Understanding Lean Manufacturing Transactions

Lean manufacturing is characterized as a product flow line driven by customer demand. You typically set up a flow line for a product family with the end item product being delivered at a continuous rate. As a consequence of this production method, the transactions that support lean manufacturing differ from traditional work order driven manufacturing.

In preparation for production on a flow line, you can create a daily plan in JD Edwards EnterpriseOne or import one from Demand Flow Manufacturing (DFM). A daily plan defines the end items and quantities that are to be produced on a flow line in a given time period.

After creating the daily plan, you have the option of preprocessing the data you need for completions. Preprocessing involves exploding the bill of material, routing, and labor records for a daily plan or item into a multilevel structure. Preprocessing an item or daily plan improves the performance of item completions. Although preprocessing is an optional activity, it is strongly recommended for customers who have large bills of material and routings or who complete at a high rate of speed.

You use the Item Completions program (PF31011) to complete the items defined in a daily plan. The Item Completions program supports item completions without the dependency of a corresponding work order. This feature enables you to significantly reduce the number of transactions required to complete items coming off of a flow line.

Note: The Item Completions program does not support JD Edwards EnterpriseOne lean solutions, such as repetitive manufacturing.

You may also perform ad hoc item completions. Ad hoc items are items for which you did not create a daily plan.

You can enter a lot number on item completions or on the daily plan. Lot numbers entered on a daily plan appear by default in item completions. Lot numbers must be entered manually and are validated by the system.

Once you have completed an item, you can review, track, and reverse lean transactions. You can track the completion on a daily plan based on the production ID used in the daily plan or the transaction ID created with each completion. The completion process associates parts list, routing, hours, and quantity information with the transaction ID. Transaction records can include both open and closed daily plans.

The system enables you to reverse an item completion. When you reverse an item completion, the system reverses all associated transactions. However, if you meet the component demand through a purchase order and receipt, the system does not automatically reverse the receipt. You have to adjust inventory manually to account for the reversal.

Because the Item Completions program does not support interactive completions, the following functionality is not available:

  • Percent Bills of Material.

  • Advanced lot processing.

  • Component lot processing.

  • Substitute item processing.

  • Outside operations.

  • Configured item completions.

  • Process completions.

  • Multi location completions.

    Because lean manufacturing supports multiple independent completion transactions, it is assumed that these are separate transactions.

  • Duplication of bill of material media objects.

  • Component scrap.

  • Integration with JD Edwards EnterpriseOne Quality Management.

  • Integration with JD Edwards EnterpriseOne Warehouse Management.