by document type. For example, you can define document type codes to indicate rework orders, prototype orders, or repair orders. If you do not specify a document type on a new work order, the system enters a document type of WO (Firm Work Order).

In the Codes field, enter the two-character document type code for which you want the system to track lot quantities. For example, enter OP to enable the system to track lot quantities for all purchase orders.

Order Type (48/OT) Order type codes enable you to distinguish each work order record in the Work Order Master File table (F4801) from other records with different work order types. For example, you do not use the same document type and work order type to represent both an equipment work order and a manufacturing work order. The relationship between the document type and its related order type is defined in the Document Type Maintenance program (P40040).
Unit of Measure (00/UM) Unit of measure codes must be assigned to each item that you purchase, issue, manufacture, or sell. Each item can have as many as eight units of measure, but one must be identified as the primary unit of measure. You must also set up the conversion tables after you have set up all unit of measure and potent unit of measure codes.

Potent units are units of measure for items with potency. The potent units always have a comparable code in UDC 00/UM. For example, if the company uses potency and measures product in gallons, you set up a code such as GA for gallon and a potent unit code such as GP for the potent gallon. When you set up potent units, you must enter P in the Special Handling Code field.

When the system creates commitments for an item that is set up with a potent unit of measure, it converts the quantity to the primary unit of measure. For example, if you issue product in GP (potent gallons), the system converts it to the primary unit of measure of GA (gallons).


4.1.4 Work Center Setup

You can maintain general information about a work center, such as pay points, prime load codes, number of machines and workers, crew size, and backflush locations. You set up work centers by branch/plant, which means that you can associate the same work center with multiple branch/plants. You can also define a unique shop floor calendar for a particular combination of work center and branch/plant.

From the Enter/Change Work Centers program (P3006), you can access business unit information to maintain business units and track costs.

Note:

If you use JD Edwards EnterpriseOne Warehouse Management and do not set up valid work center locations, the system interfaces with JD Edwards EnterpriseOne Warehouse Management when you attach a parts list to a work order. If you set up valid work center locations before you attach a parts list, but the work order quantity exceeds the quantity that you have in the work center, the system uses JD Edwards EnterpriseOne Warehouse Management to create a pick request for the remaining quantity to fill the work order request. This process follows the rules that you define in JD Edwards EnterpriseOne Warehouse Management.

Use the Enter/Change Work Centers program to set up production lines for repetitive manufacturing. This setup consists of linking work centers together to establish a specific repetitive line on which a product family will be manufactured.

4.1.5 Resource Unit Setup

Resource unit information indicates the capacity of a work center on a given day. The system uses this information to back-schedule work orders in JD Edwards EnterpriseOne Shop Floor Management and to calculate available hours for capacity planning.

You can manually change the values to account for scheduled or unscheduled downtime, additional shifts, or vacation time. However, each time that you run the Work Center Resource Units Generation program (R3007G), the system recalculates the form values based on information in the Work Center Revisions program (P3006), the Shop Floor Calendar program (P00071), and the Manufacturing Constants table (F3009), and then overwrites the changes that you entered manually, based on the effectivity dates that you specified in the processing options.

The Work Center Resource Units Generation program recalculates the work center hours and updates them on the Work Center Resource Units program (P3007). The system recalculates the resource units for a work center based on information in the Work Center Revisions program, the Shop Floor Calendar program, and Manufacturing Constants table. You can create versions to recalculate the labor, setup, or machine hours, and set the processing options to update different dates and branches.

The system multiplies the number of machines or employees by the work hours per day from the Work Center Revisions program. If the work hours per day are not available from the Work Center Revisions program, then the system uses the work hours per day from the Manufacturing Constants table that the system defines for each work day on the Shop Floor Calendar.

Resource unit calculations for machine- and labor-related hours are:

  • Machine-related hours (prime load code = C or M).

    Number of machines multiplied by work hours per day

  • Labor-related hours (prime load code = L or B).

    Number of employees multiplied by work hours per day

4.2 Setting Up Shop Floor Calendars

This section provides an overview of shop floor calendar setup and discusses how to:

  • Set processing options for the Shop Floor Calendar program (P00071).

  • Set up shop floor calendars.

  • Revise shop floor calendars.

4.2.1 Understanding Shop Floor Calendar Setup

You can use the Shop Floor Calendar program (P00071) to define the work days by month and year for each branch or all branches in the system. The system uses this calendar to determine manufacturing schedules.

You can also define calendars by shift. The system uses these calendars for line scheduling and sequencing by shift in repetitive manufacturing. Shift calendars are not used for Distribution Requirements Planning (DRP), Master Production Scheduling (MPS), or Material Requirements Planning (MRP).

