YearOne PowerLink 3.10 Manufacturing and Bill of Materials

Transcription

1 YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June 2012

2 Publication Date Product Version June 2012 YearOne PowerLink 3.10 YearOne Software Australia Pty Ltd ACN ABN Ross River Road, Mundingburra QLD 4812 Australia Tel Fax info@yearone.com.au Website: YearOne Software Australia Pty Ltd YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June 2012 ii

3 Contents Introduction 1 Quick Start 2 Using Bill of Materials and Manufacturing 4 Assemblies Workflow...4 Searching for Kits...5 Searching for Components...6 Creating Bill of Material / Kits...7 Global Kit Maintenance...8 Purchase Raw Materials...9 Create a Requisition...9 Print a Build List (Bill of Materials)...10 Issue Stock used to make Finished Goods...10 Create Requisitions from a Quote...11 Customising Manufactured Products...12 Enquiries and Reports...14 Assemblies Dashboard 15 Assemblies Home Page...17 My to Do List...17 Requisition Summary...17 Details Page...17 Summary...17 Component List...18 Requisitions in Progress...18 Active Customer Orders...18 Last Years Sales...19 Manage Page...19 Product Reorder...19 Kit Component Warnings...19 Deliveries Due...20 Low Margin Kits...20 YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June 2012 iii

4 Planning Page...20 Planning...20 Builds Page...21 Builds to Consider...21 Component Calculations...22 Favourites Page...22 Quick Add (Add New)...23 YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June 2012 iv

5 Introduction YearOne PowerLink is a powerful manufacturing solution, suitable for manufacturers s who build to order, or makes a fixed set of finished goods. Bill of Materials. You can create a BOM with unlimited levels of kits or assemblies which can include labour, on-costs and fixed setup costs. Requisitions. You can create requisitions when you want to manufacture the goods. As stock is used, it can be issued to a manufacturing job, so you know at any time the value of your work in progress. Flexibility. You can partially receipt finished goods into stock so that part of an urgent order can be shipped prior to the entire manufacturing batch being completed. Quotes. Quotes can be created within PowerLink. If a quote is accepted, requisitions and customer orders can be automatically created. Custom Jobs. If your customer s require variations to a finished product (eg. Different colour, finish etc), you can customise the finished item within the quote. When a manufacturing requisition is created, the changes to the bill of materials can be issued automatically. Reports. On-screen enquiries and reports give you a top down overview of what is going on at any time. Note: Many features in PowerLink are shared in all modules. These include dashboard features, menu access rights etc. If you cannot find details of a feature in this user guide then you should check the Getting Started Guide. NOTE: Some features require both the Bill of Materials and Manufacturing modules to be installed. Contact you Attaché consultant if you need to add modules. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

6 Quick Start This chapter contains a checklist for setting up the PowerLink Bill of Materials and Manufacturing modules. Refer to later sections in this user guide for more detailed instructions on setting up and using PowerLink. Important: You should have already installed PowerLink and completed the Quick Start checklist in the PowerLink Getting Started Guide before you can finish setting up and use the Module. 1. Menu Access Rights. By default, access to programs and reports is restricted. Login as SUPERVISOR and Select Tools System Menu Access Rights to allow access to programs and reports for individual users. 2. Search Access Rights. You can search for products and kits from the Assemblies dashboard using the Menu gadget search bar. This requires access be given to the BI ENQUIRY SEARCH RESULTS PRODUCT and BI ENQUIRY SEARCH RESULTS KITS gadget via the Tools System Menu Access Rights program. (See the Menu Gadget Search Bar section in Getting Started Guide for more details on using this feature.) 1. Dashboard Gadget Access. By default, gadgets in the Assemblies dashboard pages are not visible to users. You can allow access to gadgets on dashboard pages in Supervisor Mode. Refer to the ViewPoint (Dashboard) section below for more information. 3. Set Options. Bill of Materials is ready to use straight away, but you can configure the options to meet any special needs. a. Select Setups Product Options Kitting Options. b. Product Group for Labour. Do you want to include labour into the cost of your finished goods? If so, then you need to create a labour product with an hourly cost Attaché 7, and allocate it to a labour group (eg. LAB ) and specify this group in the options. c. Fixed Costing Method. The option Update Kit Cost in Attaché when Building should be enabled unless you are using Fixed Costing method. d. Build Options Defaults and Warnings. When you want to build (receipt finished goods into Attaché), there are defaults and warnings which can be selected. TIP: If you want to use the F8-Auto Create feature to replenish finished goods which have gone into negative (imprest system), then you will need to select which quantities are to be included in the availability (negative stock) calculation. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

