Engineer To Order (ETO) for Dynamics GP

Transcription

1 Title Page Engineer To Order (ETO) for Dynamics GP Documentation for the Builds shown below and higher: V / /

2 ETO from WilloWare Incorporated for Dynamics GP 2 Copyright Manual copyright 2016 WilloWare Incorporated. All rights reserved. Your right to copy this documentation is limited by copyright law and the terms of the software license agreement. Only the software licensee may use this documentation. Making unauthorized copies, adaptations, compilations, or accessing the web-based version by direct linking, or sharing the web-based version with unlicensed users, or making derivative works for commercial distribution or other use is prohibited, and constitutes a punishable violation of the law. Trademarks Great Plains, Dynamics, and Dynamics GP are either registered trademarks or trademarks of Great Plains Software, Inc. in the United States and/or other countries. Great Plains Software, Inc. is a wholly-owned subsidiary of Microsoft Corporation. The names of actual companies and products mentioned herein may be trademarks or registered marks - in the United States and/or other countries - of their respective owners. The example companies, organizations, products, domain names, addresses, logos, people, places, and events depicted herein are fictitious. No association with any real company, organization, product, domain name, address, logo, person, place, or event is intended or should be inferred. Warranty disclaimer WilloWare Incorporated disclaims any warranty regarding the examples contained in this documentation, including the warranties of merchantability and fitness for a particular purpose. Limitation of liability The content of this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by WilloWare Incorporated. WilloWare Incorporated assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual. Neither WilloWare Incorporated nor anyone else who has been involved in the creation, production or delivery of this documentation shall be liable for any indirect, incidental, special, exemplary or consequential damages, including but not limited to any loss of anticipated profit or benefits, resulting from the use of this documentation or sample code. License agreement Use of this product is covered by a license agreement provided with the software product. If you have any questions, please contact WilloWare at support@willoware.com. Publication date May 2016

3 ETO from WilloWare Incorporated for Dynamics GP 3 Contents Title Page... 1 Contents... 3 Implementation Guide... 4 Quick Start... 5 Installation... 6 Security... 7 Registration... 8 About Box... 9 Setup Manufacturing Estimation Overview Manufacturing Estimate Orientation Creating a New Estimate Estimation Quantities Multi-Currency Deleting an Estimate Copying a BOM Managing Attachments Tree View List View Other Costs Routing Costing BOM-Routing Link Add/Edit Component Sales Link Accepting an Estimate Where Used Inquiry ME Items... 42

4 ETO from WilloWare Incorporated for Dynamics GP 4 Implementation Guide Description of Solution ETO is a manufacturing estimation module for Dynamics GP. Additional Software Requirements The ETO module requires GP Manufacturing. Manufacturing must already be installed prior to installing ETO. ETO also required MFG PowerPack from WilloWare. The Item Copy utility in MFG PowerPack is used by the ETO module to create new items. A special integration license is available at no cost when purchasing ETO which provides access from the ETO module to ItemCopy. MFG PowerPack can be installed before or after ETO, but it must be in place before starting to use ETO. ETO requires SQL 2005 or later. Installation Checklist The first client installation of ETO will have two steps. First, the software is installed into the Dynamics GP programs folder. Launching GP will un-chunk the application dictionary. Second, you will log-in as sa and complete the installation from inside Dynamics GP to create the applications tables. All subsequent client installations will require only installing the software on the client machine and un-chunking the software. See sections: Installation, and Registration sections for detailed instructions on installing ETO.

5 ETO from WilloWare Incorporated for Dynamics GP 5 Quick Start 1. Install the software. See 2. Log-in to GP. Run the Install process inside GP to create tables. See 3. Restart GP 4. Log-in to GP. Enter Registration Key. See the REGISTRATION section in this document. 5. Perform Setup. Some setup is required in GP Inventory, Manufacturing and the ETO module for ETO to function correctly. See the SETUP sections of this document. ETO also requires WilloWare s MFG PowerPack.

6 ETO from WilloWare Incorporated for Dynamics GP 6 Installation Please see detailed installation instructions online at ETO requires GP Manufacturing, and WilloWare s MFG PowerPack. Do not install ETO until both of these other modules are installed. You must have a MFG PowerPack Registration Key for either the Suite License, or the Item Copy API.

7 ETO from WilloWare Incorporated for Dynamics GP 7 Security Version 10+ Security: During installation a default Security Task will be created called ETO. It will have access to all windows in the module. It will also create a default Security Role called ETO and assign the Task to the Role. To ensure that users have access to the windows required by you need to assign the Task to one or more Security Roles, or assign the Role to one or more Users. Assign Task to Roles: Go to Tools >> Setup >> System >> Security Roles. Select a Role, then mark the box next to the ETO Task ID. Assign Role to Users: Go to Tools >> Setup >> System >> User Security. Select a User and Company, then mark the box next to the ETO Role ID>

8 ETO from WilloWare Incorporated for Dynamics GP 8 Registration Navigation: Tools >> Setup >> System >> Registration >> Additional >> Register ETO. When you have registered you will be sent a Registration File. This is not a human readable file. It will be imported into the Registration window. On the Registration window, click the Folder button, then locate the registration file (it will have a.rg file extension). Locate where the file was saved. Select the file, then click OPEN. On the registration window, click VALIDATE. If the keys are accepted as VALID, click SAVE.

