CHAPTER 4B SHOP ORDER MAINTENANCE

Transcription

1 CHAPTER 4B SHOP ORDER MAINTENANCE Chapter 4B Shop Order Maintenance...1 Orders...3 Shop Order & Release Maintenance...4 Creating a New Shop Order...5 Creating a New Shop Order directly in Shop Order Maintenance...5 Creating a New Shop Order by Dragging and Dropping a Quote or Engineering Master Record...6 Creating Shop Order from a Sales Order...7 Creating a New Shop Order via the Production Adjustments Worksheet...8 Creating a New Shop Order via the Inventory Based Shop Order Generator...9 Creating a New Shop Order as a Copy of an Existing Shop Order Record...10 Deleting an Existing Shop Order...11 Retrieving an Existing Shop Order...12 Quick Search...12 Shop Order Maintenance General Tab...13 Shop Order Maintenance Due Dates Tab...21 Release Detail...23 Add Shop Order Releases via Auto-Create Releases...27 Infinite Project Based Scheduling...29 Operational Scheduling...32 Shop Order Maintenance Material Requirements Tab...33 Purchasing Requirements...38 Material Item Definition...40 Pricing Calculator...45 Material Calculator...46 Sheet, Coil, Plate Raw Material Shapes...51 Optimal Material Calculator...53 Scrap Weight Calculator...56 Part Weight Calculator...57 Shop Order Maintenance Operations Tab...60 Adding, Updating, and Deleting Operations...63 Adding an Operation...63 Editing an Operation...63 Deleting an Operation...63 Operations Worksheet...64 Operation Worksheet Operation Type: In-house...65 Adjust Operation Accumulative Hours/Costs...71 Tooling...73 Tooling Detail...75 Tooling Detail Formulas...80 Operation Worksheet Operation Type: Subcontract B-1

2 Additional Subcontracting Lot Charges...84 Operation Worksheet Operation Type: Comment...85 Shop Order Maintenance P.O. Review...86 Shop Order Maintenance Order Cost Tab...89 Production Adjustments Worksheet...93 Production Adjustments Worksheet Overview...94 Work In Process Pipeline Analysis...99 Inventory Based Shop Order Generator Inventory Based Shop Order Generator Overview Automatic Shop Order Detail Shop Order Production Monitoring General Tab Operations Tab Operation Detail Due Dates Tab Purchases Tab Job Cards Tab Shipments Tab Shop Order Job Costs Audit Shop Order Costs Monitoring Split Shop Order Shop Order Recap Summary Shop Order Reports B-2

3 Chapter 4B ORDERS SHOP ORDERS Visual EstiTrack s Shop Order Maintenance is fully integrated with the database to make an easy-to-use seamless and functional connection to all related business modules including Quotes, Inventory, Sales Orders, Shipping and Invoicing. Figure 4b.1 Visual EstiTrack s Order s Menu 4B-3

4 SHOP ORDER & RELEASE MAINTENANCE are the actual manufacturing orders that are released to the shop floor. The Shop Order quantity can be based on the best economic order quantity required to support the open Sales Orders that have to be delivered. There does not have to be a direct correspondence between Sales Orders and, however Sales Orders are the Customer Demands while the represent how those demands are filled. Figure 4b.2 Shop Order Maintenance Menu Selection Left click on the fourth menu heading labeled Orders Select Shop Order & Release Maintenance from the drop down list. Shortcut: toolbar. Quickly enter this module by left clicking on the displayed Shop Order Maintenance icon on the Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-4

5 Creating a New Shop Order can also be created using multiple methods. Each of the available methods are further described in the chapter below. Creating a New Shop Order directly in Shop Order Maintenance To create a new shop order using the Shop Order Maintenance form, activate the ADD pushbutton located on the bottom of the form. Figure 4b.3 Adding a New Shop Order to the System The General tab of the form is refreshed for new order entry. A new shop order number is automatically generated by the system and applied to the refreshed form. The Shop Order maybe created with reference to a Quote or Engineering Master record. Enter in the Quote Number or Engineering Master Number into the Quote Number field. If referenced, all pertinent information is automatically transferred to the new Shop Order. Once all of the pertinent information is entered into all tabulations, the user can SAVE the new shop order to the system. 4B-5

6 Creating a New Shop Order by Dragging and Dropping a Quote or Engineering Master Record To create a Shop Order using the information defined in the Job Estimating or Engineering Master Subsystem: Figure 4b.4 Creating a Shop Order using Drag and Drop Perform a Right-Click on the General tab and drag the information to the Shop Order icon as displayed in the figure above. If the transaction is performed correctly, a Gear icon will replace the regular icon during transfer. The icon will change again to a Document icon when placed correctly over the Shop Order icon signifying a correct information transfer. Confirm the Drag & Drop Shop Order Generator pop-up displayed in figure 4b.4 displayed above to complete the Shop Order creation. Once confirmed, all of the pertinent information is passed from the Job Estimating or Engineering Master record to the new Shop Order. 4B-6

7 Creating Shop Order from a Sales Order There are many advantages in creating the shop order from a sales order. The main advantage is the seamless transfer of information. All pertinent information regarding the part, quantities, customer, materials and operations are all transferred from one subsystem to the other therefore ensuring data integrity and greatly reducing data entry. The only restriction for form of shop order creation is that the sales order line items must refer to a template Quote number or Engineering Master to be fully utilized. The following steps are used in creating a shop order directly from the sales order. Retrieve the Sales Order Maintenance subsystem. Activate the Generate pushbutton located on the bottom of the Line Items Tabs for the highlighted sales order line item. The user is prompted to confirm the transaction via a pop-up window. The data flow from the Sales Order subsystem to the new shop order can be seen while the shop order tabs are populated by the system. The user has the option to print a Routing Report for the newly created shop order number. The new shop order can be accessed via the Shop Order icon or via the menu selection. Figure 4b.5 Creating through Sales Order Maintenance 4B-7

8 Creating a New Shop Order via the Production Adjustments Worksheet The Production Adjustments Worksheet displayed below, is driven by sales order releases. The worksheet retrieves open sales orders items and their quantities providing the production planner an insight to the items needing production and their ordered, available and pending quantities for a given time period. can be created or adjusted for the records retrieved and reviewed. Additional information and instruction to the Production Adjustments Worksheet is provided further in the chapter below. Figure 4b.6 Creating a Shop Order via the Production Adjustments Worksheet 4B-8

9 Creating a New Shop Order via the Inventory Based Shop Order Generator The Inventory Based Shop Order Generator is a tool used to conveniently generate shop orders based on inventory quantity levels and needed quantities for all manufactured products. The system looks across at all manufactured items and retrieves a list of items that do not have enough quantity on hand to fulfill their needed quantity. Once the list is edited as needed, with a click of a button, the user can generate a shop orders for all of the remaining items displayed on the list. Additional information and instruction regarding the Inventory Based Shop Order Generator is provided further in the chapter below. Figure 4b.7 Creating a Shop Order via the Inventory Based Shop Order Generator 4B-9

10 Creating a New Shop Order as a Copy of an Existing Shop Order Record The third method of creating a new shop order is to take an existing order and creating an exact copy of the record including all tabulations. The following steps are used when creating a new shop order using this method: Retrieve the originating Shop Order number into the Shop Order Release and Maintenance subsystem. Activate the COPY pushbutton located on the bottom of the form. Figure 4b.8 Copying a New Shop Order from an Existing Record The Shop Order Copy pop-up is retrieved displaying the new Shop Order number and validating the originating Shop Order number. Activate the COPY pushbutton located on the form to confirm the transaction and to proceed with the copy. Figure 4b.9 Shop Order Copy The system provides the user an opportunity to associate the shop order to the originating Sales Order Line item via the Keep Sales Order Association pop-up. A YES or NO association validation completes the transaction and retrieves the new Shop Order record into the Shop Order Maintenance form. 4B-10

11 Deleting an Existing Shop Order To remove a Shop Order record from the system, retrieve the order into the Shop Order Maintenance form. Once the data is displayed, activate the DELETE pushbutton displayed on the button of the screen to retrieve the Delete this Record pop-up displayed in the figure below. After the delete validation is confirmed, the record is permanently removed from the system. Figure 4b.10 Deleting an Existing Shop Order 4B-11

12 Retrieving an Existing Shop Order The pushbutton located at the bottom left corner of figure 4b.2 can be used to recall previously captured. Once activated, the Shop Order Search Criteria form is retrieved and can be used to locate existing shop orders. The Shop Order Search Criteria form is displayed below. Figure 4b.11 Shop Order Search The fields displayed above can be used to filter the. Partial words/ numbers can also be used when searching for the order. Search results will be displayed on the bottom half of the screen. The results are automatically ordered by the Shop Order Number. The user can change the order of the search results by using the Order Search Results By dropdown menu located on the bottom of the form. Once a Shop Order is selected, double click on the entry to retrieve the order into the Shop Order Maintenance form. Quick Search Alternatively, the Quick Search is available when the user wishes to directly access a known Shop Order Number. Activate a Right Click on the search key located on the bottom left corner of the Shop Order Maintenance form. The Quick Search pop-up is retrieved for Shop Order Number entry. 4B-12

13 Shop Order Maintenance General Tab The General tab of the Shop Order Maintenance subsystem is divided into multiple segments. The Order Definition section allows the user to define the Shop Order Number and tie it to a Sales order line item or even more importantly, to tie it to a quote number. Defining it to a quote number allows the user to retrieve all defined materials and operations into the shop order. Once the information is collected from the estimating system, changes may be made if necessary within the Shop Order itself. may be created without being based upon a quote number, meaning all data including materials and operations would have to be defined when the Shop Order is created. It is necessary to have at least one Due Date or shop order release number when defining the Shop Order. This defines the target date for completion of the Shop Order and will be used in Shop Order scheduling and material allocations. Additional information regarding the fields and parameters provided are further outlined in the following table. Figure 4b.12 Shop Order Maintenance General Tab 4B-13

14 Orders Shop Order Maintenance General Tab Order Definition Shop Order Number YES ALPHANUMERIC Unique characters identifying the Shop Order as it is to be printed on the Routing Report. The system stores and processes the in order of code. Incremental numbers (starting numbers) may be assigned in the Company Table; if none are assigned, the first Shop Order will be Shop Order #1. If letters area assigned only, the reports will be in alphabetical order. If you assign numbers or mix numbers and letters, the records will be in sequence with the left-most character of the Shop Order number. Order Date NO DATE System generated date based on the day the Shop Order is created. This date may be overridden by entering another date or by double-clicking to activate an interactive pop-up calendar. Order Status YES DROPDOWN Select the status from the dropdown menu. The status definition aid in classifying the shop orders for reporting purposes. The dropdown entries are maintained in the table: TABLES STATUSES Date Completed NO DATE Date the shop order is closed. The field is auto-populated with the current date if the order status is set to Closed. Days to Complete N/A DISPLAY Once the status Closed is assigned to the Order, the system automatically calculates and displays the number of days between the Completion Date and the Order Date. Finished Wt/1 NO NUMBER If the Shop Order is created without a reference to a sales order or a quote, the user may enter a value for this field manually. When a Quote is referenced, this field will automatically populate with the correct value. Approval Document NO DROPDOWN Select the document used for approvals from the dropdown menu. Dropdown entries are maintained in the table: TABLES OTHER TABLES DOCUMENT TYPES Departmental Approvals N/A PUSHBUTTON Activate pushbutton to retrieve the Departmental Approvals 4B-14

15 Orders Shop Order Maintenance General Tab subsystem. Revision Maintenance N/A PUSHBUTTON Activate pushbutton to retrieve the Revision Maintenance subsystem used to track shop order revisions. Product Code NO DROPDOWN Select the product code from the dropdown menu. Product codes are maintained in the table: TABLES PRODUCT CODES. Price Unit YES DROPDOWN Select a predefined Price Unit from the drop-down listing, which is the most applicable for the particular job you might be running. I.e., if you are running 100,000 pieces, you may wish to choose a Price Unit of 1000 (price per 1000). Price Units are maintained in the table: TABLES PRICE UNITS. Serialize NO CHECKBOX Activate the checkbox if the product requires serialization. Once activate, the checkbox is automatically replaced with a Serialization dropdown menu. Select the means of serialization from the dropdown menu. Part Number Related Documents N/A PUSHBUTTON Activate pushbutton to retrieve the Document Manger for the products part number. A list of part number related documents is automatically retrieved. Resin Formulations N/A PUSHBUTTON Activate the pushbutton to retrieve the Resin Formulation of the product when there is resin materials used in the shop order only. Heat Treat Specifications N/A PUSHBUTTON Activate the pushbutton to retrieve the Heat Treat Specifications form when applicable to the shop order. Shop Order Based On Sales Order Number and Line Item Standard Routing Quote Number NO ALPHANUMERIC Defines the Sales Order and Sales Order Line Item tied to the open Shop Order. Once a Sales Order number is entered, the system automatically populates various fields with information from the Sales Order or the originating Quote record. NO ALPHANUMERIC Enter the Quote Number tied to the Shop Order. This field is automatically populated when the shop order is created directly from the quote or from the Sales Order Line item form. 4B-15

16 Orders Shop Order Maintenance General Tab Order Type - By Piece - By Lot YES RADIOBUTTON Select the type of orders from the two available radio buttons. This selection controls how the operations may be defined. By Piece based orders allow the user to define cycle times (pieces per hour. By Lot based orders allow the user to enter the time required to complete the operation. Non-Billable NO CHECKBOX Activate checkbox if the shop order is non-billable or indirect. This is useful when accumulating time and cost for miscellaneous tasks, like sweeping up the shop or running out to pick up supplies. Note: The impact of the Non-Billable Orders may be seen in the Assigned vs. Unassigned Hours Report found in the menu: PRODUCTION PRODUCTION REPORTS Assigned vs. Unassigned Hours Report. Indirect NO CHECKBOX Available only when the Non-Billable checkbox is activated. Rework NO CHECKBOX Activate checkbox if the shop order is designated as a rework operation. If activated, it will appear on the rework router only. Part Definition Part Number NO ALPHANUMERIC Enter unique characters identifying a customer s part or job being performed, as it will be printed on the Routing Report. This number is usually located on the customer s drawing and/or Request for Quote form. Part History N/A PUSHBUTTON Activate pushbutton to retrieve the Part History subsystem for the entered part number. Revision NO ALPHANUMERIC Enter unique characters identifying the customer s drawing, part number, or job number revision, if any, as it is to be printed on the Routing Report. 4B-16