To increase plant capacity, manufacturers run production lines for more than one shift, as well as run different lines of production on different days of the week. You specify these shifts and lines in the Shop Floor Calendar program.

When you have not yet defined the shop floor calendar for the branch, month, and year, the system preloads default work days (Monday through Friday) and weekends (Saturday and Sunday). Holidays are always user-defined.

4.2.2 Forms Used to Set Up Shop Floor Calendars

Form Name Form ID Navigation Usage
Work With Workday Calendar W00071B Shop Floor Management Setup (G3141), Shop Floor Calendar

Product Data Management Setup (G3041), Shop Floor Calendar

Set up calendar year, month, type, name, and shift code.
Workday Calendar Revisions W00071A Click Add on the Work With Workday Calendar form. Set up working and nonworking days.

4.2.3 Setting Processing Options for the Shop Floor Calendar Program (P00071)

Processing options enable you to specify the default processing for programs and reports.

4.2.3.1 Interop

Type - Transaction

Specify the transaction type (UDC 00/TT) for the interoperability transaction. If left blank, outbound interoperability processing will not be performed.

Before Image Processing

Specify image processing in interoperability transactions. Values are:

1: Write before images for outbound change transactions.

Blank: Write only after images.

4.2.4 Setting Up Shop Floor Calendars

Access the Work With Workday Calendar form.

Branch/Plant

Enter a code that represents a high-level business unit. Use this code to refer to a branch or plant that might have departments or jobs, which represent lower-level business units, subordinate to it. For example:

Branch/Plant (MMCU)

Dept A (MCU)

Dept B (MCU)

Job 123 (MCU)

Business unit security is based on the higher-level business unit.

With the exception of ALL, which is a hard-coded value for the program, the branch/plant that you assign must exist in the Business Unit Master table (F0006).

Calendar Year

Enter a two-digit number that corresponds to a calendar year.

Calendar Month

Enter a number that corresponds to the month in a calendar year.

Calendar Type (optional to specify unique calendars for the same branch/plant)

Enter a value from UDC 42/WD (Work Day Calendar Type) that specifies how the calendar is used. For example, the calendar might be specific to an industry such as banking or it might be used to schedule delivery persons for a route.

Note:

If you use the default value of *, the system updates the value to Blank even though Blank is not set up as a value in the UDC table.
Calendar Name (optional to specify unique calendars for the same branch/plant)

Enter a code used to classify values within a calendar type. For example, if the calendar type is ROUTE, you can enter a code that specifies a particular route, such as Daily or Weekend.

Note:

The system does not validate the code that you enter.

If you enter a value in the Calendar Name field, you must enter a shift code.

Shift Code (optional to specify unique calendars for the same branch/plant)

Enter a value from UDC 00/SH (Shift Codes) that identifies daily work shifts.

4.2.5 Revising Shop Floor Calendars

Access the Workday Calendar Revisions form.

Day - Type of Day

Enter a code that specifies whether the day of the week is a working day, holiday, vacation day, and so on. With the exception of W, which is hard-coded as a working day, all other values specified are nonworking days. The value that you enter must exist in UDC 00/TD (Type of Day). Examples of values include:

A: Absent

B: Billable

E: Weekend

H: Holiday

W: Work Day

4.3 Setting Up Manufacturing Constants

This section provides an overview of Manufacturing Constants setup and discusses how to set up Manufacturing constants.

4.3.1 Understanding Manufacturing Constants Setup

You set up manufacturing constants to define branch-specific information that affects processing throughout the JD Edwards EnterpriseOne Manufacturing systems. You can use the Manufacturing Constants program (P3009) to specify the values for constants. This table describes the information that appears on each tab of the Manufacturing Constants program:

Tab Content
Manufacturing constants These constants specify:
  • Whether the system validates bills of material online as you enter them.

  • Whether an audit trail is created that tracks all changes made to bills of material.

  • Whether the system uses the master routing for an item or the routing instructions that are defined for the parent item.

  • (Release 9.2 Update) Whether activity rules processing is enabled for the branch plant.

Shifts These constants specify the number of work hours that the plant typically operates in a day.
Commitment Control These constants specify when inventory is committed and backflushed.
Costing options These constants specify which overhead cost calculations are used and whether the system considers work center efficiency when it calculates direct labor and overhead costs. You can specify whether costs are maintained by cost components and work center or by cost component only. Costing options also include the source for machine and labor rates.

4.3.1.1 Work Order Activity Rules Processing for Branch Plant (Release 9.2 Update)

The WO Activity Rules Processing control in the Manufacturing Constants program (P3009) enables work order activity rules by branch/plant. Setting up activity rules for manufacturing work orders establishes a process flow and avoids erroneous status updates.

