MaddenCo Retread Production System

Transcription

1 MaddenCo Retread Production System MaddenCo, Inc. Revised March, 2017 Copyright MaddenCo, Inc. All Rights Reserved.

2 Please understand that MaddenCo has expended substantial sums in developing and maintaining its software, systems and related materials, and as a result, it has and will continue to have substantial proprietary interest and valuable trade secrets therein. Also understand that MaddenCo's software, systems, related materials and the "ideas" represented by software, as well as the physical materials, are valuable trade secrets and are strictly confidential material, and important, and that its confidentiality gravely affects the successful conduct of the business of MaddenCo. 2

3 Table of Contents RETREAD BARCODE SYSTEM OVERVIEW... 5 BARCODE CASINGS... 6 RETREAD WORK ORDER ENTRY... 7 WORK ORDER AND CUSTOMER NUMBER... 8 WORK ORDER HEADER ENTRY... 9 WORK ORDER DETAIL LINE ENTRY Original Casing Model CASING CREDIT PROCESSING WORK WITH WORK ORDER DETAIL ADJUSTMENT ENTRY Adjustment Processing Detail Adjustment Information Reprocess an Adjustment Tire Selecting Repairs to Adjust Override Adjustment Percentage Passing Adjustment Credits INITIAL INSPECTION CIA INSPECTION BUFFER INSPECTION REPAIR STATION BUILD STATION ENVELOPE STATION INSPECTION FINAL INSPECTION Reject a Casing at Final Inspection Station Rerun a Casing RETREAD FINISHED GOODS LABEL PENDING SCRAP TIRES Flag as Pending Scrap Inspect Pending Scrap Casings SELECTING RETREADS TO BILL Customers with retreads to bill Select customer by status code Billing retreads Line items added to ticket Retread line item detail Retread Work Order Inquiry SETTING UP A NEW TREAD DESIGN RETREAD MAINTENANCE MENU PRODUCT MAINTENANCE Add Tread Product Number RETREAD CROSS REFERENCE FILE Add New Cross Reference Record BILL OF MATERIAL FILE Add a New Bill of Material Record Bill of Material Detail RETREAD CASING GRADE SERVICE CODES

4 4 REWORK CODES RETREAD INQUIRY RETREAD REPORTS... 65

5 Retread Barcode System Overview This document will walk you through the bar code retread process, from bar coding the casing to selecting the retreads to bill to your customer. Bar coding the casings in the retread process gives us a unique number to assign to every casing. This unique number gives us greater control for tracking the casing throughout the entire retread process and improves the efficiency and accuracy of the technicians entering the information into the system. By scanning the retreads for shipping, we will have greater control over the inventory and less errors that allow inventory to slip through the cracks. 5

6 Barcode Casings The whole bar coding system starts with bar coding the casings. There are three identical bar code labels for each casing to be processed. Two of the labels will go on each sidewall or bead of the casing. The third label is attached on the corresponding line number of the retread work order. This unique bar code will become referenced to this work order line number. (See below) In this example, these are not the real bar code labels attached to the work order. You will also only have as many bar codes as you do casings. 6

7 Retread Work Order Entry The next step in order to start working with the casings is to input the work orders into the system. Users will need Retread Work order Input set to Y in their ACCESS control record. Go to the retread production menu and take the Work Order Input option. This will bring up the work order input screen; you will first be prompted to enter a work order number and a customer number. 7

8 Work order and customer number Enter the work order number that we are going to input into the system. Then enter the customer number or take the Inquiry function to find and select the customer. If control has a value of Y, then only customers flagged in customer maintenance with a Y or W in the Retread Customer field will be displayed during the retread customer inquiry. In this example we are going to bill the retreads to our store #001. We can have two customer numbers on a work order in the system. First we have the customer that we are going to bill the retreads to and we can have a dealer customer to whom the bill to customer will deliver the tires. This allows the system to track retreads by store and by the store s customers. We will discuss dealer customers in the next section. After entering the work order number and customer number, the work order input header screen is displayed. If a customer is past due or over their credit limit, a warning message will be displayed if control keys PASTCAP are answered with a Y. A work order may be prohibited from being entered if control are also answered with a Y. Note: You can restrict which customers can be entered as the work order customer. Set control to a Y and then flag the customer s Retread Customer field in customer maintenance with a W. Use the feature if all retreads are billed back to a store before being billed to the end user. 8