17 Orders Shop Order Maintenance General Tab Description NO TEXT Enter or define description of part if applicable. This field will print just below the Part Number on selected reports. Extended Part Description N/A PUSHBUTTON Activate pushbutton to enter additional details retarding the part. When the Part Description field length is limiting the description. This is an unlimited length free form text box. This dialog box also has a button to access the Notes Library subsystem. Extended Part Attributes N/A PUSHBUTTON Activate pushbutton to enter, edit, or create other descriptive information on a list of attributes. Additional information regarding this function follows this table below. Drawing Number NO ALPHANUMERIC If applicable, enter unique characters identifying the customer s drawing. This number is usually located on the customer s drawing and/or Request for Quote form. Drawing Revision NO ALPHANUMERIC Enter any revision number of the drawing, if applicable. Notes N/A PUSHBUTTON Activate pushbutton to enter any general information and/or comments for the current Shop Order. The contents of this note field may be printed on the Routing Report. Engineering Change Order NO ALPHANUMERIC Enter in any applicable Engineering Change Order number. P.O. Number NO ALPHANUMERIC Enter the Customer Purchase Order Number. If the Shop Order is being created from an existing Sales Order, the PO Number in the header of the Sales Order is transferred to this field. Division NO DROPDOWN Select the company division initiating the Shop Order from the drop down list (if applicable). Parent Order Shop Order Number NO ALPHANUMERIC Enter in the Parent Shop Order number if the Shop Order record is a Sub-Order of another Shop Order. Aggregate NO CHECKBOX?Activate checkbox to aggregate the shop order to the parent order. Freeze Quantity NO CHECKBOX Activate checkbox to prevent the Production Adjustment 4B-17

18 Orders Shop Order Maintenance General Tab Worksheet to modify the order quantity of the shop order. Quantities Ordered NO NUMBER Define the quantity of the Order. If the Shop Order was created from a Sales Order or a Quote, this field is automatically populated. Extra for Stock NO NUMBER Define the number of extra parts being produced for stock. Previous Order Overrun NO NUMBER Define the Previous Order Overrun. Upon creating the Shop Order, the software checks to see if there is any Inventory on-hand that might be used to satisfy the Order. If so, the user will be prompted whether or not to use that on-hand inventory against this order. Returned NO NUMBER Define the number of parts that have been returned against the Order. Produced NO NUMBER Define the number of parts produced under this Shop Order. This field is automatically updated by Job Cards saved against the final operation of the Shop Order. Balance N/A DISPLAY The balance of parts to produce under this Shop Order. The system auto-calculates this as the sum of the previous fields. Shipped NO NUMBER Define the quantity of parts shipped against this Shop Order. This field is automatically updated by activity in Shipment Maintenance. On-Hand NO NUMBER Define the quantity of parts produced under the Shop Order that were not shipped. This field is automatically updated by activity in Shipment Maintenance. Runs NO NUMBER Define the Number of Workcenters this Shop Order will be run on at the same time. Date Last Updated NO DATE Enter the date that the Shop Order was last updated. Finished Good Inventory Number NO ALPHANUMERIC Define the Finished Good Inventory number of the parts being produced by this Shop Order. Create WIP N/A PUSHBUTTON Activate pushbutton to create a Work In Process 4B-18

19 Orders Shop Order Maintenance General Tab Inventory Number for each operation in the Shop Order. WIP Numbers may be based on the Shop Order Number, e.g. ORDER-10 or the WIP Numbers may be based on the Part Number, e.g. PARTNUMBER-10. Note: Inventory Numbers are allowed a maximum of 15 characters. Track WIP in F/G NO CHECKBOX Activate checkbox to track the Work In Process numbers in finished goods. Shop Order Maintenance Functions The following functions are available throughout all tabs included in the Shop Order Maintenance Subsystem Search Key N/A PUSHBUTTON Activate search key to retrieve Shop Order Search Criteria form for shop order retrieval. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Exit N/A PUSHBUTTON Exits the Shop Order Maintenance subsystem back to the main Visual EstiTrack menu system. Scroll First N/A PUSHBUTTON Scrolls back to first record. Scroll Back N/A PUSHBUTTON Scrolls back one record. Scroll Forward N/A PUSHBUTTON Scrolls forward one record. Scroll Last N/A PUSHBUTTON Scrolls to last record. Bill of Materials N/A PUSHBUTTON Activate pushbutton to retrieve the Bill of Material Structure form for the open shop order. e-advisory N/A PUSHBUTTON Click on the e-advisor button to choose either of the following alert messages: - Alert when Shop Order started - Alert when Shop Order completed Shop Order Detail Report N/A PUSHBUTTON Activate pushbutton to print the Shop Order Detail Report for the Open/Active Shop Order. Reports N/A PUSHBUTTON Left Click Routing Report: 4B-19

20 Orders Shop Order Maintenance General Tab Right Click Engineering Routing Report: 4B-20

21 Shop Order Maintenance Due Dates Tab The Shop Order Due Date tab is used to manage releases of the Shop Order. If a shop order is created directly from a Sales Order or the originating quotation, the entries in the tab are automatically created. If the Shop Order is created manually, entries maybe added and updated as needed. The Shop Order quantity can be broken down into multiple releases. As displayed in the figure below, for every release a Due Date must be defined. The Due Date is automatically populated when the shop order is created from a Sales Order with a defined Due Date or can be manually updated using the UPDATE pushbutton displayed below. It is imperative that the Due Date is defined so that the Scheduling subsystem can schedule the jobs in time to meet the defined date. Once the job is scheduled, the scheduler automatically updates the Start Date (date the first operation is started) and the End Date (date the last defined operation is completed). Figure 4b.13 Shop Order Maintenance Due Dates 4B-21

22 Orders Shop Order Release and Maintenance Due Dates Tab Add N/A PUSHBUTTON Activate pushbutton to add a Shop Order release. Note: It is recommended that at least one release be entered into the system. If a release is not entered, several features within the software will be unavailable. Update N/A PUSHBUTTON Activate the pushbutton to update the highlighted release. The Release Detail form is retrieved for update. Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted release. Auto-Create Releases N/A PUSHBUTTON Activate pushbutton to automatically create the release. Additional information regarding this function is provided in the Add Shop Order Releases via Auto-Create Releases section found below. Allocate Materials N/A PUSHBUTTON Activate pushbutton to place demand on inventory items and direct buy items needed for this Shop Order. Only material requirements with a status of Open will be allocated. Infinite Project Based Scheduling N/A PUSHBUTTON Activate pushbutton to initiate infinite project based scheduling for the shop order. Additional information regarding this function is provided in the Infinite Scheduling section found below. 4B-22

23 Release Detail The Release Detail form below is used when either adding new release dates manually or it can also be used to update exiting release records. When adding a new release manually, all pertinent information regarding the release and quantity must be entered manually in the form. Additional information regarding the fields and functions included is provided in the corresponding table below: Figure 4b.14 Release Detail 4B-23

24 Orders Shop Order Release and Maintenance Due Dates Tab Release Detail Release Number N/A DISPLAY The Release Number is an incremental number inserted by the system. Release Status YES DROPDOWN Select Status from the drop-down menu. This will help organize the Shop Order Releases for reporting purposes. Statuses maybe maintained in the table: TABLE STATUSES Note: Only Shop Order Releases with a Status of Open will be scheduled. Tracking Number NO ALPHANUMERIC Define a tracking or serial number in this field if applicable. Note: This will auto-populate in Job Card Maintenance and through out the entire life of the Job. P.O. Number NO ALPHANUMERIC Define the Customer PO number, if it is different than the PO number called out on the General Tab. Due Date YES DATE Enter a date into this field to specify a Due Date for this Shop Order Release. This is the date that the Finished Good should be completed by in-house. Double clicking in this field will open an interactive pop-up calendar where the date may be chosen by clicking on the day. Completion Date NO DATE This field will automatically populate when the Shop Order Release status is changed to Closed. Inspection Date NO DATE Define the date that the items that were produced under this release were inspected. Double clicking in this field will open an interactive pop-up calendar where the date may be chosen by clicking on the day. Quantities Release YES NUMBER Define the quantity of Finished Good to be produced under this Shop Order Release. Produced NO NUMBER This field will automatically populate when Job Cards are created for this release. Balance to Produce NO NUMBER This field will automatically populate when Job Cards are created for this release. 4B-24

25 Orders Shop Order Release and Maintenance Due Dates Tab Release Detail Scheduled NO NUMBER Define the quantity of Finished Good to be scheduled under this Shop Order Release. This value will automatically populate when the Release Quantity is defined. The User may override this value with a different one. Shipped NO NUMBER This field will automatically populate when product has been shipped against this release. Heat Treat Specifications N/A PUSHBUTTON Activate pushbutton to define any heat treat specifications if applicable. The Heat Treat Specifications form is retrieved for further entry. Scheduling Criteria Priority - Hot - Normal YES NUMBER PUSHBUTTON Define the scheduling priority for this release. A priority of one (1) is the highest priority, all nines (999999) is considered Unscheduled. A priority of 100 is Hot and a priority of 500 is Normal. A new Shop Order Release will be unscheduled (999999) by default. Unschedule N/A PUSHBUTTON Activate pushbutton to unscheduled (delete) all schedule records related to the shop order release. Scheduling Method YES RADIOBUTTON Select the scheduling method from the following two options: Forward from Start Date Activate radio button to schedule the shop order forward from the current date out to a projected end date that has been calculated based on estimated operation cycle times. Backward from Due Date Activate radio button to schedule the Shop Order from the Due Date, backwards to a starting date. Note: If the amount of time needed to complete the job is greater than the amount of time between the Due Date and the current date, the system will toggle automatically to forward scheduling from the current date. 4B-25

26 Orders Shop Order Release and Maintenance Due Dates Tab Release Detail Hours Scheduled By YES RADIOBUTTON Select from the following two options: Parts balance (Pc/Hr) Activate to schedule the shop hours based on the amount of parts remaining to produce. Hours Balance (Est-Act) Activate to schedule the shop hours based upon the difference between the Estimated Hours and the number of hours already recorded against the operation. Preferred Start Date NO DATE Enter in the preferred start date to begin the first operation. The scheduling system adjusts the schedule to accommodate the date entered. Don t Schedule NO CHECKBOX Activate the checkbox to not schedule the release. Lock Job NO CHECKBOX Activate checkbox to stop all activity regarding the released job. Delivery Schedule The delivery schedule window displays any additional releases of the shop order part. 4B-26

27 Add Shop Order Releases via Auto-Create Releases The Auto-Create Release function allows the user to quickly create a release with minimal added input. Unlike the Release Detail form, the system pulls all the pertinent information regarding the release automatically therefore requiring the user to enter in only the release date, quantity and scheduling criteria. Additional information regarding the fields and parameters are provided in the corresponding table below. Figure 4b.15 Add Shop Order Release Orders Shop Order Release and Maintenance Due Dates Tab Add Shop Order Releases Shop Order Number N/A DISPLAY Displays the open shop order number. Last Release Date N/A DISPLAY Displays the last shop order release date entered. Last Release Number N/A DISPLAY Displays the last release number Release Frequency YES DROPDOWN Select the release frequency from the dropdown list. The following options are available: - Single Release - Weekly - Monthly 4B-27

28 Orders Shop Order Release and Maintenance Due Dates Tab Add Shop Order Releases Number of Releases N/A DISPLAY Specify the number of releases required for the order. The default is 1 if the Single Release frequency is selected. Release Date YES DATE Enter the date that the Release is to be completed by. Default Release Quantity NO NUMBER Enter the default quantity to be produced under the Release(s) of the Shop Order. This quantity may be modified later at the release level. Scheduling Criteria Priority - Hot - Normal YES NUMBER PUSHBUTTON Define the scheduling priority for this release. A priority of one (1) is the highest priority, all nines (999999) is considered Unscheduled. A priority of 100 is Hot and a priority of 500 is Normal. A new Shop Order Release will be unscheduled (999999) by default. Unschedule N/A PUSHBUTTON Activate pushbutton to unscheduled (delete) all schedule records related to the shop order release. Scheduling Method YES RADIOBUTTON Select the scheduling method from the following two options: Forward from Start Date Activate radio button to schedule the shop order forward from the current date out to a projected end date that has been calculated based on estimated operation cycle times. Backward from Due Date Activate radio button to schedule the Shop Order from the Due Date, backwards to a starting date. Note: If the amount of time needed to complete the job is greater than the amount of time between the Due Date and the current date, the system will toggle automatically to forward scheduling from the current date. Hours Scheduled By YES RADIOBUTTON Select from the following two options: Parts balance (Pc/Hr) Activate to schedule the shop hours based on the amount of parts remaining to produce. Hours Balance (Est-Act) Activate to schedule the shop hours based upon the difference between the Estimated Hours and the number of hours already recorded against the operation. 4B-28

29 Infinite Project Based Scheduling The Infinite Scheduling Gantt chart provides the user a graphical summary of the shop order release schedule for each defined operation. It allows the user to override the defined capacities and therefore provide infinite capacity for each defined workcenter. The form provides the user to overload workcenters manually push a job, mover operations and reschedule orders using the defined system parameters. The attached Gantt chart color codes the operations according to their scheduled completion. Red represents a late operation, green represents a completed operation prior to the defined due date and a gray box represents an open operation scheduled within the correct time frame. Additional information regarding the available fields and parameters are provided in the corresponding table below. Figure 4b.16 Infinite Scheduling Gantt Chart (Plan for Shop Order) Moving Operations within the Gantt Chart To adjust the schedule manually, right click on the operation box within the Gantt chart and drag it into the new desired time position. 4B-29

30 Orders Shop Order Release and Maintenance Due Dates Tab Infinite Project Based Scheduling Shop Order Number YES ALPHANUMERIC Displays the shop order number. Other shop orders can also be viewed with the Gantt chart via the attached search key. Include Suborders NO CHECKBOX Activate checkbox to include any suborders into the Gantt chart. Gantt Reports N/A PUSHBUTTON Activate pushbutton to print the Gantt Report. The report displays both the shop orders operations as well as the attached Gantt chart. Calendar Scroll Bars N/A PUSHBUTTON The Gantt chart calendar can be controlled using the available scroll pushbuttons. The following scrolls are available: Scrolls back one month. Scrolls back one week. Scrolls forward one week. Scrolls forward one month. Order Number N/A DISPLAY Displays the shop order number. Release Number N/A DISPLAY Displays the shop order release number. Operation Number N/A DISPLAY Displays the operation number. Workcenter N/A DISPLAY Displays the assigned workcenter. Quantity Ordered Quantity Balanced N/A PUSHBUTTON/ DISPLAY The pushbutton is used to toggle between the ordered quantity display and the balance quantity. The column adjusts according to the selection made. Hours Needed N/A DISPLAY Displays the hours needed to complete the given operation. The hours are assigned to a workcenter in the operations tab. Start/End Date Shop Order Due Date N/A PUSHBUTTON/ DISPLAY The pushbutton is used to toggle between the Start/End Date and the Shop Order Due Date displays. The column display adjusts according to the selection made. Total Hours Needed N/A DISPLAY Displays the total number of hours needed to fulfill the entire shop order by summing the hours needed for all operations. 4B-30