9 ETO from WilloWare Incorporated for Dynamics GP 9 About Box Navigation: Help >> About Microsoft Dynamics GP >> Additional >> About ETO The About Box will display the version of the software installed on the client.

10 ETO from WilloWare Incorporated for Dynamics GP 10 Setup ETO integrates tightly with Dynamics GP Inventory and Manufacturing. You will need to set up GP Manufacturing before using ETO. Tools >> Setup >> Manufacturing >> ETO Setup Update Prorate Qty: when an ME is Accepted it can update the Prorate Setup Quantity field in GP Manufacturing. Depending on Manufacturing Costing Setup, this field is either the Average Quantity on the Item Engineering window, or the Standard Quantity on the Standard Cost Changes window. The quantity used for the update is the largest accepted Estimation Quantity (see the Estimation Quantities window). If you always create new Item Numbers as part of the estimation process, mark the Update Prorate Qty option. If you are using ME to create different configurations of existing items, you need to consider the impact of always updating the Prorate Quantity. Both Average Quantity and Standard Quantity are stored in the Item Engineering table in GP Manufacturing (even though the values are entered through different windows). This means there is one setting for this value regardless of the number of Configured BOMs you generate from ME. If each ME has different Estimation Quantities, each time you accept a different ME the Prorate Qty would change to a different value, which will affect how GP Manufacturing performs its cost rollup. In this situation it may be preferable to decide what a real average quantity will be for the item, set it manually, and do NOT update it from ME.

11 ETO from WilloWare Incorporated for Dynamics GP 11 Manufacturing Estimation Overview The purpose of the ETO module is to produce a Manufacturing Estimation, which is the estimated cost to produce an item. It is significantly easier to produce an estimate using ETO than it is using the Manufacturing Bill of Materials (BOM) and Routing because ETO does not require all of the setup needed by Manufacturing. Also, it prevents cluttering the live database with items, BOMs and Routings that will never be used if the estimate is not accepted. The flowchart below provides a high-level overview of how ETO fits into GP.

12 ETO from WilloWare Incorporated for Dynamics GP 12 The process might start with a Sales Quote, where a non-inventory item (an item that does not exist in the Item Master) has been used on the Quote to provide your customer with an estimate on an item you do not yet produce. The Sales Line is linked to the new Manufacturing Estimate (ME) directly from Sales Transaction Entry. The new estimate could be based on: A ballpark estimate. A revision to an existing item, using the existing BOM and Routing as starting points for the new estimate A detailed product and process design Ballpark Estimate A ballpark estimate is created using existing items from GP, new ME items which exist only in the ETO module, or generic ME Items that are placeholders for large assemblies to be fleshed out later. The ETO module supports using non-inventory items on the ME, which are items that do not exist in the Item Master. New part numbers can be made-up on the fly, and assigned an estimated cost, perhaps based on a quote from a Vendor. To further accelerate the process, pre-defined ME Items can be created that contain the few settings needed by the ETO module. If your company builds custom motorcycles, there might be a generic, placeholder item for ENGINE, which is assigned a ballpark cost. The cost can be updated as needed, and the item replaced later with a real item once a specific engine has been selected. Revision to Existing Item A new ME can be built using an existing ME, or GP Manufacturing BOM, as a starting point. If your company build custom motorcycles, perhaps there is a common design that is often used as a starting point, then various components are swapped out of that design based on customer requirements. Starting with an existing BOM can save a huge amount of time because the entire, detailed BOM structure is pulled in from GP Manufacturing, along with the routing. Since the entire BOM structure is captured (the top-level, and all sub-assemblies), the ME can tweak any level of the BOM. Detailed Product Design This is an ME built from the ground up by creating a detailed routing, and a BOM using all of the components needed in the final assembly. The items used on the BOM can be either GP Inventory items, or new ME items.

13 ETO from WilloWare Incorporated for Dynamics GP 13 Manufacturing Estimate Orientation Navigation: Cards >> Manufacturing >> Mfg. Est. Maintenance Everything you need to create a Manufacturing Estimate (ME) is contained in one window. The Treeview and List View tabs are used to view, create, and maintain the Bill of Materials. The Other Costs tab is used to track costs associated with the new item which cannot be directly tied to the BOM or the Routing. For example, perhaps there are product certification tests that need to be paid for. The Routing tab is used to create the routing. The Costing tab displays the costing calculations. A ME can used a combination of real items from the GP Item Master and new items which exist only in the ME Module ( ME Items ). ME Items can be components, or subassemblies with their own ME BOMs. If an ME Item is used the system will require that you link it to a Source Item. The Source Item is an existing item in the GP Item Master. The Source Item is used by the ME integration to MFG PowerPack s Item Copy as the source for the setups needed to creating the new item. If the ME is accepted, the ETO module will create new items as needed from the ME Items on the estimate. The new items are created by copying settings from the Source Item. For example, on the Item Maintenance window alone you must make the following selections to create a new item: Item Class ID Item Type Valuation Method