When work order activity rule processing is enabled for the selected branch plant, any process that updates a manufacturing work order status triggers activity rules if defined and validates the work order status updates against the defined activity rules.

4.3.2 Form Used to Set Up Manufacturing Constants

Form Name Form ID Navigation Usage
Manufacturing Constants Revision W3009B Shop Floor Management Setup (G3141), Manufacturing Constants

Locate and select a branch/plant on the Work with Manufacturing Constants form.

Set up manufacturing constants.

4.3.3 Setting Up Manufacturing Constants

Access the Manufacturing Constants Revision form.

4.3.3.1 Manufacturing Constants

Backflush Options

Enter a code to determine how the system performs commitment and release of inventory. Values are:

1: Create a standard parts list based on the value in the Commitment Control field in the Manufacturing Constants table.

2: Create a parts list, committing to the location indicated in the Work Center Master File table (F30006). The Operation Sequence field in the Bill of Material Master File table (F3002) determines the work center that is used.

Note:

You must create the work order routing before the parts list. If you are running the Work Order Generation program (R31410), you must set the Process tab, Parts List, and Routing Instructions processing option to 3 to generate the parts list and routing instructions at the same time.

If you define a consuming location on the routing instructions, this location overrides the consuming location defined in the F30006 table.

Status for Changes

Specify the status beyond which work orders and rates cannot be changed in the Line Scheduling and Line Sequencing Workbench programs.

(Release 9.2 Update) WO Activity Rules Processing (Work Order Activity Rules Processing)

Specify whether activity rule processing is enabled for the selected branch plant. Values are:

Y: Yes, activity rule processing is enabled for this branch plant.

N: No, activity rule processing is not enabled for this branch plant.

On-Line BOM Validation (on-line bill of material validation)

Specify whether the system performs an online component or parent validation and low-level code assignment when you revise a bill of material.

It is recommended that you validate items online unless the bills of material are extremely large. If you select not to validate items online, you must validate the items in batch. Run the Integrity Analysis program (R30601) after updates to the bill of material and before you run the Item Cost Component - Frozen Update program (R30835) or perform the DRP/MPS/MRP Generation program (R3482).

To specify that the system validates items online, click the On-Line BOM Validation option under the BOM/Routing Options heading. If you do not click the On-Line BOM Validation option, the system does not validate items online.

Log Bill of Material

Specify whether changes to the bill of material are recorded in the Bill of Material Change File table (F3011). When you log bill of material changes, the system saves the old bill of material and the new, changed bill of material. To record changes to the bill of material, click the Log Bill of Material option under the BOM/Routing Options heading.

Master Routings

Specify whether the system uses the master routing for an item or a routing defined for the parent item. Both routings are retrieved from the Routing Master table (F3003).

If you select to check for master routings, the JD Edwards EnterpriseOne Shop Floor Management system checks the Item Cross Reference table (F4104), cross-reference type MR, for the parent item. If it finds a cross-reference, the program uses the master routing from table F3003. If it does not find a cross-reference, the system uses the routing defined for the parent item. If you do not select to check for master routings, the program uses the parent item's routing from table F3003.

To specify that the system checks for cross-references and uses a master routing for the item, click the Master Routings option under the BOM/Routing Options heading.

4.3.3.2 Shifts

Work Hours

Enter the number of work hours that the manufacturing plant operates per day.

You can enter hours for up to six different shifts. However, the Work Hours Per Day field displays the total of only the first three shift hours.

Shift

Enter a value from UDC 00/SH (Shift Codes) that identifies daily work shifts.

In JD Edwards EnterpriseOne Payroll systems, you can use a shift code to add a percentage or amount to the hourly rate on a timecard.

For JD Edwards EnterpriseOne 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 value.

4.3.3.3 Commitment Control

Select the Commitment Control tab to select an option from the Commitment Control group box and an option from the Hard/Soft Commit group box.

Commitment Control

Select an option under the Commitment Control heading to specify the inventory location to which commitments are made.

Note:

The system activates this field only when you create hard commitments.

Further clarification of the three available options are:

  • Primary Location.

    Make commitments to the primary location in the branch/plant where the work order originates.

  • Split-Cross Branch Boundaries.

    Split the parts list and commitments to fill any component shortages. The system can cross branch boundaries to fill requirements. In this case, the system uses the next alphabetical branch/plant listed in the table that occurs after the branch/plant on the work order header.

    For example, for the branch/plants CAL, CHI, CLE, and HOU:

    If the system starts committing inventory at branch/plant CHI, it accesses CLE as the next branch/plant. If inventory is low in all locations, the system makes the remaining commitments to the primary location of the branch/plant on the work order header.