31 Orders Shop Order Release and Maintenance Due Dates Tab Infinite Project Based Scheduling Detail N/A PUSHBUTTON Activate pushbutton to retrieve the Operational Scheduling detail form for the highlighted operation. Additional information regarding the function is provided in the following section. Reschedule N/A PUSHBUTTON Activate pushbutton to allow the system s Visual Shop Manager to reschedule the shop order according to all defined jobs/criteria. Exit N/A PUSHBUTTON Exits the form back to the Shop Order Maintenance Due Dates tab. List by YES DROPDOWN The List by dropdown menu is allows the user to configure the first column display according to the selection made. The user has the option to display one of the following fields: - Shop Order Number - Part Number - Part Description - Inventory Number Show Actual Scheduled Dates Show Jobcard Start/End Dates NO CHECKBOX Activate checkbox to show the actual scheduled dates in reference to the current date. A yellow bar is drawn from the current date to the date the operation is scheduled to begin. NO CHECKBOX Activate checkbox to show the jobcards start and end dates. 4B-31

32 Operational Scheduling The Operational Scheduling form is used to review all the production details regarding a given operation number. Within this form, the user is also provided the means to adjust the following three items: manually set an operation as complete ; manually adjust the operations start and end dates; add any status notes. Figure 4b.17 Operation Scheduling Orders Shop Order Release and Maintenance Due Dates Tab Infinite Releases Operation Scheduling Infinite Schedule Information Operation Complete NO CHECKBOX Activate checkbox to manually complete the operation. The operation is then displayed green on the Infinite Gantt Chart. Start Date YES DATE Enter in the operation start date. End Date YES DATE Enter in the operation end date. Status Notes N/A PUSHBUTTON Activate pushbutton to add any status notes to the operation. 4B-32

33 Shop Order Maintenance Material Requirements Tab The Material Requirements Tab allows the user to create a laundry-list of required materials. Each item listed within the Material Requirements Tab can be an inventoried or a non-inventoried item, meaning it does not have to be defined within inventory to be used. Each defined material maybe associated with the operation that will consume the material. As a result, the shop traveler will reveal the materials required for each operation. Also, the raw materials will be identified to the operation that consumes the material during allocation. Figure 4b.18 Shop Order Maintenance Material Requirements Tab Once the raw materials are defined on the top list, the materials should be allocated by activating the Allocate pushbutton. This step transfers the material from the top list to the bottom list, therefore displaying demands for the item. If the user allocates the materials, the raw materials can not be automatically consumed while running the Shop Order. The system uses the allocations to define the material requirements and the rate of consumption of those Materials. Additional information regarding the tab is provided in the corresponding table below. 4B-33

34 Orders Shop Order Release and Maintenance Material Requirements Tab Section 1 Status Indicator N/A DISPLAY Displays the status of the raw material. The following indicators are used: A H C Open Hold Closed Material Description N/A DISPLAY Displays a description of the raw material. Shape N/A DISPLAY Displays the shape of the raw material Purchase Order Unit of Measure N/A DISPLAY Displays the purchasing unit of measure. Quantity N/A DISPLAY Displays the quantity of raw material needed to manufacture the quantity needed. Unit Cost N/A DISPLAY Displays the unit cost of the displayed raw material. Total Cost N/A DISPLAY Displays the total cost of the raw material needed. Markup % N/A DISPLAY Displays the material markup. Total Price N/A DISPLAY Displays the total price of the raw material needed. Display - Description - Inventory Number - Assign Materials to Op. YES RADIOBUTTON The radio buttons controls the display. The user can choose to display either material description (as shown in figure 4b.18), inventory number by activating the corresponding radio button. The user is also given the option to assign the raw materials to operations via the corresponding radio button. The display of the form is modified accordingly. Add N/A PUSHBUTTON Activate pushbutton to add a new raw material to the shop order using the retrieved Material Item Definition form. Update N/A PUSHBUTTON Activate pushbutton to update the highlighted raw material record. The Material Item Definition form is retrieved for update. A double-click on the record also retrieves the form for 4B-34

35 Orders Shop Order Release and Maintenance Material Requirements Tab update. Delete N/A PUSHBUTTON Activate pushbutton to remove the highlighted raw material from the shop order. After the delete validation is confirmed, the record is permanently removed from the system. Copy N/A PUSHBUTTON Activate pushbutton to copy the highlighted raw material into a new record. The record is automatically inserted into the list. Recopy Materials N/A PUSHBUTTON Activate pushbutton to recopy the materials from the originating quote or bill of material structure. The data is refreshed with the originating material requirements data. Change Status N/A PUSHBUTTON Activate pushbutton to initiate a Change Status pop-up. The function is used to change the status of the highlighted material. The following status options are available: C H O CLOSED HOLD OPEN Create Inventory N/A PUSHBUTTON The pushbutton is used to assign inventory numbers to noninventoried materials that were previously added to the material requirements form. When activated, the Create Inventory for Non-inventoried Items form is retrieved where the user can simply enter the inventory number to assign and activate the Create Inventory Item pushbutton to complete the assignment. Allocate Materials N/A PUSHBUTTON A Right Click on the pushbutton allocates material for the entire quantity. A Left Click on the pushbutton allocates material for the balance of the quantity. Request For Quote N/A PUSHBUTTON A request for quote can be issued for accurate pricing. Material Requirements Report N/A PUSHBUTTON A material requirements report can be printed or delivered in a PDF format. Section 2 Inventory Number Allocated N/A DISPLAY Displays the inventory item allocated. 4B-35

36 Orders Shop Order Release and Maintenance Material Requirements Tab Release Number N/A DISPLAY Displays the release number. Operation Line N/A DISPLAY Displays the operation number assigned to the raw material. Quantity Ordered N/A DISPLAY Displays the quantity ordered. Quantity Produced N/A DISPLAY Displays the quantity manufactured. Balance to Produce N/A DISPLAY Displays the outstanding quantity to manufacture. Quantity Needed Displays the quantity of items needed. - Stock Unit of Measure N/A DISPLAY Displays the quantity in the stock unit of measure still needed. - Pieces N/A DISPLAY Displays the number of pieces still needed. Stock On Hand Displays the item s on hand. - Stock Unit of Measure N/A DISPLAY The on-hand displayed in the stock unit of measure. - Pieces N/A DISPLAY Displays the number of pieces on-hand. Display - Inventory Number - Description Update Purchasing Requirements N/A RADIOBUTTON The user can modify the form to either display the inventory number or the inventory description by selecting the appropriate radio button. N/A PUSHBUTTON Activate pushbutton to initiate the Update Purchasing Requirements form. The user can review the raw material item specifications and is also given the opportunity to review the supplier, purchase order monitoring as well as the manufacturing Gantt schedule. This screen may be used to better communicate the Shop Order requirements to your company s purchasing agent. Additional information is provided in the following section. Reserve Lots N/A PUSHBUTTON Activate pushbutton to retrieve the Lot/Serial Number Tracking form. The user is provided the opportunity to manual select the specific lot of raw material from the list available. Update Inventory N/A PUSHBUTTON Activate pushbutton to retrieve the Inventory Maintenance subsystem for the highlighted raw material. Delete N/A PUSHBUTTON Activate pushbutton on the highlighted record to delete the allocation. This application removes the shop order s demand 4B-36

37 Orders Shop Order Release and Maintenance Material Requirements Tab for the specified material. The allocation is removed after the delete validation is confirmed. 4B-37

38 Purchasing Requirements Activate Update Purchasing Requirements pushbutton to retrieve the form below. The user can review the raw material item specifications and is also given the opportunity to review the supplier, purchase order monitoring as well as the manufacturing Gantt schedule. Figure 4b.19 Purchasing Requirements Orders Shop Order & Release Management Material Requirement Tab Purchasing Requirements Schedule to Start N/A PUSHBUTTON Activate pushbutton to view a Gantt Chart for the specified operation s schedule record. This field will display the Start Date for this operation, based on the information in the Schedule Record. Supplier NO ALPHANUMERIC Enter a valid Vendor Code. PO Number NO ALPHANUMERIC Once a PO has been created for the material requirement, the PO number will be inserted into this field. If a PO has already been created, the User may choose to associate the material with that PO. This may be done by entering the PO into the field or clicking the Search Icon and selecting the PO number from the resulting list. 4B-38

39 Orders Shop Order & Release Management Material Requirement Tab Purchasing Requirements Line Number NO ALPHANUMERIC Once a PO has been created for the material requirement, the Line Number of the material on the PO will be inserted into this field. Request Date NO DATE Enter the date that the material will be needed. The User is requesting that the material be received in by this date. Employee NO DROPDOWN Select the appropriate Employee Name from the drop-down listing. Do Not Order NO CHECKBOX Activate checkbox to indicate that this material should not be ordered. PO Monitoring N/A PUSHBUTTON Activate pushbutton to enter the Purchase Order Monitoring screen. For more information, please refer to the Purchasing chapter. Purchasing Instructions N/A PUSHBUTTON Activate pushbutton to enter in any additional purchasing instructions. A free form text box is retrieved for entry. 4B-39

40 Material Item Definition The Material Item definition form is split into two distinct divisions. The top half of the form outlines pertinent item definitions. The bottom half toggles between the pricing calculator (displayed below) and the material calculator displayed in figure 4b.22. The pushbutton located in section one is used to toggle between the two forms. Each calculator is further described below. Sect. 1 Sect. 2 Figure 4b.20 Material Item Definition with Pricing Calculator 4B-40

41 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Item Type Non-Inventoried/ Inventoried YES RADIO BUTTON Select whether or not the material required for the job is an Inventoried item or a Non- Inventoried item. If an Inventory item is chosen, many of the fields will be pre-populated and cannot be overridden as they have been previously set up in Inventory Maintenance. Inventory Number NO ALPAHNUMERIC Enter the Inventory Number of the Raw Material to be consumed, or click on the search icon to activate the Inventory Search dialog box where you can select an inventory item. This field will be grayed out if Non-Inventoried has been chosen. Alternative Materials N/A PUSHBUTTON Left Click Allows the user to select alternative materials from the retrieved Material Specification form. Right Click Allows the user to select the optimal sheet, plate or coil material. Additional functionality is described in the section Optimal Material Calculator. Part Number NO ALPAHNUMERIC Input the Supplier Part Number if Non- Inventoried has been chosen. If Inventoried is selected, this field will autopopulate with information from Inventory Maintenance. Description NO ALPAHNUMERIC Input the Description of the material to be consumed. If Inventoried is selected, this field will autopopulate with information from Inventory Maintenance. Extended Part Description N/A PUSHBUTTON Activate pushbutton to enter additional text if the Description field length is inadequate. 4B-41

42 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Stock UOM NO DROPDOWN Select the Stock Unit Of Measure from the dropdown menu. This unit is based on how the item will be tracked in inventory. Consume by Stock UOM NO CHECKBOX Activate checkbox to bypass the Raw Material Calculator. When activated, the system is notified that the entire raw material is used during production. Certification/Lot NO ALPAHNUMERIC Enter in any corresponding raw material certification or lot number. Purchase UOM NO DROPDOWN Select the Purchase Unit Of Measure from the drop-down menu. This unit is based on how the item will be purchased from your vendor. Stock UOM/Piece NO NUMBER If a Shape has been defined, the pieces per shape will be auto-populated by the Raw Material Calculator. By Lot NO CHECKBOX Activate checkbox to allocate the specified quantity directly (as a lot) rather than on a per piece basis. Drawing Number NO ALPAHNUMERIC Enter in the part s drawing number if a drawing is applicable. Preferred Supplier NO ALPAHNUMERIC Enter the Vendor Code or use the search key for vendor selection via the Supplier Search dialog box. Supplier Part No. NO ALPAHNUMERIC If applicable, enter the Vendor Part Number. Std. (Raw Material Specification) N/A PUSHBUTTON Select any raw material specifications from the pop-up dropdown menu. Allocate to Operation No. NO DROPDOWN The system will automatically default the material requirement to the first operation listed within the Operations tab. The user may override this default and select from the drop down list. Operations will need to be defined first, before any drop down is available. 4B-42

43 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Source NO DROPDOWN Select the source of the material from the dropdown menu. The two available source options are: Make or Buy. Lead Time (Days) NO NUMBER Enter in the days needed to procure material. Purchasing Instruction N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to add any additional purchase details. Information entered is included in the PO Generator and the Direct Buys report. The information entered is meant to be viewed by the purchasing department and will not be included in the actual Purchase Order. Raw Material Shape NO DROPDOWN Choose a stock Shape from the drop-down menu. Certain Shapes have unique characteristics and physical qualities, such as, width, length, diameter, that need to be captured within the form. The required material characteristic fields are automatically displayed for entry. Material Type (Alloy) NO DROPDOWN Choose a Material Type from the drop-down menu. Weight per ft. NO NUMBER Enter in the weight per foot of the selected material. Do Not Buy NO CHECKBOX Activate checkbox if the material should be excluded from the Direct Buy s PO Generator. Obsolete NO CHECKBOX Activate checkbox if material should not be copied to shop orders. When activated, the material is designated as obsolete. Pricing/Material Calculator N/A PUSHBUTTON This pushbutton toggles the display of the form between the Pricing Calculator and the Material Calculator. The Pricing Calculator display is shown in figure 4b.20. Each calculator is individual described later in this chapter. Recalculate N/A PUSHBUTTON Recalculates the Pricing Calculator using any changes made to material specifications in section 4B-43

44 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition 1 of figure 4b.20. Clear All Values N/A PUSHBUTTON Clears the entire Material Item Definition form for reentry. Default Costs N/A PUSHBUTTON The default cost pushbutton can be retrieves a pop-up window that allows the user to select the Global Defaults as either the Standard Costs, Average Cost, or Last Cost. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Save & Add N/A PUSHBUTTON Saves any changes made to the form and reopens the Material Item Definition form for additional material entry. Next Material N/A PUSHBUTTON Scrolls back to a previously defined material. Previous Material N/A PUSHBUTTON Scrolls forward to a previously defined material. Markup Method N/A PUSHBUTTON Select the markup method from the dropdown menu. 4B-44