7 e. Next Requisition Number. If you are moving from another system, you can continue your numbering by entering the Next Requisition Number. 4. Create Bill of Materials. Enter the raw materials and quantities required to build each of your finished goods. Finished goods and raw materials should already be setup in Attaché 7. a. Masterfiles Products Maintain Products / Kits. b. Select code and go to Kit Details and enter BOM. c. Select Refresh Cost to update the total cost based on the current raw material cost. 5. Print Kit Listing Report. Print and check that all kits have been entered correctly. d. Reports Products Kit Listing. 6. Enter Requisitions. Enter any currently outstanding finished goods as requisitions. Use F4 to generate the next requisition number, or enter it manually. e. Transactions Products Create or Modify Kit Requisitions. 7. Print Requisition Report. Print and check that all requisitions have been entered correctly. f. Reports Products Kit Requisition Report. 8. Custom Fields. Do you need to capture any information against batches beyond the standard data entry fields? If so, you can create custom Batch and Product fields and enter data in them when you create jobs. g. Setups Products Setup Custom Kit Batch Fields h. Use F7-Add to create fields. Use F8-Update to save and update database. 9. Build Report Layout. Do you need a layout for the Build report that is different from the default? i. Setups Custom Reports Custom Reports Designer j. Select Copy - Standard Report and then Build List (for example) and F9-Copy to create a customised version of the standard Build List (printed when you receipt batches). k. After making changes, you can Preview and the Save changes. TIP: You must have the Reports Designer module (module code R ) installed to create your own reports. Contact your PowerLink Consultant if you want to add modules. (See Reports Designer User Guide.) YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

8 Using Bill of Materials and Manufacturing Assemblies Workflow The Assemblies workflow can be accessed by clicking on the Assemblies menu button on the Start Page. Common tasks are displayed as icons in a work-flow arrangement. The solid arrows show the suggested processing flow. The dimmed arrows show additional optional but nonetheless important tasks. When you hover over an icon, you ll see help text that explains more about the task. When you click an icon it launches the relevant program, report or dashboard page. The following tasks are accessible from the Assemblies Workflow. It is important to know that not all tasks are shown on the workflow. Only commonly used tasks are shown. Create or Modify Kits. Kits hold details of the raw materials, sub-assemblies, labour and the quantities of each needed to manufacture the finished product, along with sequence and build instructions. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

9 Check Dashboard Warnings. The Assemblies Manage page includes warnings about kits with low margins, <BR> or those that include components which are inactive, deleted or have negative stock. Create Requisition. Requisitions are internal manufacturing orders for batches of kits. Requisitions can be created manually or generated from a customer quote; refer to the CRM workflow. Monitor Builds in Progress. The Builds page allows you to monitor active requisitions and check that sufficient stocks of components are held. You can check capacity over a specified period, e.g. can we complete the builds due this week? Post Stock Issues. For requisitions which are linked to a manufacturing job, components are normally issued to the job as they are used. To maintain accurate stock levels you should run this process regularly. Manufacturing work in Progress Report. For requisitions which are linked to a manufacturing job, see total costs (materials, subcontractor, machine and labour) are compared to total invoiced. Also refer to the Jobs workflow. Receipt Kits. This receipts the batch of finished goods into Attaché. Component stock levels are reduced according to the kit definition. You can also partially receipt a batch so urgent orders can be shipped. Update Kit Costs. This process should be run on a regular basis to ensure that the cost of the kit product keeps pace with changes in component costs. Sub-assembly costs can be updated during this process. Plan Production. The Planning page displays kit sales and order information for a selected period and suggests a build quantity. This helps answer the question, "What should we build this month to meet expected sales?" Searching for Kits (See the Menu Gadget Search Bar section in Getting Started Guide for more details on using this feature and customising searches.) The best way to search for a kit is using the Menu Search Bar on the Assemblies dashboard. Enter the search text and press ENTER or the magnifying glass button. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