14 ETO from WilloWare Incorporated for Dynamics GP 14 Quantity Decimals Sales Tax Option Tax Schedule ID U of M Schedule Purchase Tax Option A new item also requires Item-Site assignment, Item Price List setup, Item Resource Planning setup, Item Engineering setup, and much more. The Source Item is used to provide all of those settings to the new item. ETO integrates with WilloWare s Item Copy module in the MFG PowerPack Suite. Item Copy is used to copy the Source Item setup to the new ME Items. After creating the new items, specific settings can be tweaked as needed on a per-item basis, but this is much less time-consuming that performing all of the setup from scratch. Time Saving Tip Create GP Inventory Items that have typical set-up for a class of items. For example, all raw materials might have the vast majority of their settings the same (i.e. same site assignment, same Purchasing Options, etc). Or create generic items that represent smaller sub-set of inventory such as metal bar stock versus cabling. This might be a slightly lower level than an Item Class. There might be an Item Class for METALS, but round stock, flat stock, bar stock, and so on each have some different setups in GP. In this case you could create generic items in GP which carry the settings needed for each type of inventory, then use those generic items as the Source Items in ME. The key feature of a Source Item that will impact the ME is the U of M Schedule and the Quantity Decimals. Those are the only two settings from the Source Item that will directly affect how the new ME Item can be used, so at a minimum it will be important to create generic items that represent the different Units of Measure you will need.

15 ETO from WilloWare Incorporated for Dynamics GP 15 Creating a New Estimate Navigation: Cards >> Manufacturing >> ME Maintenance Item Number: this can be either an existing GP Item, if you are creating a variation of an existing Item, or a new item (an ME Item). The ME BOM is entirely separate from the GP Manufacturing BOM, although you can begin an estimate by copying an existing Manufacturing BOM. The ME BOM is analogous to the GP Manufacturing Archived BOM or Configured BOM in that it is a Named BOM. If you are going to create the ME by copying an existing Mfg BOM or ME, do not fill in the Item Number yet, just click the COPY button. See the Section Copying a BOM. The Item Number Lookup will show GP Items and ME Items: Once you enter a new Item in the ME Maintenance window it is remembered so that you can use it again later. These become Estimation Items, which are available from the Item Number Lookup in the ME module Description: for ME Items, provide a description. If the parent item is a GP Item, the description will fill in from the Item Master. BOM ID: every ME is similar to a named Archived BOM in GP Manufacturing. The BOM ID is the same as the Archived BOM Name, and if the ME is Accepted, the ME BOM will become a named Archived BOM in Manufacturing. Develop a naming convention for BOM IDs. For example, if creating MEs for specific customers or jobs, use Customer Name or Job Number as the BOM ID. If there are multiple sub-assemblies in the design, use the same BOM ID at each level of the ME. There are a couple of reasons to follow this procedure:

16 ETO from WilloWare Incorporated for Dynamics GP The Delete ME process can delete all related records based on the BOM ID. So if all sub-assemblies have the same BOM ID as the parent, the parent ME, BOM, all sub-assembly BOMs, and all related routings can all be deleted in a single step. 2- The BOM Lookup (below) can be restricted by BOM ID, so it will display all BOMs related to a specific ME. To work with an existing ME you can select the BOM ID directly without having to first select the Item Number. To do this, click the BOM ID Lookup button, then select a BOM. Both the Item and BOM ID will be returned to the ME window. The BOM Lookup window (below), shows all ME BOMs. Select a BOM by doubleclicking on it, or by clicking once on the row then clicking the SELECT button. BOMID Note: The Note button attaches a note to the BOM. If the Estimate is Accepted, this note is transferred to the Manufacturing Bill of Materials note, shown below. Find by BOM ID performs a contains search on the BOM ID field. This can be especially useful when trying to locate all of the parent and child BOMs associated with a single estimate. In the example below, putting 200 into the Find field will restrict the display to show only the 200XLG BOM ID rows. BOM Description: enter a more detailed description of the ME. Source Item: if the Item Number entered above does not exist in GP Inventory, it is a ME Item and must be linked to a Source Item. The Source Item should, at a minimum, have the Quantity Decimals and Unit of Measure Schedule you will need for the ME Item.

17 ETO from WilloWare Incorporated for Dynamics GP 17 Issue From Site: the inventory location that will contain the item, if it is a subassembly. Post To Site: the inventory site into which manufacturing orders will produce the item. Attachments: link an unlimited number of files to the ME. Any file type can be linked to an ME. See Managing Attachments below. Open the Attachments window by clicking the Attachments Expansion Button (blue arrow). If there are attachments, the will be a checkmark next to Attachments: Linked To Sales: if the ME was initiated from a Sales Quote, the link can be viewed by clicking the Sales Link Expansion Button (blue arrow). If there is a link, there will be a checkmark next to Linked To Sales: BOM Status: this field is informational only and has no effects on the ME. Available BOM Status codes are: Design Preliminary Prototype Pilot Conditional Production Pending Inactive Unqualified Disqualified Obsolete Other BOM Type: The top-level of an ME is always a Mfg Est BOM. If made subassemblies are used as components, those may have a BOM Type from GP Manufacturing such as MFG BOM. BOM Category: This is set automatically and is always Regular. This is the same BOM Category as appears in GP Manufacturing. Backflush: backflush all components on the BOM. Estimation Quantity: An estimate can be calculated for any number of user defined quantities. See the Estimation Quantities section for more information. Effective Date: This field is informational only. Revision: This field is informational only. Cost Rollup: the Cost Rollup button executes a roll up and revalue process on the selected ME BOM. It starts at the lowest level of the BOM and recalculates the costs at each level, rolling-up the costs to the top-level parent item. Component and Parent shrink are factored into the Extended Cost for each item.