45 Pricing Calculator Figure 4b.21 Material Requirements Pricing Calculator Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Pricing Calculator Qty to Run N/A DISPLAY This field is auto-populated by the quantities that were originally entered earlier in the Qty/Part Spec tab of Multiple Materials Quotation Maintenance. Total Shape Descriptor (Pieces above) Cost per Purchase UOM (Piece above) NO NUMBER If a cut size was entered in the Raw Material Calculator, the field will auto-populate. If the data was not entered in the calculator, the values may be entered manually. NO NUMBER This field may be auto-populated by clicking on the Default Costs button at the bottom of the screen. If data is not available, the value may be entered manually. Misc. Cost NO NUMBER Enter in any miscellaneous costs. Total Cost N/A DISPLAY This field is auto-calculated by multiplying the Total Material by the Cost plus any entered miscellaneous costs. This calculated value may not be manually modified. MU% NO PERCENT Enter a Material Markup percentage. The Total Cost will either be multiplied or divided by this percentage depending on which method has been chosen at the bottom of this screen. Total Price N/A DISPLAY The Total Price is the Total Cost that has been affected by the Markup. This value may not be manually modified. 4B-45

46 Material Calculator Figure 4b.22 Material Calculator Note: The field definitions here will vary dependent on raw material shape selected during quote setup. We will reference the fields shown on above screen shot, but understand that the field definitions will vary dependent on the shape of part being produced. Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Material Calculator PART SPECIFICATIONS Note: Part specifications change according to the material shape selected. The fields given below are automatically populated for bar stock. An example of the raw material shape sheet follows the table below. In (Inches) / mm (millimeters) YES RADIO BUTTON Toggles the part specifications entered below from inches to millimeters. Part Description NO ALPAHNUMERIC Enter in the Part Description. 4B-46

47 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Material Calculator Part Length NO NUMBER Enter in the actual overall Part Length in decimal form. This maybe determined by the customer's print. Cut off Width NO NUMBER Enter the kerf lost for each cut piece (i.e.- if your saw blade is 1/16 wide, enter.0625 here so this material loss is deducted from raw material for each piece that is saw cut). This field should also be used for laser cutting, plasma cutting, water jet cutting, or any process where raw material is being consumed in cutting process. Face Length NO NUMBER Similar to the kerf loss entered in the Cut Off Width field above, face length will deduct raw material if face (i.e.- the bar end, if round bar) will be further ground, deburred, or reduced in overall raw material usage for some reason. Total Length NO VALUE This field is auto populated by the system and is calculated by adding together the 3 fields directly above (Part Length, Cut Off Width, and Face Length). It is used to calculate the actual raw material requirements, since it compensates for kerf loss, or other metal/raw material being consumed in the cutting process. Part Diameter NO NUMBER Enter diameter of round bar in the decimal form. Tolerance + NO NUMBER Enter in the maximum tolerance for the finished bar diameter. Tolerance - NO NUMBER Enter in the minimum tolerance for finished bar diameter. If the shape selected was Sheet or Plate, this field would display as Face Length. This is because plate and sheet have two dimensions being cut (as opposed to a bar). See Face Length above. 4B-47

48 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Material Calculator Material Increase NO PERCENTAGE Used for the Bar raw material. Used to compensate any additional material loss. Ex. Used to account for the material lost to grip chucks used during manufacturing. SCRAP WEIGHT CALCULATOR Scrap Weight Calculator N/A PUSHBUTTON Activate pushbutton to retrieve the Chip Weight Calculator. The calculator is further described in the chapter below. Scrap NO PERCENTAGE If applicable, enter in the estimated percentage of scrap created in manufacturing the parts. Chip Lb/1 NO NUMBER The system will automatically display the calculated Chip Weight per part defined that was calculated using the Chip Calculator. This calculation can be overridden to allow the user to simply enter in the Chip Weight. Chip Price/Lb NO NUMBER Enter in the scrap rate (Price per Pound paid by the scrap dealer for the alloy). This will be automatically multiplied by the Chip Weight per Part, by each Quantity to Quote, and then subtracted from the Material Cost in the Quotations Final Worksheet screen. USABLE RAW MATERIAL Bar End Length NO NUMBER If applicable to the selected material shape, enter the length of bar that is scrapped when processing (material lost to a gripper or collet). This is often dependent on the job and machine running. Bar end lengths are predefined by machine code in the table: Tables Workcenters for Inventory items. Length of Bar Used N/A DISPLAY If applicable to the selected material shape, this field is auto populated by program. It is calculated by taking the original bar Length field specified minus the Bar End Length. 4B-48

49 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Material Calculator PART WEIGHT Part Weight UOM YES DROPDOWN Select the part weight Unit of Measure required for the selected quotation, from the drop-down menu. For your convenience you may define your most common Unit of Measure in your Company Table, which is located in Tables drop down menu. Pcs. Needed/ Finished Unit Part Weight UOM (pound above)/piece NO NUMBER Enter how many pieces of this material are required for a complete part. NO NUMBER The [Part Weight UOM]/Piece value is calculated by taking the weight of the whole Raw Material Shape and dividing it by the number of pieces per Raw Material Shape. This calculation provides an estimate and may be over-ridden, if necessary. Pieces/Shape (Bar) NO NUMBER The Pieces/[Shape] value is calculated using the following formula: Pieces/(Shape)=[(Shape length/part length)/pieces needed per Finished Unit] Actual Unit of Weight/Price Unit (entered in General Tab) NO DISPLAY This field is calculated by the system and represents the gross weight of raw material to manufacture the quantity of finished parts in denominator. Shown above Actual Lb/1 Round N/A PUSHBUTTON Left click this button to enter pieces per unit rounding criteria. If the round button is activated, the system will automatically round the quantities down to the nearest complete part. Scrap Markup % NO PERCENTAGE If a yield loss is expected when running the part (such as getting only 95 good parts of 100), enter a percentage which represents this yield loss. The raw material weight needed will be calculated based on the extra material required, and displayed in the next field being discussed. 4B-49

50 Orders Shop Order & Release Management Material Requirement Tab: Material Item Definition Material Calculator Total Unit of Weight/Price Unit (entered in General Tab) NO NUMBER The field is system calculated and represents the gross weight of raw material to manufacture the quantity of finished parts in denominator. The Scrap Markup % is also applied to the calculation. Finished Lb/1 NO NUMBER This field is auto populated by calculations made in the Part Weight Calculator Price Lock Down N/A PUSHBUTTON Left click the padlock icon to lock down displayed prices and prevent changes made in auto calculations. Part Weight Calculator N/A PUSHBUTTON The Part Weight Calculator is used to calculate revised part weights when stock is removed from the outside and/or the inside of the bar. It can only be used for Round, Hex and Square bar items. Recalculate Part Weight N/A PUSHBUTTON If field entries are modified, click this button to refresh fields with new calculations. 4B-50

51 Sheet, Coil, Plate Raw Material Shapes Part specifications change according to the material shape selected. Specifically, the material shapes of sheet, coil and plate offer additional functionality in the part specification material calculators. An example of the functionality offered for the raw material shape sheet is given below. Figure 4b.23 Raw Material Shape: Sheet Orders Shop Order & Release Management Material Requirement Tab: Material Calculator Sheet Material Shape PART SPECIFICATIONS Inches/ Millimeters YES RADIOBUTTON Select unit of measurement. Calculation Method YES RADIOBUTTON The calculation method is used to determine the number of pieces that can be manufactured from the selected raw material. --- L/L W/W This radio button calculates the maximum number of pieces that can be manufactured by dividing material length by the part length. (The part is cut along the material grain.) --- L/W W/L This radio button calculates the maximum number of pieces that can be manufactured by dividing the material length by the part width. (The part is cut across the material grain.) --- Both Determines the best layout by rotating the material to minimize scrap. Part Description NO ALPHANUMERIC Enter in a part description. 4B-51

52 Orders Shop Order & Release Management Material Requirement Tab: Material Calculator Sheet Material Shape Part Length NO NUMBER Enter in the length of the manufactured part. Cut Off Width NO NUMBER Enter in the cut off width that will be lost when manufacturing the part. Face Length NO NUMBER Enter in the face length that needs to be compensated for during calculation. (Amount of material lost to clamps, fixtures, etc.) Total Length N/A DISPLAY This field is a sum of the part length, cut off width, and face length. This calculated sum will be used to determine the maximum number of pieces produced. Part Width NO NUMBER Enter in the width of the manufactured part. Cut Off Width NO NUMBER Enter in the cut off width that will be lost when manufacturing the part. Face Length NO NUMBER Enter in the width that needs to be compensated for during calculation. (Amount of material lost to clamps, fixtures, etc) Total Length N/A DISPLAY This field is a sum of the part width, cut off width, and face length. This calculated sum will be used to determine the maximum number of pieces produced. 4B-52

53 Optimal Material Calculator The Optimal Material Calculator provides a resourceful method for selecting the most efficient material specifications from inventory for the given part parameters. This option is only available for the raw material selections sheet, plate or coil material. The Optimal Material Calculator can be accessed by right clicking the mouse on the Alternative Material pushbutton circled in the figure below. Figure 4b.24 Optimal Material Calculator Retrieval Once activated, a list of materials that have assigned inventory numbers are retrieved for the given material shape and material composition. Figure 4b.25 Optimal Material Calculator 4B-53

54 Orders Shop Order & Release Management Material Requirement Tab: Alternative Material Calculator Inventory Number N/A DISPLAY Displays the selected inventory number defined in the Material Item Definition screen. Description N/A DISPLAY Displays the inventory description defined in the Material Item Definition screen. Thickness N/A DISPLAY Displays the thickness of the material defined in the Material Item Definition screen. Material N/A DISPLAY Displays the selected material type defined in the Material Item Definition screen. Material Shape N/A DISPLAY Displays the raw material shape defined in the Material Item Definition screen. Blank Width N/A DISPLAY Displays the part width defined in the part specifications section of the Material Item Definition screen. Width Loss NO NUMBER Enter in any expected width loss. The entered value will be used during calculation. Blank Length N/A DISPLAY Displays the part length defined in the part specifications section of the Material Item Definition screen. Length Loss NO NUMBER Enter in any expected length loss. The entered value will be used during calculation. Analyze N/A PUSHBUTTON Recalculates the maximum number of pieces and percent loss using any new changes made to the form. Inventory Number N/A DISPLAY Displays the inventory number of the retrieved list of alternative materials. Description N/A DISPLAY Displays the inventory description of the retrieved list of alternative materials. Width N/A DISPLAY Displays the width of the retrieved material. Length N/A DISPLAY Displays the length of the retrieved material. 4B-54

55 Orders Shop Order & Release Management Material Requirement Tab: Alternative Material Calculator Max. Pieces N/A DISPLAY Displays the automatically calculated maximum number of pieces that can be manufactured from the inventory item. % Loss N/A DISPLAY Displays the percent of the material lost to scrap. The user may want to select an inventory item that has the least amount of material scrap. In the example above, inventory number may only produce 6 parts per sheet but has the lowest percent of scrap. UOM N/A DISPLAY Displays the inventory item s unit of measure. On-Hand N/A DISPLAY Displays the quantity on hand for the given material. Available N/A DISPLAY Displays the available quantity for the given material. 4B-55

56 Scrap Weight Calculator Figure 4b.26 Scrap Weight Calculator Activate the SRAP WEIGHT CALCULATOR pushbutton found in the Material Item Definition form s Material Calculator (figure 4b.22) to add a new calculation. Once activated, the Chip Calculator form displayed below is retrieved. Select the base shape used for the calculation from the dropdown menu. Various shape options are included. Once selected, the system automatically displays the required fields and generates a drawing that is used to aid in the calculation. The Drawing Location field is used to enter drawing coordinates that define the stock removal location. Figure 4b.27 Chip Calculator Note: The shapes selected are used to calculate the amount of stock removed in the machine process. 4B-56

57 Part Weight Calculator The Part Weight Calculator is used to compute revised part weights when stock is removed from the outside and or inside of the bar. The calculator is only used for Round, Hex and Square bar raw materials. Sect. 1 Sect. 2 Figure 4b.28 Part Weight Calculator The top half of the form above (section 1) is used to define material removed from the outside of the bar. The lower half (section 2 of figure 4b.28) is used to define material removed from the inside of the bar (drilling a hole through the center). The Outside and Inside calculators both operate using the same functions. To remove stock from the outside of the bar, activate the ADD pushbutton found in section 1 of figure 4b.28. The Part Weight Details form is automatically retrieved and displayed below. 4B-57

58 Figure 4b.29 Part Weight Details The fields retrieved for material removal are automatically populated according to the shape selected from the drop down menu. More material can be removed from the Outside or Inside of the bar by following the same procedure. Any number of steps can be used, providing they do not exceed the overall length of the finished part. Part Weight Calculator Part Weight Details Table Guide Orders Shop Order & Release Management Material Requirement Tab: Material Calculator Part Weight Calculator Details Quote Number N/A DISPLAY The Quote number is auto populated by the Material Item Definition screen. Raw Material Shape N/A DISPLAY The raw material shape is auto populated by the Material Item Definition screen. Size N/A DISPLAY The size is auto populated by the Material Item Definition screen. Length N/A DISPLAY The length is auto populated by the Material Item Definition screen. Shape YES DROPDOWN Select the shape of the stock removal item from the dropdown list. In this example, the material removed is round and is a 3 diameter round bar. 4B-58

59 Orders Shop Order & Release Management Material Requirement Tab: Material Calculator Part Weight Calculator Details Diameter 1 YES DISPLAY Enter in the diameter of the location where the stock removal begins. In the example displayed, the bar will be machined to a 1.75 diameter. Diameter 2 YES DISPLAY Enter the diameter of the part where the stock removal ends. In this example, the bar will be taper machined from 1.75 diameter (diameter 1) to a 1 diameter of 4 overall length. Length YES DISPLAY Enter the overall length of the stock removal. In this example, 4 of the 10 long bar are being machined. The 4 length is actually a cone section starting with a 1.75 diameter and tapered down to a diameter of 4 overall length. Volume N/A DISPLAY The system automatically calculates the volume after the dimensions are defined. It will deduct the volume of the machined area is used when calculating the finished part weight. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Once the shape, diameter 1, diameter 2, and Length fields are defined, the machined bar would look something like the drawing below. Figure 4b.30 Drawing of the machined part in the example above. 4B-59

60 Shop Order Maintenance Operations Tab The Operations Tab is used to determine, obtain, and maintain Workcenter, Operation and Setup. All the associated production and subcontracting costs are determined and maintained as well. As a result, the Operation tab supports multiple subsystems that can be accessed throughout. Each subsystem is individual defined within the Operations Tab section. Sect. 1 Sect. 2 Figure 4b.31 Shop Order Maintenance Orders Tab Orders Shop Order Release and Maintenance Operations Tab Raw Material Type NO DROPDOWN Select the raw material type from the dropdown list if it was not automatically populated. Raw Material Inventory Number NO ALPHANUMERIC Enter in the raw material inventory number if was not automatically populated. Operations Revision NO ALPHANUMERIC Enter in the operation revision. Last Changed By NO TEXT Enter in the name of the user who last made changes to the operations. 4B-60