10 Select Edit to open the Product / Kit Maintenance program or Details to view kit details on the Assemblies dashboard Details page. TIP: The Quick Find feature is also available in most PowerLink programs and is launched using F2-Find or by clicking on the Search Tool icon (magnifying glass). This can also be used to search for a product while in a program. Customising Search Results Columns The search results can be customised using the Report Designer. Copy the BI ENQUIRY SEARCH RESULTS KIT gadget and add any additional fields (columns) that you want to see. Customising Search Fields Results (Context) You can modify the scope of the search by modifying the SQL of the BI ENQUIRY SEARCH RESULTS KIT report. Creating Custom Search You can also create your own custom search gadgets using the ViewPoint module which may be better than customising the existing search results as a custom gadget will not affect other users. With ViewPoint, you can also design a dashboard to house your custom search gadget and add more gadgets. (See the ViewPoint User Guide for more details.) Searching for Components The best way to search for a product is using the Menu Search Bar on the Assemblies dashboard. Enter PROD: followed by the search text and press ENTER or the magnifying glass button. You can also switch between searching for a product or a kit using the search links (highlighted below). YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

11 Creating Bill of Material / Kits The first thing we need to do is setup our formulae or kit definitions. This is done in the Maintain Kit program (Masterfiles Products Maintain Products / Kits). YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

12 Global Kit Maintenance It is necessary to sometimes relace components in a kit with another. For example, you may change to another supplier, or a component may simply become obsolete. These components can be changed using the Masterfiles Products Global Kit Component Maintenance program. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

13 Purchase Raw Materials Raw products are receipted like any other product via an Attaché Supplier Invoice. Create a Requisition You can create a Kit Requisition via Transactions Products Create or Modify Kit Requisitions. A Requisition is effectively an internal manufacturing order. Manufacturing Job. Select this if you need to track batch numbers, or if it is a manufacturing job where stock is issued over a period of time, or you want to track labour costs. For simple kitting applications, you can leave un-selected. PowerLink automatically creates a job with the same number as the Requisition batch number in the manufacturing department (X in this example). YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

14 Print a Build List (Bill of Materials) F5-Build. Select initially to print a bill of materials (Build List). This document shows the materials required, and can be used as an internal manufacturing job card The standard build list prints the currently available stock levels and the cost (if that option was selected). This report can be customised using the PowerLink Reports Designer. Issue Stock used to make Finished Goods For manufacturing jobs, PowerLink expects stock to be issued to the job as it is used. This allows your inventory to be updated as soon as stock is issued. Auto Issue. Automatically issues the necessary stock for the job. This option is useful if you want to reserve all stock required to build the finished goods. This feature is only available when no stock has been issued to the job. Post Stock Issues Attaché. Loads the Stock Issues program, where stock can be posted using F7-Post Attaché. You should only post as regularly as needed. If seeing accurate stock levels are critical, you should post immediately after issuing stock, otherwise you should post at least once per month, prior to processing period end for the Attache Products module. Receipt Manufactured Stock into Attaché Finished goods can be receipted using the Transactions Products Receipt Kit Requisitions program. To Receipt You can enter the quantity you want to receipt at this time in this field. The quantity to YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

15 be receipted defaults to the Batch Qty. Receipted The quantity which has already been receipted is shown in the Receipted field. Receipts the quantity in the To Receipt field into stock. The inventory is updated next time you post stock issues to Attache. TIP: When you use F12-Receipt, the goods are receipted into Attache using a product adjustment with a positive quantity (increasing available stock) at a cost calculated based on the current components. The product adjustment will revalue all existing stock based on this calculated cost. If you do not want this to happen you must receipt goods via the Attache Product Receipts program. You can do this using F5-Build (Generate Attache Stock Receipts KFI File), and ensure that the Receipt Kits using Product Adjustments is disabled in the Product Options. Create Requisitions from a Quote You can create a requisition from a customer quote, if you have included products with a Bill of Materials within a quote. This is ideal for manufacturers who manufacture to order, rather than hold products in stock. A quote can be created via Transactions Quotes Maintain Quotes (or Maintain Quotes Simple) program. Prior to processing the quote, you can select the POrd (Purchase Order) column. When you process the quote, PowerLink knows that the line is a manufactured product and is not to be ordered from a supplier. Instead PowerLink creates a Kit Requisition, which is really an internal purchase order for the manufacturing part of the business. Selected lines will appear on a new Attache customer order created when you process the quote. After selecting which lines are to processed, select F7-Process We can select to generate Kit Requisitions and Customer Orders at the same time. You can select to automatically issue (reserve) stock at the time the requisition is created, which is a time saving feature for small manufacturers. Now the Requisition can be processed as normal. You can see all requisitions created using the Managers, Customer or Products enquiry. Refer to the section later in this manual. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