18 ETO from WilloWare Incorporated for Dynamics GP 18 An example of the effect of Shrink % is shown above. Without Shrink the Extended Cost would be $100 (100 pieces times $1.00 per piece). The Shrink calculation adjusts the quantity needed based on the assumption that 50% will be lost during manufacturing. So that if 100 pieces are NEEDED to produce the desired quantity of the made item you must START will 200 pieces. The Rollup also includes labor and machine costs from the Routings at each level, and Other Costs. The ME rollup and costing routine also includes all of the fixed and variable overhead values used in GP Manufacturing. Those values will be pulled into the ME when GP Items are used on a ME BOM, and also from the Routing. The ME Routing uses GP Manufacturing Work Centers, Labor and Machine Codes.

19 ETO from WilloWare Incorporated for Dynamics GP 19 Estimation Quantities An estimate can be calculated for any number of user defined quantities. By default ME will always create one for for Quantity = 1. This line (for Quantity = 1) cannot be removed. Accept: mark which line, or lines, have been accepted by your Customer. If the Estimate is linked to a Sales Quote line, and multiple Estimation Quantities are accepted, additional lines will be added to the Quote for each accepted quantity. Esimation Quantity: enter a quantity for which you would like to calculate an estimate. % Markup/Margin: the column header will display either % Markup or % Margin, depending on the Price Method selected on the Item Price List Maintenance window for the Source Item. If the primary Item Number on your estimate is already an Item in GP, the the Price Method is used from that item. If you enter a percentage in this column the system will calculate the Unit Price. Enter the Estimation Quantity and Markup/Margin, then click Recalculate. Unit Price: you can manually enter a Unit Price. If a value exists in the Markup/Margin column it will be set to zero when a Unit Price is manually entered. Unit Cost: This is calculated from the BOM, Routing and Other Costs. The Unit Cost may be lower at larger Estimation Quantities because fixed costs in the estimate are spread across a larger number of items. For example, if one of the Other Costs is $1500 for certification testing, the impact of that cost is smaller when spread across 1000 pieces rather than 10 pieces. Profit: This is the difference between the extended Cost and the extended Price at a given Estimation Quantity. The Recalculate button recalculates the costing information based on the Estimation Quantities. NOTE: this does not perform a complete cost rollup (see Cost Rollup

20 ETO from WilloWare Incorporated for Dynamics GP 20 below). It uses the current costing information from the BOM s top-level to recalculate the Unit Cost, Total Cost, and Profit. You may need to perform a Cost Rollup on the Estimate, then return to the Estimation Quantities window and Recalculate to arrive at an accurate estimate. Update SOP is enabled if the ME is linked to a Sales Quote. One or more of the Estimation Quantities can be sent back to the linked Sales Quote by clicking the Update SOP button. Update SOP can be clicked multiple times as changes are made to the ME. If additional Estimation Quantities are added, click Update SOP again to send the additional lines to the Quote. Likewise, lines can be removed from the Quote by unmarking Estimation Quantities. When Multi-Currency is enabled, the ME and Estimation Quantities are in the Functional Currency. However, Update SOP will calculate the Originating Amounts using the Currency assigned to the Sales Quote.

21 ETO from WilloWare Incorporated for Dynamics GP 21 Multi-Currency If Multi-Currency is enabled, all of the currency value fields on the ME windows will show the number of currency decimals of the Functional Currency. If Multi-Currency is NOT enabled, the currency fields on the ME windows will show the number of currency decimals assigned to the Item Number (or Source Item). An ME is always in the Functional Currency. Even if the ME is linked to a Sales Order in a different currency, the ME will still be in the Functional Currency.

22 ETO from WilloWare Incorporated for Dynamics GP 22 Deleting an Estimate Clicking the DELETE button on the ME window checks if the selected BOM is in use as a subassembly on another BOM. If so, it cannot be deleted. It must first be removed from the BOMs where it is a component. See Where Used Inquiry. The Delete Options are: This BOM Only All BOMs by BOMID This BOM Only The following will be deleted: The currently selected BOM All first-level ME components. Subassemblies with their on ME BOMs will not be deleted. All Attachment links. The attachments will not be deleted. The Sales Link, if one exists. The Sales Transaction will not be affected. Other Costs The top-level Routing. Routings for sub-assemblies will not be deleted. Costing information. All BOMs by BOMID All of the records described above will be deleted for all ME BOMs that have the same BOM ID. When creating an estimate it is good practice to use the same BOM ID for any subassemblies created for the estimate. If a subassembly is designed specifically for the estimate (i.e. you create a ME BOM for the subassembly) use the same BOM ID as is used for the top-level item. Then if the estimate is deleted, selected the All BOMs by BOM ID option will remove all of the related subassembly BOMs.