9 Work Order Header Entry The customer information is carried into the work order input. You will see above that the customer is MaddenCo #001. Order Date The order date will default to the current date when the work order is first entered. It may be changed on this screen. Promise Date The promise date is the date that the work order should be completed. This field must have a value entered. The promise date can be automatically filled in with a date that has a certain number of days added to the current date if control is set up with a value. (Ex. If you wanted to add 3 days then you would set up the control key with a value of 003.) This date may be used as a sort order on work order reports. Production Date This field is optional. This date would be the scheduled date to begin processing this work order in order to have the work order completed by the promise date. The production date can be automatically filled in with a date that has a certain number of days added to the current date if control is set up with a value. (Ex. If you wanted to add 7 days then you would set up the control key with a value of 007.) Receiving Location This is currently being used by custom written programs for a specific application. Route Code This code can be used to identify certain routes (or days) for the route drivers. This field along with the salesman number will be printed on the final inspection label and can be used to stack finished tires together that are going on the same truck on the same route to make the loading of the route trucks faster 9

10 (easier). This code can be set up to default for customers by entering the code in the customer file with the Retread Memo function. The memo function is available as from the Retread Maintenance Menu Ship to Location This is for the ship to address in case the retreads are to be shipped to a location other than the customer s billing address. This field is for reference information only. Note: If the dealer customer is flagged as a cash customer (Walk In Y/N field in customer maintenance) then you will be required to enter a customer name in the ship to field. This will also be the customer name that will print on the final retread label. Customer Memo If a customer has a memo set up in the customer memo file, the two reverse image lines below the ship to fields will display the memo. If the customer does not have a memo set up, then two blank reversed image lines will appear. Dealer Invoice Y/N If this field is answered Y, then the system will allow you to enter a dealer customer number. This customer number will allow us to create a second invoice in the system, billing this end user customer. This option is usually used when the retread plant sells primarily to the other stores within the same company. This enables us to track the retreads by store location and by the end user s account number. The default answer for this field can be set up by control Dealer Customers To add a dealer customer to a work order, enter a Y in the dealer invoice field. Now enter a dealer customer number or take the Prompt function to search for a customer. The customer search can be limited to retread customers only by answering control with a Y. Note: All retread customers will have to be flagged as retread customers in customer maintenance. You may change the price code and tax exempt codes if needed. After verifying that the correct customer is displayed, we will now add detail lines to the work order. 10

11 Work Order Detail Line Entry The system automatically takes us to insert mode to begin adding the detail lines of the work order. The work number and the line number that we are working on is displayed. Barcode Number Control must have a value of Y to allow us to enter a bar code number for each work order line number. The cursor will be on the bar code field. Scan the bar code that is assigned to line one to input the number or enter the number from the bar code into the field. We are assigning this bar code number to this work order line number in the system. If control is set to Y, once you enter the bar code number, it will be automatically incremented. Casing Size Enter the size of the casing to be processed or prompt to display a list of valid sizes from your casing size file. Note: This must be a valid size in your cross-reference file to be able to final the line item. Casing Manufacturer This field is optional. Enter in the manufacturer s code or use the Find function and Select from a list of valid manufacturer s codes that exist in your manufacturer s code file. Note: The cross-reference file may be set up with a manufacturer if different product numbers are to be used for different manufacturer s casings. See control Tread Design Enter the tread design to be used on this casing or use the Find function and Select from a list of valid tread designs. If control has a value of Y then the complete tread design and width must be entered. If the control key has a value of N then the tread design may be entered at this time and the width may be entered later. Note: There are two fields for entering the tread design. The top one is the tread that is to be used and the bottom field may be used for an alternate tread design. The system will prompt you for a tread if the field is left blank has a value of Y. For a repair only tire, use REPAIR as the tread design. 11

12 DOT/Serial Number Enter the DOT (Department of Transportation) number or serial number on the top field. This is an optional field. Brand Number Enter the brand number below the DOT number to use as an alternative number for tracking the customer s casings. Mounted This field can be answered Y or N if the casing was mounted on a rim/wheel and needs to be remounted before being delivered. You may also enter a rim/wheel code or use the Find function to display a list of valid rim/wheels. This may be used to print the specific type of rim/wheel on the finished label. Valid codes are set up in Rim Description Maintenance from the Retread Maintenance menu. Customer Casing This should be answered with Y if this is a customer s casing and answered with N if this is a plant owned (stock) casing. A default value can be entered in control This field can be set to default to Y and will be protected is set to a Y. Note: If answered N, then a raw casing will be relieved from inventory. A retread product and finished casing will be received into inventory. is answered Y then a single product number for the retread and casing will be used from the cross reference file for the finished product (refer to cross reference maintenance). GL can also be distributed for repairs on a stock casing differently. If control has a value of Y, and the Customer Casing field is answered with an N, then a screen will be displayed to enter a casing supplier. Prior Caps The number of times the casing has been previously capped may be entered here. If the casing has never been capped before, tab over the field leaving the 00 in the field or enter 01, 02, etc. This field is optional and the times capped can be printed on the finished retread label. RAR Y/N (Returned As Received) This field flags if a casing is rejected whether the casing is returned to the customer (RAR = Y) or we scrap the casing (RAR = N). If we scrap the casing, a disposal fee can be set up to automatically charge the customer when the work order is billed. The value of this field will default to the value set up in the customer memo file. You can also set up control with the value Y or N to have the value default for customers who do not have a customer memo file entry set up. Note: Control determines which customer s memo file to use to determine the RAR flag. If answered Y then the dealer customer is used, if N the work order customer is used. Adjust/Credit Leave the field blank for a normal entry. Enter an A if this casing is in for a possible adjustment. Enter a C if the casing is for a possible casing credit. Note: If a C is entered, a screen will be displayed after all detail information is completed, to enter the dollar amount of the casing credit if the casing can be recapped. The customer casing field should still be answered with Y because it is a customer casing at this point. (See below) 12