61 Orders Shop Order Release and Maintenance Operations Tab Revision Date NO DATE Enter in the date of the last revision. A double click on the date field automatically retrieves the interactive Visual EstiTrack calendar. Operation N/A DISPLAY Displays a list of Operation numbers. Workcenter N/A PUSHBUTTON Displays the workcenter selected for the current operation. Note: For worksheets with undefined operations, the pushbutton can be used to retrieve a workcenter/operation default form. This form allows the user to define a number of workcenter from an available list. The user can reposition the selected Workcenters by dragging them via their associated pushbuttons. SETUP COLUMN Hours N/A DISPLAY Displays the hours required for the given operation. Rate N/A DISPLAY Displays the rate (pieces per hour) for the given operation. Total N/A DISPLAY Displays the total number of hours for the given operation. PRODUCTION Gross N/A DISPLAY Displays the gross (pieces per hour). % N/A DISPLAY Displays the percent yield. Net N/A DISPLAY Displays the net production. Hours/Quantity Unit N/A DISPLAY Displays the hours divided by the quantity unit. In the example above, Hours are divided by 1. Rate N/A DISPLAY Displays the hourly production rate. Cost/Quantity Unit N/A DISPLAY Displays the cost divided by the quantity unit. In the example above, Cost is divided by the unit 1. Add N/A PUSHBUTTON Activate pushbutton to Add a new operation. The Operation Worksheet form is retrieved in Add mode for entry. Update N/A PUSHBUTTON Activate pushbutton to Update the highlighted operation. 4B-61

62 Orders Shop Order Release and Maintenance Operations Tab The Operation Worksheet form is retrieved in Update mode for further update. Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted entry. The record is permanently removed from the system after a delete validation is performed. Remove Zero Hour Operations Overlap Percentage Operation Master Library N/A PUSHBUTTON Upon copying a Master Operation into the Quote, the user may update the applicable operations. Once updated, click on this button to remove the unnecessary operations and cause the system to re-increment the operations. N/A PUSHBUTTON Percentage button will calculate % (Percentage) complete for each operation. This is the overlap rate at which to schedule each operation. N/A PUSHBUTTON Click on this button to open the Operations Master Library. The Operations Master Library serves as a database of predefined operations and cycle times that are related to specific manufacturing functions within the organization. It is possible to add customized, searchable attributes to the library item. Total Setup N/A DISPLAY This system-calculated number adds up all setup costs listed under the Setup Totals column directly above. Increment Re-increment NO NUMBER (SPINNER) PUSHBUTTON A convenient way to change operation numbers is to select a number from the Increment spinner arrows and then left click the Re-increment button. The operation numbers will then re-increment based on the increment number chosen. This is helpful when needing to insert an operation between previously defined operations or wanting to change from 1 place operation number to two place operation numbers, e.g., 1, 2, 3 to 10, 20, 30. Cost per Quantity Unit Total N/A DISPLAY This system-calculated number adds up all lines of the Production Cost/Quantity Unit column directly above. 4B-62

63 Adding, Updating, and Deleting Operations Adding an Operation To add a new operation to the quote, select the ADD pushbutton found in section 2 of figure 4b.31, Operations Tab. The Operations Work Sheet is retrieved in the ADD mode for entry. The Operations Worksheet is further outlined in its corresponding section below. Editing an Operation To edit an existing operation, highlight the desired operation from the Operations Tab (Section 1 of figure 4b.31 Operations Tab). Select the EDIT pushbutton found in section 2 of figure 4b.31, Operations Tab. The Operations Work Sheet is retrieved in the UPDATE mode for edit. The Operations Worksheet is further outlined in its corresponding section below. A double click on the highlighted entry immediately retrieves the Operations Work Sheet in UPDATE mode for edit Deleting an Operation To delete an existing operation, highlight the desired operation from the Operations Tab (Section 1 of figure 4b.31 Operations Tab). Select the DELETE pushbutton found in section 2 of figure 4b.31, Operations Tab. The user will be prompted for delete confirmation with the following pop-up. Once the user validates the deletion via the YES pushbutton, the record is permanently removed from the system. 4B-63

64 Operations Worksheet The Operation Worksheet is similar to the Operations tab in that it maintains supporting functions that are made available from within the form. Each of these supporting functions is accessed through the Operation Type display box shown in the right hand corner of the figure below. The Operation Worksheet form is divided into three main sections. Section 1 displays the operation number and workcenter along with additional operational instructions. This information remains stagnant for both the In-house and Subcontract displays. The function and format of section 2, changes according to the radio button selected in the operation type. Section 3 remains stagnant throughout all three operation types selected. Sect. 1 Sect. 2 Sect. 3 Figure 4b.32 Operation Worksheet 4B-64

65 Operation Worksheet Operation Type: In-house All three sections of figure 4b.32 Operation Worksheet are outlined in the table below. Section 2 specifically refers to the In-house operation type selected. Orders Shop Order & Release Maintenance Operations Tab Operation Worksheet In house Operation Number YES NUMBER The required Operation Number for each Machine or Operation. All operation numbers are listed in numerical sequence. For example, operation 45 is sequenced between operation 40 and 50. Post to Finished Goods NO CHECKBOX Activate checkbox to direct the system to post a Quantity Produced on the General tab of the Shop Order when parts are produced by the Operation. This is normally activated for the last operation completing the finished good. It posts the completed part to inventory as available. Split Schedule NO CHECKBOX This feature is intended for high production manufacturing facilities that typically perform the primary operation to completion, but complete the secondary operations on an as-needed basis. This feature will cause the secondary operations to be scheduled by release. OPERATION TYPE In-house N/A RADIO BUTTON Select In-house for operations that are completed internally. Subcontract N/A RADIO BUTTON Subcontract should be selected if a subcontractor (outside vendor) will process this operation. The fields used in this Subcontract option will be further described below. Master N/A RADIO BUTTON Select Master to create a Master Operation that may consist of several operations that have been predefined in the Operations Master Library. 4B-65

66 Orders Shop Order & Release Maintenance Operations Tab Operation Worksheet In house Comment N/A RADIO BUTTON The Comment radio button will put text in the router (as typed into the text box), but will have no actual operation assigned to it. It will only appear on the router as a text comment Workcenter YES DROPDOWN Select the Workcenter from the dropdown list that will be used for the defined operation number. The workcenters are user-defined and are maintained in the table: TABLES WORKCENTER Scheduling Group NO DROPDOWN Select the source Scheduling Group. This is needed in order to allow multiple scheduling groups to be assigned to each Workcenter. % Complete NO PERCENTAGE Select percentage of operation to be complete prior to scheduling the following operation. Use either the arrow spinner controls to adjust the number, or type the percentage directly in this field. This is used in Auto-Priority Scheduling & Drag & Drop Scheduling. Schedulable NO CHECKBOX If activated, the operation will be schedulable via Automatic Priority-based Scheduling and will appear on the router. Conversely, if the box in not checked, the operation cannot be scheduled and will not appear on the router. Rework NO CHECKBOX If activated, the operation will be designated as a rework operation and will appear on a rework router only. Force Workcenter NO CHECKBOX If activated, the selected Workcenter will only be scheduled (will not defer to other available Workcenters in the selected Scheduling Group). Operation Instructions NO ALPAHNUMERIC This is a free format text area where any alphanumeric information can be entered relating to the operation. This is a handy way to develop your Process Plan in Quotations and a Routing Report in Operation Scheduling, since the notes are printed on both reports. SETUP (LOT CHARGE) 4B-66

67 Orders Shop Order & Release Maintenance Operations Tab Operation Worksheet In house Hours NO NUMBER The total amount of required hours to setup each operation. Applicable Setup Hours, if any, should be entered for each machine or operation defined. If the Default Setup Hours are pre-populated in the Workcenters Table, the system will automatically display (default) the Setup Hours for the chosen Workcenter. These hours can be over-ridden at any time. The default setup hours are maintained in the table: TABLES WORKCENTERS. Hourly Rate NO NUMBER The system automatically displays the predefined hourly Setup Rate defined in Workcenters Table. This field can be over-ridden at anytime. Total Cost NO NUMBER The system automatically calculates and displays the Total Setup Cost by multiplying the Setup Hours by the Hourly Rate defined. If more than one setup is defined in the Quantities Tab, the Grand Total Setup Costs automatically calculates and is displayed in the Operations Tab Queue Days NO NUMBER Define the number of days required between the current operation and the next defined operation. This is used during scheduling of the shop order. Tooling N/A PUSHBUTTON The Tooling pushbutton allows you to identify and store tools, speeds and feeds data and cycle time for each operation or workcenter. This function is further defined in a subsection below. PRODUCTION CYCLE TIME CALCULATOR Hours/Pc NO NUMBER Enter in the quantity in hours needed to complete the part. Pressing the Enter key or the Save button will automatically recalculate the other 3 displayed fields. Minutes/Pc NO NUMBER Enter the quantity in minutes needed to complete the part. 4B-67

68 Orders Shop Order & Release Maintenance Operations Tab Operation Worksheet In house Pressing the Enter key or the Save button will automatically recalculate the other 3 displayed fields. Seconds/Pc NO NUMBER Enter the quantity in seconds needed to complete the part. Activating the Enter key or the Save button will automatically recalculate the other 3 displayed fields. CYCLE TIME Gross Pcs/Hr NO NUMBER Cycle Time. Actual parts per hour each machine/operation will be geared for the quoted job. If you prefer to enter Hours per Unit first, the system will automatically calculate and display the Production Gross for you. Percentage YES PERCENTAGE Estimated percentage of corrected actual time each workcenter will be running. This is the estimated adjustment for projected downtime. The system automatically displays the predefined Production % defined in Workcenters Table. This can be over-ridden at anytime. Net Pcs/Hr N/A DISPLAY The system will automatically calculate and display the Net Production parts per hour based on the Production Gross and Production Percentage fields Net Hrs/Price Unit defined in General Tab N/A DISPLAY This field shows the hourly production rate the system will automatically calculate and display the production hours required per Price Unit based on the Production Net field. If the Gross Cycle time is unknown, the required hours per unit maybe entered in order for the system to automatically calculate and display the Gross Cycle time. Burden Hourly Rate NO NUMBER The system automatically displays the burden/overhead rate per hour predefined for the given workcenter in the Workcenters Table. This field maybe over-ridden if necessary. Labor Hourly Rate NO NUMBER The system automatically displays the labor hourly rate per hour predefined for the given workcenter in the 4B-68

69 Orders Shop Order & Release Maintenance Operations Tab Operation Worksheet In house Workcenters Table. This field maybe over-ridden if necessary. % Attended YES NUMBER Define the percentage this operation will be attended by an employee. The system will default to 100%. Cost/Price Unit defined in General Tab N/A DISPLAY The system will automatically calculate and display the Production Cost per predefined Price Unit. This is based on the Production Hours per Price Unit and Production Rate fields Page Break on Router NO CHECKBOX Activate checkbox to automatically insert a page break on the router prior to the given operation. Exclude Operation on Router NO CHECKBOX Activate checkbox to exclude the given operation from the router. Simple Calculation NO CHECKBOX Activate checkbox to use a simple production calculation. The simple calculation is as follows: Qty * (Unit Rate * Surcharge %) = Cost/Price Unit. If activated, the production calculation displayed in figure 4b.32 above is replaced by the above equation. Obsolete NO CHECKBOX Activate checkbox in order to flag the current operation as obsolete. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Alternates N/A PUSHBUTTON Activated pushbutton to retrieve the following options: 4B-69

70 Orders Shop Order & Release Maintenance Operations Tab Operation Worksheet In house Select Workcenter as the primary. Add an alternative workcenter. Scroll back through alternative workcenters. Scroll forward through alternative workcenters. Remove alternative workcenter. Default Inventory N/A PUSHBUTTON Pushbutton is used to identify default inventory numbers that are normally used during manufacturing as well as the inventory numbers of the actual produced parts. Along with the inventory numbers, the corresponding locations and bins can also be defined. E-Advisor N/A PUSHBUTTON Activate pushbutton to retrieve the E-Advisory subsystem. Operational Loss % N/A PUSHBUTTON Part Loss percentage is used for estimating part counts from machine counters. Actual Cost N/A PUSHBUTTON Activate pushbutton to view the combined postings of Job Cards against this operation. The Adjust Operation Accumulative Hours/Cost worksheet is retrieved for review. Additional information regarding the worksheet is provided further in the chapter below. Scrolls to Next Operation Scrolls to Previous Operation N/A PUSHBUTTON Scrolls forward to the next defined operation. N/A PUSHBUTTON Scrolls back to the previously defined operation. 4B-70

71 Adjust Operation Accumulative Hours/Costs The Adjust Operation Accumulative Hour/Costs worksheet displays the combined postings of Job Cards against this operation. The values maybe entered manually, however, saving a Job Card against this operation will cause the system to repost all Job Card transactions for this operation and the manual entry will be overwritten. Figure 4b.33 Adjust Operation Accumulative Hours/Costs Shop Order Maintenance Operations Tab Operation Worksheet Adjust Operation Accumulative Hours/Cost Shop Order Number N/A DISPLAY Displays the Shop Order Number Operation Number N/A DISPLAY Displays the Operation Number Setup Hours NO NUMBER Define the total setup hours for this operation as recorded through Job Card Maintenance. Labor Cost NO NUMBER Define the total labor cost for the setup hours recorded for this operation through Job Card Maintenance. This cost is derived from the employee s Job Cost Hourly Rate, defined in the table: TABLES EMPLOYEES Burden Cost NO NUMBER Define the total burden cost for the setup hours recorded for this operation through Job Card Maintenance. This cost is derived from the Burden Rate, defined in table: TABLES WORKCENTERS. 4B-71

72 Shop Order Maintenance Operations Tab Operation Worksheet Adjust Operation Accumulative Hours/Cost Production Hours NO NUMBER Define the total production hours for this operation as recorded through Job Card Maintenance. Labor Cost NO NUMBER Define the total labor cost for the production hours recorded for this operation through Job Card Maintenance. This cost is derived from the employee s Job Cost Hourly Rate, defined in the table: TABLES EMPLOYEES Burden Cost NO NUMBER Define the total burden cost for the production hours recorded for this operation through Job Card Maintenance. This cost is derived from the Burden Rate, defined in the table: TABLES WORKCENTERS. Quantities NO NUMBER Produced NO NUMBER Define the quantity of parts produced for this operation as recorded through Job Card Maintenance. Reviewed NO NUMBER Define the quantity of parts in review for this operation as recorded through Job Card Maintenance. Reworked NO NUMBER Define the quantity of parts to be reworked for this operation as recorded through Job Card Maintenance. Scrapped NO NUMBER Define the quantity of parts that were scrapped for this operation as recorded through Job Card Maintenance. Good N/A DISPLAY Define the quantity of good parts produced for this operation. This field is the sum of the previous quantities. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. 4B-72