23 ETO from WilloWare Incorporated for Dynamics GP 23 Copying a BOM Create a new ME by copying an existing GP Manufacturing BOM, or an existing ME. Source: select the BOM Type (one of the GP Mfg BOM Types, or Mfg Est BOM). Select the made Item. If the BOM Type is Archived BOM or Mfg Est BOM you will also have to select the BOM ID (which is the BOM Name for an Archived BOM). If you are copying an existing Mfg Est BOM, it is easier to lookup the BOM by using the BOM ID lookup rather than by selecting the Item Number first. Destination If the ME was started from Sales Transaction Entry, the ME window will have required enter of all of these fields on the ME window prior to opening the Copy window. Since the Destination Item information is linked to the Sales Transaction, this information cannot be changed. If creating a new ME not linked to a Sales Transaction, the ME window had to be empty prior to opening the Copy window, so the Destination Item Number, Description, BOM ID and BOM Description must be entered. All are required prior to starting the Copy process. Copy Options By default all options are marked. When copying an existing GP Manufacturing BOM all levels will be copied into the ME, and all levels will be assigned the same BOM ID. This creates a copy of the entire BOM structure where any aspect of any subassembly can be changed. When the ME is Accepted and new records are created in GP Manufacturing, a set of new, named, archived BOMs will be created so that the changes made in the ME apply only to the new item. To copy only the top-level of a BOM, unmark the All Levels box. Notes from the Routing Sequences, the BOM Lines and the BOM Header are also copied. The note from the source is copied to a new note on the ME record. The ME record has its own copy of the notes, so changes made do not affect the original source records. When the ME is Accepted, the new BOM and Routing in GP Manufacturing will have the notes from the ME.

24 ETO from WilloWare Incorporated for Dynamics GP 24 If you select to copy both the Bill of Materials and the Routing, and BOM-Routing Links exist, the BOM-Routing Links will be copied too. ETO supports linking only by quantity, whereas GP Manufacturing provides three linking options: All, Percent of Total, Number of Total. When the BOM-Routing Links are copied all quantities will be calculated and coverted to Number of Total. Likewise, when BOM-Routing Links are later created from the ME, the links will be created using Number of Total. If you are copying a Mfg Est BOM the BOM Status of the new BOM will always be set to Design.

25 ETO from WilloWare Incorporated for Dynamics GP 25 Managing Attachments The Attachments Expansion button on Manufacturing Estimation opens the Attachments window. Click the FOLDER button to select a file as an attachment. Provide an Attachment Name (or Description). If software is installed locally to view the file, click the BINOCULARS to open the file. The RED X deletes the line. Edit >> Delete Row can also be used to un-attach a file. The file itself is not deleted.

26 ETO from WilloWare Incorporated for Dynamics GP 26 Tree View The Tree View provides a way to view the complete, exploded BOM for the Estimate. New Items (items that do not exist in the GP Item Master), and new BOMs (such as HA100G copied in from the MFG BOM) are indicated with a green triangle. To add/edit components in the BOM click the Add/Edit Components expansion button (blue arrow). See Section Add/Edit Components. The Per Piece quantity and Fixed quantity are displayed for each line. As shown above, CORDG has 3-Each per-piece quantity plus 1-Each Fixed quantity. You can zoom to the BOM for a subassembly by expanding the assembly, then doubleclicking on one of the components. In the example above you could zoom to the ME BOM for HA100G by double-clicking on BOT100G. When you zoom into a subassembly BOM the BACK button will become enabled. Clicking BACK will take you back up one level in the BOM. You can drill downwards into a BOM structure for an many levels as exist, the move back towards the top by repeatedly clicking the BACK button.

27 ETO from WilloWare Incorporated for Dynamics GP 27 List View List View provides a detailed view of the top-level components in a BOM. Click the DETAIL button to expand the line to show more information. To edit or delete an existing line, select it then click the Add/Edit Component Expansion Button (blue arrow). The selected line will open in the Add/Edit Component window. To add a new item, click the Add/Edit Component Expansion Button (blue arrow). See Section Add/Edit Components for more information.

28 ETO from WilloWare Incorporated for Dynamics GP 28 Other Costs Use the Other Costs window to record miscellaneous costs related to the design, testing, and production of the new item. Any cost related to the product which does not fit cleanly into the item as a component or a sequence in the routing should be recorded as a miscellaneous cost. On the Costing tab the Other Costs will be prorated by the Standard Quantity.

29 ETO from WilloWare Incorporated for Dynamics GP 29 Routing The routing is a series of steps needed to produce the item. To have the ME include labor and machine costs in the estimate you will need to create Labor and Machine codes. You may want to create special Labor and Machine codes that have the labor and machine costs you want to use for estimating (i.e. on the high-side to ensure you do not under-estimate). See the GP Manufacturing documentation for setting up Labor and Machine codes. The method of calculating direct labor, machine, and overhead costs is the same in the ETO module as in GP Manufacturing. Costing will be explained in more detail in the Costing section. The Routing Sequence number will increment automatically based on the Manufacturing Routing Preference Defaults Sequence Spacing setting. See Tools >> Setup >> Manufacturing >> System Defaults >> Routings. The Routing Sequence Note will be transferred into the GP Manufacturing Routing sequence Note: See the BOM-Routing Link section for more information related to Routings.