16 Customising Manufactured Products Some customers may require special variations of a standard product. The variation can be as simple as a different paint colour on a chair, or a different quantity of chemical in a cleaning product. You do not have to create a new Bill of Materials every time a customer wants a slight variation to a standard product. You can simply make the change within the customer quote. To customise the product, simply double click on the Product Code field, and then select to Create Custom Kit. The standard kit definition is shown to begin with. You can double click on sub-kits to explode and customise them, if required. Otherwise, just change the Bill of Materials to suit the customer s requirements. For example, this customer may want a higher content of Citric Acid and a lower content of Lauramine Oxide. Use the Refresh Cost button to update costs on the screen. Now when we create a requisition, and automatically issue components, the variation to the standard Bill of Materials is used. So to create a batch of 50 The amount of Citric Acid required is 50 x 25 = 1250 and the amount of Lauramine Oxide is 50 x 10 = 500. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

17 When the goods are receipted into Attache using F12-Receipt, all existing stock is revalued at the cost of the variation. For this reason, variations should be limited to changes which do not dramatically effect cost. Alternatively, you can create a new product which can be used for customer specific variations, and ensure that these are invoiced to the customer after they are receipted into Attache (therefore always bringing the in stock quantity back to zero and hence not being affected by revaluations). YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

18 Enquiries and Reports Product Enquiry A number of standard enquiries can be viewed from the Masterfiles Products Maintain Products / Kits program. TIP: Drill down support allows you to double-click on a requisition (batch) number to see the details; or the quote; or the customer; or the job etc. Customer enquiries can be viewed from the Masterfiles Customers Maintain Customers program. You can trace the status of a Requisition including in progress, and completed requisitions for individual customers. Managers Enquiry Manufacturing enquiries can also be viewed from the Masterfiles Management Managers Enquiry program. This allows for an enterprise wide view of what is going on. Custom Enquiries YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

19 You can also customise the standard enquiries, create your own enquiries (using the PowerLink Reports Designer), and even assign your own special quick access buttons on the toolbar (via Setups System Options Managers Enquiry). Product Reports A number of standard manufacturing reports are available within the Reports Products menu. All reports have several parameters so you can limit reports to showing only the information you want. And if this is not enough, you can modify the reports or create your own using the PowerLink Reports Designer. Assemblies Dashboard Most of the features described in this user guide are accessible from gadgets on the ASSEMBLIES dashboard. Assemblies gadgets are the same as ViewPoint gadgets in that you can sort, filter, print, and view the data in various formats. For more information see the ViewPoint User Guide. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

20 Some pages and gadgets are filtered using the currently selected kit or sales rep. Selected Kit To select a kit, type part of the description or code into the menu search bar and press ENTER. Select Details (highlighted below) to populate the gadgets on the page. To show all items enter *. Selected Sales Rep To select a sales rep, choose from the Rep drop down list (highlighted below) on the main toolbar. This should automatically be selected for you when you login. If not, you will need to assign your sales rep code to your user name in the Dashboard Options (also highlighted below). Refer to the Getting Started Guide for more information. Assigned Employee Some gadgets display information only for manufacturing jobs assigned to your employee code (highlighted below) in the job master file. This should automatically be determined when you login. If not, you will need to assign your employee code to your user name in the Dashboard Options (similar to the selected sales rep discussed above). It should be noted that the sales rep assigned to the job is not used to determine ownership of jobs because both employee and sales rep can be assigned to the job, and most people use employee code to assign ownership to a job. If you do not use the Attaché Payroll you can still enter employee codes via the Masterfiles Payroll Maintain Employee program. Drill Down and Mouse Over Many gadgets allow drill down into the requisition, product master file or have other mouse events enabled. These drill down fields are identified by a dotted blue line in the gadget. The function for most drill down fields is obvious and will not rate a mention in the gadget help. Only special drill down fields will be documented. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

21 Assemblies Home Page The Assemblies Home page contains gadgets which provide information about things you need to do today. Information available includes outstanding requisitions and tasks. My to Do List The To Do List shows all tasks for the selected sales rep which are active. Requisition Summary A list of all active requisitions is shown in this gadget. Active when selected displays incomplete requisitions. Complete when selected shows completed requisitions. All when selected shows all requisitions. Details Page The Assemblies Details page displays information for the selected kit in separate gadgets. Summary A summary of the basic information for the selected kit is show in this gadget. Edit Kit will open Product / Kit Maintenance program to edit kit details. Update Kit Costs will open the Update Kit Costs program. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