73 Tooling The Tooling pushbutton is accessed from Operations In house worksheet. The tooling worksheet allows you to identify and store tools, speeds and feeds, data and cycle time for each operation or workcenter. The Tooling form is an overview of all the tools defined for an operation. Each tool is separately defined per each line item. Details regarding each defined tool are maintained in the Tooling Detail form. The Tooling Detail form can be accessed by double-clicking the line item. Figure 4b.34 Tooling Adding a Tool Select the ADD pushbutton found on the bottom of the screen to add new tooling for the displayed operation. The Tooling Detail form is retrieved for entry. 4B-73

74 Updating an Existing Tool To update an existing tool, highlight the desired tooling line number from the tooling form (figure 4b.32 Tooling). Select the UPDATE pushbutton The Tooling Detail form is retrieved in the UPDATE mode for edit. The Tooling Detail Form is further outlined in its corresponding section below. A double click on the highlighted entry immediately retrieves the Tooling Detail Form in UPDATE mode for edit Deleting an Existing Tool To delete an existing tool, highlight the desired entry from the Tooling Form Select the DELETE pushbutton found in the bottom of the figure 4b.32, Tooling. The user will be prompted for delete confirmation with Delete pop-up. Once the user validates the deletion via the Yes pushbutton, the record is permanently removed from the system. 4B-74

75 Tooling Detail The Tooling Detail form is used to maintain the machining category, the tool type, and cycle time calculations. The first step is to identify the Machining Category the tool will be operating within. The system will then only display in the Tool Type list, the tools available for the selected Machining Category. Figure 4b.35 Tooling Detail 4B-75

76 Orders Shop Order Maintenance Operations Tab Operation Worksheet Tooling Tooling Detail TOOLING DEFINITION Tool Line N/A DISPLAY As tools are added to each operation line, the system assigns a Tool Number in numerical sequence. Note that components of an operation that are really not associated with a specific tool (such as indexing) are also assigned a tool number. Machining Category NO DROPDOWN Select the type of machining operation from the drop down list. These predefined categories are used to identify the process the tool will perform (e.g., DRILL for Drilling, MILL for Milling, etc.). The machining categories are maintained in the table: TABLES TOOL & DIES MACHINING CATEGORY Tool Number NO DROPDOWN Select the general category of tooling from the drop down list. This list is auto populated according to the machining category selected. Tools can be added or edited in the table: TABLES TOOL & DIES TOOL & DIES Tool Material NO DROPDOWN Select the material that the tool is made of from the drop down list. The system will automatically display the Tool Material defined in the Tool Type Table. Tool Materials can be added or edited from Tables menu: TABLES TOOL & DIES TOOL MATERIAL TYPE Notes NO ALPAHNUMERIC Additional notes can be added for each individual tool. This is a handy way to store any helpful information relating to the Tool. RAW MATERIAL Material Type NO DROPDOWN Select raw material grade or alloy from drop down. New Material Types can be added under the Tables drop down menu Define New Tool N/A PUSHBUTTON This pushbutton retrieves the Tools form. It is subdivided by four tabulations and is further described in the following Define New Tool subsection. 4B-76

77 Orders Shop Order Maintenance Operations Tab Operation Worksheet Tooling Tooling Detail Calculate S & F N/A PUSHBUTTON Speeds and Feeds Calculator. Activate the pushbutton to recalculate all data entered in the Speeds and Feeds box as well as the Cycle Time box displayed in the lower part of the screen. MACHINE RATES Maximum Speed (RPM) NO NUMBER The system automatically displays the maximum Speed (Revolutions Per Minute) based on the Workcenter selected in the Operations screen. The system will not allow the calculated Speed (RPM) to exceed this number. Maximum Feed (IPM) NO NUMBER The system automatically displays the maximum Feed (Inches Per Minute) based on the Workcenter selected in the Operations screen. The system will not allow the calculated Feed (IPM) to exceed this number TOOL SPECIFICATIONS Cutting Speed (SFM) NO NUMBER The system automatically calculates and displays the SFM (Surface Feet per Minute) by multiplying the stock Material Type's base SFM Value by the Tool's Material Type SFM Conversion factor. This field maybe over-ridden if necessary. IPR / IPT N/A RADIO BUTTONS The system automatically displays the specified tool's Cutting Feed, Inches per Tooth (IPT) or Inches per Revolution (IPR). the values are maintained in the table: TABLES TOOL & DIES TOOL & DIES: MACHINABILITY CONSTANT TAB Cutting Feed NO NUMBER The specified tool's Cutting Feed displayed is dependent on the radio button (IPR or IPR)] selected. Workpiece Diameter. (In) NO NUMBER If a diameter is entered, the system automatically displays the specified Tool's Diameter in Inches that is predefined in the Tools Table. If a Tool Diameter is not entered, the Work Diameter will be displayed and the user will be prompted for the diameter of the workpiece. Number of Flutes NO NUMBER Automatically displays the specified tool's Number of Flutes predefined in the Tools Table B-77

78 Orders Shop Order Maintenance Operations Tab Operation Worksheet Tooling Tooling Detail SPEED & FEED CALCULATIONS Speed (RPM) NO NUMBER The system will automatically calculate and display the Theoretical Speed (Revolutions Per Minute) by multiplying the specified tool's SFM factor by the CONSTANT, 3.82 for inches, and then dividing by the Tool Diameter. The system will not allow the calculated Speed (RPM) to exceed the specified machine/operation's Maximum established in the Machine/Operation Types Table. Adjustment Percent NO PERCENTAGE The system automatically displays 100% for the maximum or base theoretical Feed to be calculated, but can be overridden at any time. This Adjusted Percentage is multiplied by the Calculated Speed (RPM) and is displayed in the Adjusted Speed (RPM) field. Adjusted Speed (RPM) NO NUMBER A system calculated field: (Speed (RPM)) x (Adjustment Percent) Feed (IPM) NO NUMBER The system will automatically calculate and display the Theoretical Feed (Inches Per Minute) by multiplying the Calculated Speed (RPM) by the specified tool's Cutting Feed (IPT) and Number of Flutes. The system will not allow the calculated Feed (IPM) to exceed the specified machine/operation's Maximum Feed given in the Workcenters Table. Adjustment Percent NO PERCENTAGE The system automatically displays 100% for the maximum or base theoretical Feed to be calculated, but can be overridden at any time. This Adjusted Percentage is multiplied by the Calculated Feed (IPM) and displayed in the Adjusted Feed (IPM) field. Adjusted Feed (IPM) NO NUMBER A system calculated field: (Feed (IPM)) x (Adjustment Percent) B-78

79 Orders Shop Order Maintenance Operations Tab Operation Worksheet Tooling Tooling Detail CYCLE TIME Length of Cut (In) NO NUMBER The total length (inches) of all cuts, depths and etc. A calculator is available by selecting the F10-Calculator function key for calculating the total length. The Length of Cut will automatically be multiplied by the Number of Passes and then will be divided by the Adjusted Feed (IPM). It is further displayed in the Cycle Time (Minute) field and Adjusted Cycle Time (Minute) field. Number of Passes NO NUMBER The total number of passes for each Length of Cut. The Length of Cut will automatically be multiplied by the Number of Passes and then will be divided by the Adjusted Feed (IPM). It is further displayed in the Cycle Time (Minute) field and Adjusted Cycle Time (Minute) field. Cycle Time (Min) NO NUMBER The system will automatically calculate and display the Cycle Time or Pieces per Minute by dividing the sum of the Length of Cut (In) times the Number of Passes by the Adjusted Feed (IPM). The Cycle Time (Minute) will automatically be displayed in the Adjusted Cycle Time (Minute) field for adjustment if needed. Adjusted Cycle Time (Min) NO NUMBER The system will automatically display the Cycle Time (Min.) but can be over-ridden so that the Cycle Time can take into consideration rapid time, etc. This Adjusted Cycle Time (Min.) will be automatically displayed in the Tooling screen when clicking the Save button Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. 4B-79

80 Tooling Detail Formulas RPM Speed Formula The Theoretical Speed (Revolutions Per Minute) is automatically calculated by multiplying the specified tool s SFM factor by the CONSTANT 3.82 for inches, and then dividing by the Tool Diameter. Speed Formula: RPM = 3.82 * SFM Working Tool Diameter IPM Feed Formula The Theoretical Feed (Inches Per Minute) is automatically calculated by multiplying the Calculated Speed (RPM) by the specified tool s Cutting Feed (IPT) and the Number of Flutes. Feed Formula: IPM = RPM * IPT (# of Flutes) Cycle Time Formula The cycle time is automatically calculated by dividing the sum of the Length of Cut (In) times the Number of Passes by the Adjusted Feed (IPM). Cycle Time Formula: (Length of Cut)*(Number of Passes) Adjusted Feed (IPM) Note: The factor 3.82 is a CONSTANT used to convert SFM to inches, since the diameters are given in inches. 4B-80

81 Operation Worksheet Operation Type: Subcontract As mentioned previously, the Operation Worksheet is used to maintain both in house operations as well as subcontracted work. The Operation Worksheet is split into two specific divisions; Section 1 remains stagnant for both the In-house and Subcontracted displays and Section 2 adjusts per radio button selection. The definition of fields and parameters for section one can be viewed in the chapter section Operation Worksheet Operation Type: In-House. Section two is subcontract specific and is outlined in the table below. Sect. 1 Sect. 2 Figure 4b.36 Operations Worksheet Subcontract 4B-81

82 Orders Shop Order Maintenance Operations Tab Operation Worksheet Subcontract (Section 2) Recalculate Lot Prices NO CHECKBOX Activate the Recalculate check box to recalculate the Cost for each Quantity to Quote. You might activate this checkbox because you originally overwrote many of the Quantity to Quote field costs and want to recalculate all fields with the new costs. Min. Qty NO NUMBER Enter in the minimum quantity for the subcontracted order. Distribution Code YES DROPDOWN Select the distribution code for this subcontracted operation from the dropdown list. Distribution codes can be added or modified under the Tables menu Distribution Codes are maintained in the table: TABLS DISTRIBUTION CODES. Unit Type YES DROPDOWN Select the unit to quote from the dropdown menu. Supplier Code NO ALPAHNUMERIC Enter the vendor s code (if known) or retrieve the information using the associated search button. Queue Days NO NUMBER Enter the lead-time required for this subcontracted operation. Include ALL days required as system works off an actual calendar. Days should include weekends; holidays and even shipping times, as they will all affect the ultimate delivery date. Extend Charges N/A PUSHBUTTON Extend the minimum charge, Unit Cost and Markup % fields to all columns. Run Quantities Row N/A DISPLAY Auto populated by quantities originally entered in the Quantities to Run fields under the Qty/Part Spec Tab Minimum Charge Row NO NUMBER Enter the minimum that the vendor charges for this subcontracted operation (if there is a minimum charge). Unit Cost Row NO NUMBER Enter the subcontracted cost per unit quoted by this vendor, associated with the quantity of this column. This figure will be multiplied by the following X Quantity field. Pounds from Matl. Req. N/A PUSHBUTTON When activated, the system automatically enters all quantity fields with the total pounds entered in the Material Requirements tab. 4B-82

83 Orders Shop Order Maintenance Operations Tab Operation Worksheet Subcontract (Section 2) Row N/A ROW PUSHBUTTON Row Enter the piece quantity that will be multiplied by the Unit Cost field. This quantity may or may not be the same as listed in the Run Qtys column heading. There may be reasons that the quantities in these two fields are different (for instance, you might want to enter a lot price instead of a unit cost). This allows for more flexibility in your estimate. Pushbutton When activated, the system automatically enters all quantity fields with the Run Quantities defined in the Quantities tab. Total Cost N/A DISPLAY This system-calculated field totals all costs for each quantity column. If the extended unit cost is below the vendor s minimum charge, the minimum charge will appear in this field. x Markup % NO PERCENTAGE Enter the percentage to mark up the Total Cost field (use this only if you want to markup this subcontracted cost). One time lot Charge N/A PUSHBUTTON Pushbutton automatically retrieves the Additional Subcontracting Lot Charges subsystem. This subsystem is used to add any additional one time charges associated with the subcontracting estimate. Additional information regarding the subsystem is given below. Lot Price Row NO NUMBER This system-calculated field takes the = Total Cost field and multiplies it by the x Mark Up % field to give the marked up price. If no markup is entered in the x Mark Up % field, the Lot Price displayed will be the same number as the = Total Cost since there is no mark up. 4B-83

84 Additional Subcontracting Lot Charges The additional subcontracting lot charge pushbutton is used to itemize any additional internal or vendor related charges. Figure 4b.37 Additional Subcontracting Lot Charges To add a new subcontracting lot charge, Activate the ADD pushbutton on the retrieved form. Once activated, the identifying fields located on the bottom of the form are made available. Select either a Vendor or Internal radio button. This identifies the type of charge added. Add a description of the charge Add a amount to the charge SAVE any changes made to the screen. Use the corresponding UPDATE and DELETE pushbuttons on a highlighted item to either update or delete existing entries. 4B-84

85 Operation Worksheet Operation Type: Comment The Comment Operation type is used to create an operation that is not billable but that may still appear on the routing report. For example, a routine inspection could be identified using this form. Figure 4b.38 Operation Worksheet Comment In the figure below, the fourth operation was added using the Comment Operation Type from the Operation Worksheet. Figure 4b.39 Operations Tab section 1 displaying non-billable operation number 4 4B-85

86 Shop Order Maintenance P.O. Review The PO Review Tab is an optional screen that is useful when ensuring all required documents are in place and the order is ready to be released to the shop floor. Numerous items can be documented within the form such as blueprints, materials, routings, tooling and etc. This form provides an audit trail ensuring the requirements are properly met. Figure 4b.40 Purchase Order Review 4B-86

87 Orders Shop Order and Release Maintenance P.O. Review Military Commercial Precision NO RADIOBUTTON Select the type of customer from the three available. Buyer NO TEXT Enter in the name of the buyer. DPAS Rating NO TEXT Enter in the DPAS rating if applicable. Special P.O. Statement Notes Customer Source Inspection N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter any special P.O. statement notes. NO CHECKBOX Activate pushbutton if a customer source inspection is required. Nondestructive Testing NO CHECKBOX Activate pushbutton of any nondestructive testing is required. Nondestructive Testing Notes Special Pack/Ship Requirement Notes Material Spec. Notes Special Marketing Notes Outside Process Spec. Notes Certification Requirements Notes N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter in any nondestructive testing notes. N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter in any special packaging shipping requirements. N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter in any material specification notes. N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter in any special marketing notes. N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter in any outside process specification notes. N/A PUSHBUTTON Activate pushbutton to retrieve a free form text box used to enter in any certification requirements. Date P.O. Received NO DATE Enter date the purchase order is received. Hardcopy Other NO RADIOBUTTON Select the type of purchase order received from the two available options. Date Programs Available NO DATE Enter in the date programs are made available if applicable. 4B-87