30 ETO from WilloWare Incorporated for Dynamics GP 30 Costing The Costing tab calculates the estimated cost to manufacture the item given the BOM, at each of the Estimation Quantities. The Cost Rollup Button at the top of the ME window will recalculate the cost of the entire ME BOM. This function is equivalent to a Standard Cost Rollup in GP Manufacturing. It starts at the lowest level of the ME BOM, calculates the cost to produce the lowest level assembly given the BOM, routing and miscellaneous costs, then rolls-up that cost to the next level of the BOM. This process continues up the multi-level BOM until all levels have been re-costed and the costs rolled-up to the top. The ETO module uses the same costing logic as GP Manufacturing. A Labor code has a Shop Rate which is defined per Hour or per Piece. The Labor Fixed and Variable Overhead Amounts are calculated as a fixed Amount, or a Percent, of either the per hour labor rate, or the per piece labor rate. The multiple possible settings results in a large number of calculation options. A similar level of complexity exists with the machines. Refer to the GP Manufacturing documentation for more information about its Costing functionality. There are examples on the following page of a Labor Code setup and a Machine ID setup. Example of a Labor Code Setup.

31 ETO from WilloWare Incorporated for Dynamics GP 31 Example of a Machine Code Setup. Cost Rate Type Calculation Labor Per Hour Labor Time * Shop Rate Per Piece Shop Rate Labor: Fixed Overhead by Amount Shop Rate Per Hour Fixed Overhead Amt * Labor Time Shop Rate Per Piece Fixed Overhead Amt Labor: Fixed Overhead by Percent Shop Rate Per Hour Labor Time * Shop Rate * (Fixed OH% / 100) Shop Rate Per Piece Shop Rate * (Fixed OH% / Labor: Variable Overhead by Amount Labor: Variable Overhead by Percent Machine Machine: Fixed Overhead by Amount Machine: Fixed Overhead by Percent 100) Shop Rate Per Hour Variable Overhead Amt * Labor Time Shop Rate Per Piece Variable Overhead Amt Shop Rate Per Hour Labor Time * Shop Rate * (Variable OH% / 100) Shop Rate Per Piece Shop Rate * (Variable OH% / 100) (Machine Time * Operating Cost) + Piece Cost Per Hour Fixed OH Amt * Machine Time Per Piece Fixed OH Amt Per Hour Machine Time * Operating Cost * (Fixed OH% / 100) Per Piece Piece Cost * (Fixed OH% / 100)

32 ETO from WilloWare Incorporated for Dynamics GP 32 Machine: Variable Overhead by Amount Machine: Variable Overhead by Percent Per Hour Per Piece Per Hour Per Piece Variable OH Amt * Machine Time Variable OH Amt Machine Time * Operating Cost * (Variable OH% / 100) Piece Cost * (Variable OH% / 100) Setup Costs are calcuated the same as Labor Costs, but using the Labor Code assigned to the Setup Time, and the Setup Time occurs once regardless of the number of pieces produced. The Estimation Quantity is used to calculate the cost per piece by dividing the Setup Costs by the Estimation Quantity. Material Costs are calculated by using the cost assigned to the item. If the ME BOM uses GP Inventory items which have a Standard Cost Valuation Method, there may be Overhead values assigned from the Manufacturing Module. If so, those Overhead values will be pulled into the calculation. Shrink % is also factored in at the component and subassembly level. Fixed Material Costs are broken out separately so that it is easy to see how much material cost is incurred per-made item, and how much is incurred per-run. GP Manufacturing Costing vs ETO GP Manufacturing incorrectly rounds values in the Overhead calculations. For example Labor Variable Overhead is calculated as shown below: MO Quantity * Routing Sequence Hours * Shop Rate * (Variable OH%/100) 50 * 1 * $15 * 0.05% Manufacturing begins by calculating $15 * 0.05%, which it then rounds. In this case: $15 * 0.05% = $ Manufacturing rounds this to the Item s Currency Decimals, which results in $0.01. That Overhead value is then used to calculate the total Overhead: 50 * 1 * $0.01 = $0.50 Because Manufacturing rounds the Labor Rate * Overhead Percent calculation, any rounding error at that point is magnified by the subsequent multiplication steps. The correct way to perform the calculation is to round as the final step: 50 * 1 * $15 * 0.05% = $0.375 Which when rounded is $0.38, for a difference of $0.12 The ETO costing window can display either method. By default it matches how Manufacturing performs calculations. You can enable the ETO Costing Method by adding the following DEX.INI setting: ETOCOSTING=TRUE

33 ETO from WilloWare Incorporated for Dynamics GP 33 BOM-Routing Link The BOM-Routing Link functionality is intended to be used when designing your manufacturing process dictates the selection or choice of components. For example, your thought process might go like this: In the first step we create the Cab for the crane. In order to create the Cab we need the following parts. You will beging the process of creating the ME BOM by entering a step on the Routing. Click the Link button, then add the parts needed at that step. You may need more of the same part later on another step, but you will add that quantity separately when you create the Routing Sequence. The LINK button will be yellow when the selected Routing Sequence has linked components. To add Components to a routing sequence, select the routing sequence by clicking into the row, then click the LINK button. The BOM-Routing Link window displays all of the components linked to the selected Routing Sequence. Add additional components by clicking the ADD ITEM button. Delete a component by selecting the line, then clicking Edit >> Delete Row.

34 ETO from WilloWare Incorporated for Dynamics GP 34 Edit a component by select a line, then clicking the BOM Line zoom (blue, underlined BOM Line column header). See Section Add/Edit Component. When the Add/Edit Component window is opened from BOM-Routing Link all components added will be linked to the current Routing Sequence. To link components to a new sequence, close Add/Edit Component, then click DONE on the BOM-Routing Link window. On the Routing window select a new sequence, click the Link button, and start the process again of adding components.