  • Split-Don't Cross Branch Boundaries.

    This option is similar to Split-Cross Branch Boundaries, but the system cannot cross branch boundaries.

    Note:

    When you set the Commitment Method field in the Item Branch File table (F4102) table to 2 or 3 (lot number or expiration date control), you must use the Split-Don't Cross Branch Boundaries option.
Hard/Soft Commit

Select an option under the Hard/Soft Commit heading to specify how JD Edwards EnterpriseOne Shop Floor Management commits inventory.

The options are:

  • Hard commitment at creation of parts list.

    The system performs a hard commitment at the creation of the parts list. The hard commitment remains in effect until inventory is relieved.

  • Soft commitment, then changed to hard commitment when printing.

    The system performs a soft commitment at the creation of the parts list. The system then changes the commitment to a hard commitment during the pick list print process for the work order. The hard commitment remains in effect until inventory is relieved.

  • Soft commitment at creation of parts list.

    The system performs a soft commitment at creation of the parts list. The soft commitment remains in effect until inventory is relieved.

When you set the Commitment Method field in the Branch/Plant Constants form to 2 or 3, you must use either Hard commitment at creation of parts list or Soft commitment, then hard commitment when printing because a hard commitment must be performed.

If you want to identify substitute items when a shortage occurs, you must select the hard commitment at creation of parts list option.

When you select either soft, hard when printing, or soft at creation of parts list, any line item in the parts list may be hard-committed before inventory is printed or relieved.

4.4 Setting Up Employee Labor Rates

This section provides an overview of employee labor rate setup and discusses how to set up employee labor rates.

4.4.1 Understanding Employee Labor Rate Setup

You can set up codes that represent the hourly labor rates for employees. The Generic Message/Rate table (F00191) contains employee labor rates that the system uses to calculate actual labor costs. For each code, you can define the name or type of employee that the code represents and the hourly labor rate for the employee or job category.

When you use actual costing, the rate that you define for each employee appears in the Employee Rate field on the Time Entry Revisions form (W311221C) when the employee enters time transactions.

4.4.2 Form Used to Set Up Employee Labor Rates

Form Name Form ID Navigation Usage
Enter Generic Message/Rates W00191D Shop Floor Management Setup (G3141), Employee Labor Rates

Select Message/Rates from the Row menu on the Work With Generic Message/Rate Types form.

Set up employee labor rates.

4.4.3 Setting Up Employee Labor Rates

Access the Enter Generic Message/Rates form.

Code

Enter a code that should represent an address book record of an employee who completes work on a work order.

Rate

Enter a code used to define rate information in the Generic Rate/Message table (F00191).

4.5 Setting Up Item-to-Line Relationships

This section provides an overview of item-to-line relationship setup and discusses how to set up item-to-line relationships.

4.5.1 Understanding Item-to-Line Relationship Setup

For repetitive manufacturing, the item-to-line relationships define the lines on which an item is produced and the amount of resources consumed by an item on each line. The Line/Item Relationships program (P31093) enables you to add, change, and delete data that is stored in the Line/Item Relationship Master table (F3109). You can define work center operations within a production line.

Note:

The JD Edwards EnterpriseOne Requirements Planning system uses the record that you identify as the default line when the system creates rates. The specifications for shift and period are valid only for the default line.

4.5.2 Form Used to Set Up Item-to-Line Relationships

Form Name Form ID Navigation Usage
Line Item Relationships Revisions W31093B Shop Floor Management Setup (G3141), Line/Item Relationships

Enter a branch/plant and item number and then click Add on the Work With Line/Item Relationships form.

Set up item-to-line relationships.

4.5.3 Setting Up Item-to-Line Relationships

Access the Line/Item Relationships Revisions form.

Line/Cell Identifier

Enter a number that defines a production line or cell. Detailed work center operations can be defined inside the line or cell.

Capacity consumed

Enter a number that indicates how many of the line's resource units are needed to produce one item.

Use As Default (0/1)

Enter a code that determines which relationship the system uses as a default value.

Default Shift

Enter a value from UDC 00/SH (Shift Code) that identifies daily work shifts.

In JD Edwards EnterpriseOne Payroll systems, you can use a shift code to add a percentage or amount to the hourly rate on a timecard.

For JD Edwards EnterpriseOne 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 value.

The system uses this field as the default value when you enter rates.

Default Period

Enter a code that determines the frequency of the schedule. Values are:

1: Monthly

2: Weekly

3: Daily

4: Per Shift (for future use)

The system uses this field as the default value when you enter rates.