88 Orders Shop Order and Release Maintenance P.O. Review Date Released to Production NO DATE Enter in the date the order is released to production. Sketches Available/Current NO CHECKBOX Activate checkbox if sketches are made available. Correct Revision Blueprint NO CHECKBOX Activate checkbox if the correct revision of the blueprint is provided. If No, Date Requested NO DATE Enter in the date a correct revision of the blueprint is requested. Material On-Hand NO CHECKBOX Activate checkbox if the necessary material is on-hand. If Not, Date Ordered NO DATE Enter in the date the material is ordered. Routing Book Completed NO CHECKBOX Activate checkbox if the routing book is completed. Date Due in-house NO DATE Enter in the date the routing book is due in-house. Date Tooling Ordered NO DATE Enter in the date the tooling is ordered if applicable. Due NO DATE Enter in the tooling due date. Date Gages Ordered NO DATE Enter in the date the gages are ordered. Due NO DATE Enter in the gage due date. P.O. Review Report N/A PUSHBUTTON Activate pushbutton to print a P.O. Review Report. Inventory requirements may also be included into the report. The report can be viewed or sent to the printer. Reviewed By NO TEXT Enter in the name of the employee that reviewed the document. Date Reviewed NO DATE Enter in the review date. 4B-88

89 Shop Order Maintenance Order Cost Tab The Order Cost tab provides the user a summary of all of the shop order costs accumulated thus far in addition to any additional itemized costs. Additional information regarding the fields and functions are provided in the corresponding table below. Figure 4b.41 Shop Order Maintenance Order Cost Tab Note: A double click on a highlighted shop order entry retrieves the Shop Order Job Costs Audit form. The audit form displays a summary of the Job Cards used to complete the shop order as well an individual cost breakdown of each completed card. 4B-89

90 Orders Shop Order and Release Maintenance P.O. Review Shop Order Number N/A DISPLAY Displays the shop order number. Status N/A DISPLAY Displays the shop order status. Total Hours N/A DISPLAY Displays the total hours used to complete the entire part. Shop Order Cost Summary Labor N/A DISPLAY Displays the shop order s total labor cost. Burden N/A DISPLAY Displays the shop order s total burden cost. Material N/A DISPLAY Displays the shop order s total material cost. Other N/A DISPLAY Displays any other shop order costs. Total N/A DISPLAY Displays the total cost of the shop order. Per Piece N/A DISPLAY Displays the shop order s total cost per piece. --- Include Subs N/A CHECKBOX Activate checkbox to include any suborders that are associated to the shop order. Suborders are normally created via the Suborders pushbutton located in the Shop Order Maintenance lower tool bar. Cost Detail N/A DISPLAY Displays a list of individual one time charges defined for the shop order. P.O. Number N/A DISPLAY Displays the P.O. numbers associated with the defined costs. Supplier N/A `DISPLAY Displays the supplier name. Description N/A DISPLAY Displays a description of the defined cost. Quantity N/A DISPLAY Displays the quantity of the associated cost if applicable. Pounds N/A DISPLAY Displays the total pounds of the associated cost if applicable. 4B-90

91 Orders Shop Order and Release Maintenance P.O. Review UOM N/A DISPLAY Displays the unit of measure. Unit Cost N/A DISPLAY Displays the unit cost. Extended Cost N/A DISPLAY Displays the calculated extended cost. Add N/A PUSHBUTTON Activate pushbutton to add an additional cost. The Cost Detail form is retrieved in Add mode for cost entry. Update N/A PUSHBUTTON Activate pushbutton to edit the highlighted cost. The Cost Detail form is retrieved in Update mode for further entry. Delete N/A PUSHBUTTON Activate pushbutton to remove the highlighted cost from the list. After the delete validation is confirmed, the record is permanently removed from the system. Shop Order Costs Detail Report N/A PUSHBUTTON Activate pushbutton to print the Shop Order Cost Details Report. Each outlined cost is included in the report Details N/A PUSHBUTTON Activate pushbutton to maintain any shop order details. The Shop Order Detail form is retrieved for maintenance. Any details can be added, updated or deleted within the form. Profit/Loss N/A PUSHBUTTON Activate pushbutton to retrieve the Shop Order Profit/Loss Summary form. An example of the form is provided in the section following this table. Entry Date Range NO DATE Enter a date range to show only costs with entry dates that fall within this range. Leaving the date range empty will return all order costs. Scrap Reimbursement NO NUMBER Enter the actual scrap reimbursement value. Calculator N/A PUSHBUTTON Activate pushbutton to retrieve the Scrap Reimbursement Calculator used to aid in reimbursement calculation. Miscellaneous Cost NO NUMBER Enter the actual miscellaneous cost value. Sales Person NO DROPDOWN Define the Sales Person who has received the commission check for this Shop Order. Commission NO NUMBER Define the Sales Person who has received the commission check for this Shop Order. Note: Keep in mind that the value will NOT auto-populate 4B-91

92 Orders Shop Order and Release Maintenance P.O. Review from Quotation Maintenance. This is NOT a cost until it is paid to your Sales Person. Estimated Material Cost/Unit Define the estimated raw material cost per unit. This value is auto-populated from the Quotation. Note: This value is used in determining the estimated raw material cost in the Shop Order Recap Report Shop Order Recap Report Work in Process Report N/A PUSHBUTTON Activate pushbutton to print the Shop Order Recap Report. The report individualizes each operation and the associated hours and costs. N/A PUSHBUTTON Activate pushbutton to print the Work in Process report. The user may configure the report to four specific types: report with totals only, summary report, detailed report, and a valuation report. The report maybe printed for either sales or shop orders or maybe printed for all orders that fall within a specified date range. Time and Materials Report Shop Order Component Costs Report Shop Order Costs Audit Report N/A PUSHBUTTON Activate pushbutton to print the Time and Materials report. The user has the option to calculate the price using either the Sell Rate or the Charge Back rate. The report maybe detailed by workcenter or department. N/A PUSHBUTTON Activate pushbutton to print a Shop Order Component Costs report. The report can be printed for a specific shop order or for a group of shop orders completed within a defined date range. N/A PUSHBUTTON Activate pushbutton to print a Shop Order Costs Audit report. The report can be filtered for a specific shop order or for a group of shop orders completed within a defined date range. The associated job cards are itemized for the shop ordered and include all quantities and costs. 4B-92

93 PRODUCTION ADJUSTMENTS WORKSHEET The Production Adjustment Worksheet is a valuable tool used for production planning. The worksheet displayed below (figure 4b.42) retrieves open sales orders items and their quantities providing the planner an insight to the items needing production and their ordered, available and pending quantities for a given time period and across all open customer orders. The worksheet is driven by sales order releases. Quantities can be adjusted manually or the user can select the automatic system suggested amount that is calculated relative to the customer demand. can also be created or adjusted to the new specified quantity. Only shop orders without any activity such as job cards or reserved raw materials can be automatically adjusted. Figure 4b.42 Production Adjustments Worksheet Menu Selection Left click on the fourth menu heading labeled Orders Select Production Adjustments Worksheet from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-93

94 Production Adjustments Worksheet Overview The Production Adjustments Worksheet is broken down into three distinct sections. Section one is used to filter sales order release records. In the example below, a production analysis was performed for one particular inventory number, VISEROD4, and therefore retrieved only one record in section 2. Section two displays the retrieved records and section three provides additional functions available to the form. The user should use the worksheet screen to determine the appropriate increases or decreases of parts to run on the shop floor. Each finished good inventory number that currently has open Sales Order releases (i.e., customer demand) will be displayed in this screen for analysis. This form also provides the user the ability to drill down to examine the details behind each calculated number. The label of each calculated field is actually a button that can be clicked allowing the User to examine the detail that makes up the displayed number Information outlining all the fields and functions available within the worksheet are provided in the corresponding table below. Section 1 Section 2 Section 3 Figure 4b.43 An Analysis of the Production Adjustments for Inventory Number VISEROD4 4B-94

95 Orders Production Adjustments Worksheet Section 1 Period Ending NO DROPDOWN Select the period to review from the dropdown list. The period ending date is used to calculate the total number of finished good parts that need to be shipped during the specified period. Therefore, only sales releases that fall within the specified period are retrieved. Note: The interactive calendar is available for specific date selection. Division (Cell) NO DROPDOWN Records maybe reviewed for a particular sales division. Sales divisions are available via the dropdown list. All NO CHECKBOX Activate checkbox to include all workcenters in division even if there is no activity. Workcenter NO DROPDOWN Records maybe reviewed for a particular workcenter. Select the desired workcenter from the dropdown list. Part Number NO ALPHANUMERIC A production analysis maybe performed for a particular part number. Enter in the part number to review. Inventory Number NO ALPHANUMERIC A production analysis maybe performed for a particular inventory number. The inventory number maybe directly entered into the field or maybe selected using the attached search key. Customer NO ALPHANUMERIC A production analysis maybe performed for a particular customer. The customer maybe directly entered into the field or can be selected using the attached search key. Firm Only NO CHECKBOX Activate checkbox to review sales order releases tagged as Firm only. Calculate Adjustments N/A PUSHBUTTON Activate pushbutton to calculate adjustments using the defined parameters. The results are listed in section 2 of figure 4b.43. Sort Results By NO DROPDOWN The retrieved results can be sorted using the available dropdown criteria. The default is set to sort the results by division and workcenter. 4B-95

96 Orders Production Adjustments Worksheet Quantities Color Key N/A DISPLAY Section 2 The quantities are identified using the following color codes: Quantity on Hand Quantity WIP Quantity Available Quantity Pending Recommended Adjustment Quantity Quantity Adjusted Part Number N/A PUSHBUTTON Activate pushbutton to Work in Process Pipeline Analysis form for the given part number. The Work in Process Pipeline Analysis form displays all defined releases for the given part number and quantities. Additional information regarding the form is provided further in the chapter below. Revision N/A DISPLAY Displays the part revision. Parent Number N/A LINK Click on the link to retrieve the Order Production Monitoring form for the given part number. A list of all open shop orders is retrieved for the item. Parent Number N/A PUSHBUTTON Activate pushbutton to retrieve the Inventory Maintenance subsystem for the particular inventory number. Description N/A DISPLAY Displays the part description. Reorder quantity N/A DISPLAY Displays the reorder quantity defined in the General tab of the Inventory Maintenance subsystem. First Due NO DATE Displays the first sales order release date for the defined for the item. Workcenter N/A PUSHBUTTON Displays the first defined workcenter for the defined item. The Schedule Workcenter form is retrieved for the defined workcenter when the pushbutton is activated. 4B-96

97 Orders Production Adjustments Worksheet Total Quantity Ordered N/A DISPLAY Displays the entire total quantity ordered. This value is the entire quantity calculated outside of any date range. Period Ordered N/A DISPLAY Displays the quantity ordered within the defined cutoff period. Quantity on Hand N/A PUSHBUTTON Displays the quantity on hand. Activating the pushbutton provides the user access to the Inventory Maintenance subsystem for the particular item. Quantity WIP N/A PUSHBUTTON Displays the WIP quantity. Activating the associated pushbutton retrieves the Order Production Monitoring form for the F/G inventory number. Quantity Available N/A DISPLAY This number represents the parts that either have been completed and thus are ready to ship (i.e., finished goods) or that is in process (WIP) that can be immediately applied to covering the target release quantity (Period Ordered). Quantity Pending N/A DISPLAY This number represents the total open shop order parts that have NOT yet started (i.e., have not moved pass the first operation). Recommended Adjustment Quantity N/A PUSHBUTTON The final calculation starts by subtracting both the quantity available and the quantity pending from the period ordered quantity so we can arrive at a recommended adjustment quantity (RED). The recommended adjustment quantity represents the quantity that should be increased or decreased on the shop floor to meet the target release quantity (Period Quantity). Quantity Adjustment NO NUMBER The final adjustment number can be entered into the quantity adjustment field (yellow). This number can be either manually entered or can be defaulted by clicking on the button found at the top of the recommended adjustment field (i.e., apply increase or apply decrease). 4B-97

98 Orders Production Adjustments Worksheet Section 3 Create/Update Shop Orders N/A PUSHBUTTON The system is also designed to automatically create and adjust existing shop orders applying the specified increases and decreases in production levels. Activate pushbutton to initiate the Shop Order creation/update process. Note: This routine will automatically adjust production by creating new or by adjusting existing Shop Orders. Only that have no activity, such as Job Cards or reserved raw materials can be automatically adjusted. Use Ship by Date NO CHECKBOX Activate checkbox to calculate the due date based on the Ship by Date rather than the Due Date. Include Alloc/Reorder NO CHECKBOX Activate checkbox to add allocations and safety stock requirements to period ordered sales order quantity. Show Needed Only N/A PUSHBUTTON Click to show only the items that require adjustment. Use this option to filter out items that do not need to be adjusted. Auto Apply N/A PUSHBUTTON Activate pushbutton to automatically apply all recommended adjustments. Exit N/A PUSHBUTTON Activate pushbutton to exit back to the main Visual EstiTrack menu system. Adjust by Reorder Quantity Calculate WIP from Inventory NO CHECKBOX Activate pushbutton to make the adjustments based on the increments of the reorder quantity. NO CHECKBOX Activate checkbox based on the on-hand quantity at a WIP location. Shop Floor N/A PUSHBUTTON Activate checkbox to retrieve the Visual Shop Management subsystem for the period date and division. Production Adjustments Worksheet Report N/A PUSHBUTTON Activate pushbutton to print a Production Adjustments Worksheet report. The report is primarily a printout of the data retrieved in the form. 4B-98

99 Work In Process Pipeline Analysis The Work in Process Pipeline Analysis is accessed via the Part Number pushbutton located in the Production Adjustments Worksheet. The Work in Process Pipeline form shown in figure 4b.44 below is broken down into three distinct divisions. Section one displays a list of all sales order releases for the particular F/G Inventory Number therefore calculating the item s total delivery requirements and the total balance not covered. Section two displays a list of the item s open shop orders fulfilling the demands and section three displays the corresponding shop order s individual operations and quantities including any work in process quantities. Section 1 Section 2 Section 3 Figure 4b.44 Work in Process Pipeline Analysis 4B-99

100 INVENTORY BASED SHOP ORDER GENERATOR The Inventory Based Shop Order Generator is a tool used to conveniently generate shop orders based on inventory quantity levels and needed quantities for all manufactured products. The system looks across at all manufactured items and retrieves a list of items that do not have enough quantity on hand to fulfill their needed quantity. This feature allows the user to review the items in one central location, provides the user a suggested line item order quantity and allows the user to manually override the system preferences if necessary. Once the list is edited as needed, with a click of a button, the user can generate a shop orders for all of the remaining items displayed on the list. Section 1 Section 2 Figure 4b.45 Inventory Based Shop Order Generator Menu Selection Left click on the fourth menu heading labeled Orders Select Inventory Based Shop Order Generator from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-100