35 ETO from WilloWare Incorporated for Dynamics GP 35 Add/Edit Component The Add/Edit Component window is opened from several different locations: Tree View expansion button List View expansion button BOM-Routing Link Line: the BOM Line will increment automatically based on the Manufacturing BOM Preference Defaults setting for New Component Position Number incremental spacing. See Tools >> Setup >> Manufacturing >> System Defaults >> Bill of Materials. Component Item Number: Enter an Item or select one from the Lookup. The item can either be a GP Inventory item, or a new ME Item. If it is a new item you will be required to enter a Source Item Number. Source Item Number: for new Items, this field is required. The Source Item provides two important settings for the new component: (1) Unit of Measure schedule and (2) Quantity Decimals. Later when the ME is Accepted, the Source Item will be used when creating the new item to provide all of the other setup information needed by GP for an item. BOM Type: if the component is a made item (either GP Manufacturing, or it has an existing ME BOM), select the appropriate BOM Type. BOM ID: if the BOM Type selected was ARCH BOM or Mfg Est BOM, a BOM ID will be required. For ARCH BOMs the BOM Name is the BOM ID. Quantity: Enter the quantity needed of the item per-unit of the made item. U of M: select the Unit of Measure. Item Description: for new ME Items the Item Description will be a required field.

36 ETO from WilloWare Incorporated for Dynamics GP 36 Shipping Weight: This is informational only. The Shipping Weight will be set on Item Maintenance when a new item is created. Unit Cost: enter the Unit Cost of the item. Extended Cost: The extended cost reflects the total quantity needed of a part (Per Piece Quantity + Shrink and Fixed Quantity) multiplied by the Unit Cost. Total Quantity: Shows the total quantity needed, which includes Per Piece Quantity + Shrink, and Fixed Quantity. Issue From Site: enter the site where the material will be issued from for a manufacturing order. Issue To Site: enter the site (work center) where the item will be issued to. Vendor Quote Information: the fields below Vendor ID are intended to record the information related to a quoted price from a Vendor. If this information is provided, when the Mfg Est is accepted, an Item-Vendor record will be created using the information provided, and the Quoted Unit Cost will be come the Last Invoice Cost / Originating Invoice Cost. If the Item-Vendor record already exists, the Last Invoice Cost / Originating Invoice Cost fields will be updated. Vendor ID: enter the Vendor ID Vendor Item Number: enter the Vendor Item Number (the part number as it is ordered from the Vendor). Vendor Item Description: description of the Vendor s part. Quoted Unit Cost: Quoted Extended Cost: neither of the cost fields affect the item s Unit Cost. Fixed Quantity: a fixed quantity is used if, regardless of the quantity of finished good produced, you need the same quantity of the component. U of M: select the Fixed Quantity s unit of measure. User Defined Fields: the two fields labeled UDF1 and UDF2 are user defined fields. The labels are set in the Manufacturing BOM Preference Defaults window. See Tools >> Setup >> Manufacturing >> System Defaults >> Bill of Materials. Floor Stock: floor stock are inexpensive items that can be used at will. These items should be backflushed. GP Manufacturing will not include the cost of these items in the standard cost calculation, however the ME Costing routine will include them. Backflush: backflushed items do not need to be Issued with a Component Transaction to an MO. Use Single Lot: when consuming the item (lot controlled items only), the entire quantity must be pulled from one Lot Number. Alternate: this item can be used as an alternate for another item on the ME BOM. Lead Time Offset: the number of days affects how MRP calculates the date on which the component is required, and affects when it is required by an MO when the MO is scheduled. Refer to Lead Time Calculations in the manufacturing help or online documentation.

37 ETO from WilloWare Incorporated for Dynamics GP 37 Shrink %: the anticipated loss of the component during manufacturing. The Shrink % affects the amount of the item needed by an MO because it will calculate the quantity needed to compensate for the expected shrink. See Shrinkage for Bill of Materials Components in the manufacturing help or online documentation. Shrink affects the Per Piece quantity, and is always rounded up. For a component measured in whole units, any amount of shrink can result in adding another unit because the required quantity is rounded up to the next whole unit. Option %: this field is not used by ME BOMs. Option BOMs are not supported. In Date: the In-Date controls when an component will start being used by Manufacturing Orders. An MO created before an item s In-Date will not include the item on the Picklist. Out Date: the Out-Date controls when a component will no longer be used by Manufacturing Orders. An MO created after an Item s Out Date will not include the item on the Picklist. See Bill of Materials And Component Effective Dates in the manufacturing help, or online documentation for more information about In/Out Dates. Notes: the BOM Line notes are accessed through the Notes button in the lower-right of the window. The Note button next to Component Item Number opens the Item Number note. The BOM Line notes on the ME are converted to Manufacturing BOM Line Notes when the ME is Accepted: New items (ME Items) are automatically added to the ME Item Master. This is a table that tracks the new items and the settings on the item. See the Section Mfg Estimate Items.