22 Note: To update Attaché with this information, you need to have the Data Transfer enabled. See Enable Attaché Data Transfer in the Getting Started Guide. Component List Components which are in the selected kit are shown in this gadget. To Level 1 when selected will show component exploded to the highest level. Next Level when selected will explode the kit to the next level and show the components. Requisitions in Progress Requisitions which are in progress for the selected kit are shown in this gadget. Create Requisition when selected will open the Create or Modify Requisition program. Active Customer Orders Active customer Orders for the selected kit are shown in this gadget. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

23 Last Years Sales Recent sales displayed as a bar chart for the selected kit are shown in this gadget. 3 Months or 6 Months when selected controls the sales period. When the bar chart is selected (highlighted below), individual sales are displayed in a pop-up window. Manage Page The Assemblies Manage page displays management information about kits, components and requisitions in separate gadgets. Product Reorder Components that have reached their reorder levels are shown in this gadget. Select to see just Kits or All products. Inactive products are excluded. Kit Component Warnings Kits with components that have been deleted, flagged as inactive or have negative stock levels are shown in this gadget. The Sub-Kit field indicates whether this component is a sub-assembly. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

24 Deliveries Due Components on order with suppliers which have not arrived are shown in this gadget. This gadget uses the information on Attaché Purchase Orders. Once the PO has been completed then the information in the gadget will no longer appear. Low Margin Kits Kits with a Level 1 selling price which yields a profit margin of less than 20% is shown in this gadget. TIP: This gadget can be copied and used as a template to create your own low margin gadget depending the selling prices and margins used in your business. Planning Page The Assemblies Planning page provides you with the tools to plan your build requirements for the future using the previous year s sales information. Planning Sales and order information for all active kits for a selected Consideration Period (CP) are shown in this gadget. Consideration Period when selected applies the timeframe you d like to consider for your production planning. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

25 Sales Last Year (A) is recalculated based on sales at the same time in the previous year, when a new CP is selected. Quantity in Stock (B) is the quantity which is currently in stock. Quantity on Customer Order (C) is the quantity on customer order. On Requisition (D) is the quantity currently on active requisitions. Suggested Build Quantity is calculated as (A B + C D). If this figure is less than or equal to zero, the suggested build is zero. You can click on the Sales Last Year, or Quantity on Customer Order, or On Requisition (as highlighted), to see transaction details. Quantity to Build can be modified by clicking on the current value (as highlighted). This opens a popup data entry form. Enter the value you want and press ENTER. TIP: If you do not want to see a kit in the list, use the Filter Excluding Selection tool (via the right-click context menu) to exclude it from the display. Create Requisitions when selected will create separate requisitions for any kits using the Quiantity to Build value. Builds Page The Assemblies Builds page answers the questions Do we have sufficient stock of components to complete our builds? It includes 2 gadgets as described below. Builds to Consider All kits on active requisition where the batch (requisition) delivery date falls within the selected period are shown in this gadget. Overdue builds are highlighted in red. Day, Week, Month, Quarter or All Active when selected displays requisitions which fall in the selected period. For example, if today s date is 12/01/2012, the gadget will display where the Delivery Date falls within the period: 12/01/ /01/2012 if you select Week 12/01/ /02/2012 if you select Month 12/01/ /04/2012 if you select Quarter All products on active requisition if you select Show All Active YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

26 Explode when selected will use the displayed requisitions for the Component Calculation (in the gadget below). Note: The speed of display will be impacted by the delivery period selected, i.e. Show All Active will take the longest time. To exclude individual requisitions or delivery dates, use the right-click Filter Excluding Selection tool. Hover over a Batch No for more details, or click to drill in. Component Calculations Component availability for the requisitions displayed in the Builds to Consider gadget is shown in this gadget. The Quantity to Build value in the Builds to Consider gadget is used for the calculations. Required displays the total quantity needed to complete all requisitions that include this component. Shortfall displays if a component will be in short supply and is calculated as Quantity in Stock + On Purchase Order is less than the Required quantity. Affected components appear at the top of the gadget, highlighted in red. Click a product code to see all active batches requiring this component. This allows production decisions to be made when a component shortfall exists. Explode when selected, will explode to the level you want and recalculates component requirements based on sub-assembly quantities. By default, the Level 1 of assembly is displayed but you can explode to the Next Level and beyond. New requisitions can be created via the Create Requisition button, e.g. if there is a short fall for a sub-kit. Favourites Page The Favourites page can be used to add any gadget content that you want. See the Favourite Gadgets section in Getting Started Guide for more details on using this feature. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June

27 Quick Add (Add New) The Quick Add button is not a dashboard page but a quick access menu for adding new Manufacturing documents and items. YearOne PowerLink 3.10 Manufacturing and Bill of Materials User Guide June