101 Inventory Based Shop Order Generator Overview The Inventory Based Shop Order Generator form reviews all make items and their corresponding quantities. Items that do not have enough Quantity on-hand to fulfill their minimum quantity levels or any open allocations are added to the list as items needing manufacturing. The system also applies the minimum lot size and offers the user a suggested line item order quantity for each item included on the list. The form is broken down into two divisions. The top division (section 1 of figure 4b.54) displays the retrieved make items list. The bottom division (section 2 of figure 4b.45) provides the user the means to filter the retrieved list as well as configure the shop orders according to the specifications defined. The specifications defined are applied to shop orders created for the entire list. Individual specifications can be made by double-clicking on a highlighted record. Additional information regarding the fields and parameters included are provided in the corresponding table below. Note: Only Inventory Numbers that have valid Quote Numbers or Engineering Master records associated with them can be created as shop orders. Orders Inventory Based Shop Order Generator Section 2 Division NO DROPDOWN The inventory based shop orders can be retrieved per defined company division. If the field is left blank, a list of all inventory based shop orders across all divisions is retrieved. Planner NO ALPHANUMERIC Inventory items can be associated to a defined Planner Code. The planner code typically maybe associated to a person that is responsible for a series of parts. By tagging the inventory items with a Planner Code, the items maybe filtered out by the defined code. Default Shop Order Due Date NO DATE Enter in the default shop order due date. This current date is automatically defaulted to the field. All shop orders generated will be assigned with the defined due date. Use Ship By Date NO CHECKBOX Activate checkbox to calculate the due date based on the 4B-101

102 Orders Inventory Based Shop Order Generator ship by date rather than the due date. Calculate WIP from Inventory NO CHECKBOX Activate checkbox to calculate WIP based on on-hand quantity at WIP location. Order Monitor N/A PUSHBUTTON Activate pushbutton to retrieve the Order Production Monitoring subsystem. Additional information regarding the subsystem is provided further in the chapter below. Analyze Inventory Make Items Palm Operating System Interface N/A PUSHBUTTON Activate pushbutton to begin the system review of the inventory make items. The system lists all records that meet the quantity criteria in the display box above. N/A PUSHBUTTON Activate pushbutton to initiate communication between the Palm based operating system and the Visual EstiTrack TM system. Add N/A PUSHBUTTON Activate pushbutton to add a new record to the automatic shop order list. The Automatic Shop Order Detail pop-up is retrieved in add mode for entry. A shop order is created for the added item only if there is demand (quantity needed) for the item. Update N/A PUSHBUTTON Activate pushbutton to update an existing automatic inventory shop order record. The Automatic Shop Order Detail pop-up is retrieved in update mode for the highlighted record. Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted record. The record is removed from the list after a delete validation is confirmed. Delete All N/A PUSHBUTTON Activate checkbox to remove all records from the list. Inventory N/A PUSHBUTTON Activate pushbutton to retrieve the Inventory Maintenance subsystem for the highlighted record. Generate N/A PUSHBUTTON Activate pushbutton to initiate the automatic shop order creation routine. A shop order is created for every record included in the list that has an associated quote number or engineering master. 4B-102

103 Orders Inventory Based Shop Order Generator Shop Order Listing Report N/A PUSHBUTTON Activate pushbutton to print the Shop Order Listing Report. A list including the shop order number, inventory number and due date is available after the Generate Shop Order routine is complete. Exit N/A PUSHBUTTON Exits form back to the main Visual EstiTrack menu system. 4B-103

104 Automatic Shop Order Detail The Automatic Shop Order Detail pop-up is retrieved when a record listed in the Inventory Based Shop Order Generator is either added to the list or when an existing record is selected for update via the UPDATE pushbutton. Information such as Due Date and Order Quantity can be manually updated within the form. The information saved to the record is used during automatic shop order generation. Figure 4b.46 Automatic Shop Order Detail 4B-104

105 SHOP ORDER PRODUCTION MONITORING The Order Production Monitoring screen is designed to allow the user to review the status of open shop orders. The monitor is broken down into six tabulations. Each tab provides specific information regarding the shop order production. As the user tabs through the provided Order Production Monitoring tabs, information is retrieved on the selected tab for the highlighted shop order selected in the General Tab. The following tabs and corresponding information is provided: General Tab Operations Tab Due Dates Tab Purchases Tab Job Cards Tab Shipments Tab The General Tab is used to filter the monitor list of corresponding shop orders. A general overview of the listed shop orders is provided including the inventory number, order dates, due date as well as the calculated number of days late. The Operations Tab lists the defined operations for the selected shop order. Quantities, calculated efficiencies and both estimated and actual hours are all included in the tab. The Due Dates tab lists both Shop Order releases and Sales Order releases defined for the selected part. The Purchases Tab lists any associated purchase orders for the selected Shop Order record. The Job Cards tab lists all job cards created fro the selected Shop Order. All relevant job card information such as the associated operation, workcenter, hours, quantities and net production is provided within the form. The Shipments tab lists all corresponding shipments associated with the selected shop order. Ship code, date, part number, and quantity shipped are all included in the display. 4B-105

106 Figure 4b.47 Order Production Monitoring Menu Selection Left click on the fourth menu heading labeled Orders Select Shop Order Production Monitoring from the drop down list. Shortcut: toolbar. Quickly enter this module by left clicking on the displayed Production Monitoring icon on the Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-106

107 General Tab The General Tab is divided into two distinct sections: Section 1 of figure 4b.48 is used as search criteria used to filter the results according to the user defined specifications and section 2 displays the results list. Information listed in section 2 includes the shop order, due date, and number of days late are provided along with all relevant quantities. The information provided in the additional Shop Order Production Monitoring tabs all reference the highlighted shop order selected in section 2 of the figure below. Additional information regarding the fields and parameters are provided in the corresponding table below. Section 1 Section 2 Figure 4b.48 Order Production Monitoring General Tab 4B-107

108 Orders Shop Order Production Monitoring General Tab Section 1 Search Criteria The search criteria entered in below is used as a filter for the results retrieved in section 2. Shop Order NO ALPHANUMERIC Enter in a specific shop order number to retrieve into the list. Include Suborders NO CHECKBOX Activate checkbox to include all associated suborders into the list. Late Only NO CHECKBOX Activate checkbox to list late shop orders only. Customer NO ALPHANUMERIC Enter in the customer code to retrieve a list of shop orders created for the defined entry. Part Number NO ALPHANUMERIC Enter in a Part Number to retrieve a list of shop orders manufacturing the defined number. Division NO DROPDOWN Enter in a Division to retrieve a list of identified to the defined Division. Status NO DROPDOWN Select a status from the dropdown list to retrieve a list of that meet the defined criteria. Exclude Closed NO CHECKBOX Activate checkbox to exclude all closed orders from the retrieved list. F/G Inventory Number NO ALPHANUMERIC Enter in a Part Number to retrieve a list of manufacturing the defined F/G Inventory Number. Show Ready to Close Shop Orders NO CHECKBOX Activate checkbox to retrieve a list of that are ready to close only. Track Number NO ALPHANUMERIC Enter in a track number to retrieve a list of identified with the defined track number. P.O. Number NO ALPHANUMERIC Enter in a P.O. number to retrieve a list of associated to the defined P.O. number. Sales Order Number NO ALPHANUMERIC Enter in a Sales Order Number to retrieve a list of shop orders associated to the defined Sales Order number. 4B-108

109 Operations Tab The Operations Tab lists the defined operations for the highlighted shop order record selected in the General Tab of the Shop Order Production Monitoring subsystem. Quantities, calculated efficiencies and both estimated and actual hours are all included in the tab. Figure 4b.49 Shop Order Production Monitoring Operations Tab Orders Shop Order Production Monitoring Operations Tab Exclude Comment Operations NO CHECKBOX Activate checkbox to exclude component operations from the list. Operation Detail N/A PUSHBUTTON Activate pushbutton to retrieve the Operation Detail form for the highlighted operation. Workcenter Schedule N/A PUSHBUTTON Activate pushbutton to retrieve the Schedule Workcenter subsystem for the highlighted operation workcenter. Additional information regarding the retrieved subsystem is provided in the Scheduling chapter. Exit N/A PUSHBUTTON Exits the Shop Order Production Monitoring subsystem back to the main Visual EstiTrack menu system. 4B-109

110 Operation Detail The Operation Detail window displayed below can be accessed with a double-click of the mouse on an operation from the Operations Tab. The form can also be activated by highlighting the selected operation record and subsequently activating the OPERATION DETAIL pushbutton located at the bottom of the Operations Tab (figure 4b.49). Figure 4b.50 Operation Detail 4B-110

111 Due Dates Tab The Due Dates tab is divided into two sections. The top half (section 2 of figure 4b.51) displays a list of shop order releases defined for the selected shop order. The bottom half of the form displays a list of the corresponding sales order releases defined for the selected shop order number. A scheduling Gantt chart is also available for the shop order release via the GANTT CHART pushbutton located on the bottom of the form. Section 1 Section 2 Figure 4b.51 Shop Order Production Monitoring Due Dates Tab 4B-111

112 Purchases Tab The Purchases Tab lists any associated purchase orders for the selected Shop Order record. The Purchase Order Maintenance subsystem can be directly accessed from the form by activating a double click of the mouse on the selected PO entry. Figure 4b.52 Shop Order Production Monitoring Purchases Tab 4B-112

113 Job Cards Tab The Job Cards tab lists all job cards created fro the selected Shop Order. All relevant job card information such as the associated operation, workcenter, hours, quantities and net production is provided within the form. The Job Card Maintenance subsystem can be accessed for the highlighted entry by either activating the PRODUCTION DETAIL pushbutton or by activating a double click of the mouse on the selected entry. Figure 4b.53 Shop Order Production Monitoring Job Cards Tab 4B-113

114 Shipments Tab The Shipments tab lists all corresponding shipments associated with the selected shop order. Ship code, date, part number, and quantity shipped are all included in the display. The Shipment Maintenance subsystem can be accessed for the highlighted entry by activating a double click of the mouse on the selected entry. Figure 4b.54 Shop Order Production Monitoring Shipments Tab 4B-114

115 SHOP ORDER JOB COSTS AUDIT Enter in Shop Order number into the appropriate field or use the attached search key for selection. The listed job cards can be sorted by either the Transaction Date or the Source and Transaction Date via the available Sort By radio buttons. A double click on the job card record retrieves the Job Card Maintenance form for review or update as needed. Figure 4b.55 Shop Order Job Costs Audit Menu Selection Left click on the fourth menu heading labeled Orders Select Shop Order Job Costs Audit from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-115

116 SHOP ORDER COSTS MONITORING The Shop Order Costs Monitor provides the user a cost overview for the manufacturing of the ordered quantity. The user only needs to input the Shop Order Number and has the option to include Allocated Inventory only via the associated checkbox. Figure 4b.56 Shop Order Costs Monitoring Menu Selection Left click on the fourth menu heading labeled Orders Select Shop Order Costs Monitoring from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-116

117 SPLIT SHOP ORDER This utility is designed to split an existing shop order, including all components and costs into a new shop order number. This utility is useful to a shop floor because it allows the user to split an order even if an open job card is created for the original shop order number. A new Job Card is created for the new shop order number if a job card was previously created in reference to the original shop order number. Figure 4b.57 Split Shop Order Menu Selection Left click on the fourth menu heading labeled Orders Select Split Shop Order from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-117

118 The following field definitions are available for the Split Shop Order Utility. Orders Split Shop Order to Split Shop Order Number YES ALPHANUMERIC Enter in the Shop Order Number to split or use the attach search key for selection. Part Number N/A DISPLAY Once the Shop Order is entered, the part number is displayed within the field. Revision N/A DISPLAY Once the Shop Order number is entered, the part revision is displayed within the field. Quantity Ordered N/A DISPLAY Once the Shop Order number is entered, the quantity order is displayed within the field. Create New Shop Order Shop Order Number YES ALPHANUMERIC Enter in the new Shop Order Number that will be created upon splitting the first Shop Order. Default Next New Number N/A PUSHBUTTON Activate pushbutton to use the next available incremental Shop Order number as the new number. The default Shop Order numbers are defined in the Company Tables. Percentage to Split N/A DISPLAY The system automatically calculates the percentage of the original shop order number to split upon entry of the quantity to split. Quantity to Split YES NUMBER Enter in the quantity of parts to split into the new shop order. Split Shop Order N/A PUSHBUTTON Activate the pushbutton to execute the Split Shop Order routine. Exit N/A PUSHBUTTON Exits the Split Shop Order utility back to the main Visual EstiTrack menu system. 4B-118

119 SHOP ORDER RECAP SUMMARY The Shop Order Recap Summary form provides the user the total number of hours and all associated costs for producing a specified Shop Order. The Selling Price of the manufactured part is calculated. The form also provides the user an opportunity to markup the selling price of the item. Figure 4b.58 Shop Order Recap Summary Menu Selection Left click on the fourth menu heading labeled Orders Select Shop Order Recap Summary from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-119

120 Orders Shop Order Recap Summary Criteria Input Fields Shop Order Number NO ALPHANUMERIC Enter in the Shop Order number to retrieve information for a specific shop order part or use the attached search key for selection. Part Number NO ALPHANUMERIC Enter the Part Number to retrieve a list of all shop order created for the part. This provides the user the opportunity to analyze the hours and costs associated with each shop order. Revision NO ALPHANUMERIC Enter in the Part Revision of necessary. F/G Inventory Number NO ALPHANUMERIC Enter the finished good number to retrieve a list of all shop order created for the F/G Inventory number. This provides the user the opportunity to analyze the hours and costs associated with each shop order. Search N/A PUSHBUTTON Activate pushbutton to retrieve the list based on the criteria entered above. Exit N/A PUSHBUTTON Exits the form back to the main Visual EstiTrack menu system. Print Shop Order Recap Report N/A PUSHBUTTON Activate pushbutton to print the Shop Order Recap Report. Markup Spinner NO SPINNER Activate the up or down arrows to mark up the Order Cost by the percentage shown. The user may choose to enter a markup value within the field in lieu of using the arrows. Adding a Markup will updates the Selling Price. Selling Price NO NUMBER The Selling Price can be manually overridden within the field. Note: No change will be made to the selling price while within Shop Order Maintenance. This screen may also be accessed from Invoice Maintenance Invoice Detail Update Mode. This feature may be used from within that module. 4B-120

121 SHOP ORDER REPORTS Figure 4b.59 Shop Order Reports Menu Selection Left click on the fourth menu heading labeled Orders Select Shop Order Reports from the drop down list. Security The system administrator controls access to this menu item via User access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 4B-121