38 ETO from WilloWare Incorporated for Dynamics GP 38 Sales Link A Manufacturing Estimate (ME) can be started from a Sales Quote. When an ME is linked to a quoted item the cost calculation on the ME will update the cost and price on the quote. Also, if the quoted item is a non-inventory item, when the ME is Accepted it will convert the item into a Sales Inventory type item so that it can be fulfilled from inventory. An ME can also be linked to an existing Sales Line from the ME window. From a Quote, select the sales line for which you want to create an ME, then select Additional >> Mfg Estimation. Or from an ME click the Linked To Sales expansion button: The checkmark is displayed when a link exists. Click the SOP Number Lookup button to select a document line. The Lookup will show only Sales QUOTE lines for the Item Number on the ME BOM. The same sales line can be linked to multiple ME BOMs.

39 ETO from WilloWare Incorporated for Dynamics GP 39 Accepting an Estimate If your customer accepts the estimate, the ME can be transferred into GP to be used by Manufacturing to produce the item. Clicking the ACCEPT will perform the following checks: 1. that WilloWare s MFG PowerPack is installed. ME uses and integration to Item Copy to produce new items in GP. 2. the correct minimum version of MFG PowerPack is installed. 3. that Item Copy is registered under either the Suite License or the Item Copy API license. 4. that at least one Estimation Quantity is marked Accepted. 5. that a Manufacturing Routing does not already exist with the Item Number and BOMID (BOMID is used as the Routing Name). 6. that a Configured BOM does not already exist with the Item Number and BOMID (BOMID is used as the BOM Name). If those checks pass, you will be asked to confirm you are ready to accept the ME. You may cancel at this point. The Accept process performs the following: 1. ME Items: if new items are on the BOM they will be created as real items in the GP Inventory Module. The ETO module connects to the Item Copy utility in WilloWare s MFG PowerPack Suite to create the new items. The new items are created by copying the setup information from a Source Item to the new item. Refer to the MFG PowerPack documentation for more details on how Item Copy works. The following information will be copied from the Source Item to the New Item: a. Item Master (IV00101) b. Serial/Lot Mask (IV00109) c. MFG IC Cost Item Master (CT00102) d. MFG IC Cost Standard Item Class Default (CT00003) e. MFG IC IV Standard (ICIV0323) f. Item Currency Master (IV00105) g. Item Price List Options (IV00107) h. Item Price List (IV00108) i. Item Quantity Master (IV00102) quantities are zeroed j. Item Site Bin Master (IV00112) k. Item Site Bin Priorities (IV00117) l. Item Purchasing (IV00106) m. Multiple Manufacture Items Master (IV00115) n. Item Vendor Master (IV00103) o. Item Kit Master (IV00104) p. MFG Fulfillment Item Master (IS090000) q. MFG Item Engineering File (IVR10015) r. MFG Alternate Parts (IVR10100) s. MFG QA Item Procedure (QA160032) t. SVC Item Master Extensions (SVC00951) 2. If a Vendor was specified on the Add/Edit Component window, the Item- Vendor record will be updated (if it exists), or it will be created, and the Quoted Unit Price will be moved into the Last Invoice Cost/Originating Invoice Cost. 3. Bills of Material: all new Bills of Material from the ME will be created in GP Manufacturing as Configured BOMs with the ME BOMID becoming the BOM

40 ETO from WilloWare Incorporated for Dynamics GP 40 Name. If a MFG BOM type does not exist for the item a MFG BOM will also be created. 4. For Standard Cost items the complete rolled-up costing information will be pushed into the manufacturing costing tables, and the Standard Cost will be set on Item Maintenance. For Actual Cost items the Current Cost will be set on Item Maintenance. 5. Depending on ETO Setup, the largest accepted Estimation Quantity will be set as the Prorate Setup Quantity in Manufacturing. Depending on Costing Setup in GP Manufacturing, this quantity is either set in the Average Quantity on the Item Engineering window, or in the Standard Quantity on Standard Cost Changes window. 6. Routings: all new Routings from the ME will be created in GP Manufacturing. The BOMID will become the Routing Name. If a Primary Routing does not exist for the item, the new Routing will be set as Primary. 7. BOM-Routing Links: the links will be created using the Number of Total option on the Manufacturing BOM-Routing Link window. They will be created for the Configured BOM, and also for the MFG BOM (if one was created). 8. Sales Link: if the Quote used a non-inventory item, the item will be converted to a Sales Inventory item. This step ensures that when the item is produced by a manufacturing order, the Quote, when transferred to an Order or Invoice, will allocate the inventory. The quote line will be recalculated using the accepted Estimation Quantity, Unit Cost and Unit Price. If multiple Estimation Quantities are marked Accepted, additional lines will be added to the Quote. 9. The ME BOM Status is set to Accepted. This locks the ME and prevents further changes to it.

41 ETO from WilloWare Incorporated for Dynamics GP 41 Where Used Inquiry Navigation: Inquiry >> Manufacturing >> ME Where Used The Where Used window will open automatically from the ME Maintenance window when attempting to delete an item that is on other BOMs. The Where Used Inquiry will show the entire exploded BOM of every item that contains the specified component item, and highlight the component with a red dot.

42 ETO from WilloWare Incorporated for Dynamics GP 42 ME Items Navigation: Cards >> Manufacturing >> ME Item Maintenance Items are added automatically to ME Item Maintenance when they are added to a BOM. The settings from the Add/Edit Component window are saved to the ME Item. If the ME Item is used on another BOM all of the settings here will be pulled into the Add/Edit Component window. Me Items are used only to speed data entry of an estimate. The settings can be overwritten on the BOM, and any changes made to the ME Item in the Maintenance window has no effect on existing BOMs.