13 Original Casing Model If control has a value of Y, then a casing model can be input. Initially Scrap If is set with a valid pending scrap rejection code, then the Initially Scrap field is available. Place a Y in this field to set as a pending scrap tire. Comments Comments can be input and flagged to print on the invoice as well. Comment Line You have one line of comments per work order line that may be entered and printed on the invoice if you answer the Print on invoice field with Y. This message line is displayed at all stations for this line of the work order. Casing Credit Processing As mentioned on the previous page, if a C is entered in the Adjust/Credit field, then this window will be displayed to enter a credit dollar amount. The screen to enter the casing credit amount is not displayed until all necessary fields are completed. Control contains the default price or cost code for the credit amount for this size casing. Valid codes are price codes 1-6, A for actual cost or R for replacement cost. This will determine the default dollar amount for the credit but it can be changed. 13

14 Insert Detail Lines After all necessary fields are completed, the screen will display the line was added and next line is now ready for entry. If control has a value of Y, then all the information from the previous line is retained for the next line, except the bar code and serial number. Continue until all detail lines have been entered. If you are entering a work order with multiple lines of the same size casing and tread design, simply scan the bar code for each line and enter the DOT/Serial number for each line. Change any other information that may need changed. After all lines have been entered, Exit to view the detail lines that you entered. 14

15 Work with Work Order Detail Use the Edit option to change a detail line item. Use the Delete option to remove a line item. The system will ask you to confirm that you want to delete the line. Use the Adjustment option if you want to enter the adjustment information now. We will cover this in another section. 15

16 Adjustment Entry Take the Adjustment Input option from the Retread Production Menu. Enter in the work order number and line number for which we want to enter adjustment information. You will be taken directly to input adjustment information. 16

17 If you leave the line number blank to display all adjustment lines for this work order you will need to use the Enter Adjustment Information option. Adjustment Processing The system will display the line and all the information that has already been entered at work order input. Using the following function keys can change the casing size, casing manufacturer and tread. has a value of Y, then a line is available to input an adjustment message when inputting the adjustment information. The Change Case Size function displays a window allowing you to change the casing size. The Change MFG function displays a window allowing you to change the casing manufacturer. The Change Tread function displays a window allowing you to change the tread. Now we will begin to enter the adjustment information. First we can enter or change the serial number. Now we can enter the number of times the casing has been retreaded if it was not entered during work order input. The next field is the adjustment code or non-adjustment code. Enter the correct code or use the Prompt function to display a list of codes and make a selection. A window will be displayed and we simply input AJ for adjustment codes or NA for non-adjustment codes. We will now enter the remaining tread depth. Enter the week/year and whether the casing and repairs are to be adjusted. If we choose to adjust the repairs, then another screen will be displayed, where we select the quantity of each repair to be adjusted. First let s decide whether the casing can be reprocessed before we continue. 17

18 Detail Adjustment Information We have now entered all the information. If the casing can be reprocessed take the function to Process the Adjustment Line. A Print Label function has been added. Printer control key RLBL is used to determine where it will print. 18

19 Reprocess an Adjustment Tire Make any changes that need to be made. Note: The comment line shows that this is a rerun of line #10. This is contained in control Control should be answered Y to use this feature. 19

20 Selecting Repairs to Adjust After we enter the information from the previous screen, another screen is displayed to select the quantity of repairs to be adjusted. Enter the quantity of each repair to be adjusted. The system will now display the adjustment percentage and allow you to override the percent if needed. 20

21 Override Adjustment Percentage The system calculated the adjustment percent. You can now override the percent. Note: If you change the adjustment percent, be sure to include the decimal. Passing Adjustment Credits The adjustment has been processed. If we reprocess the casing, the customer will get billed their regular price for the new retread on the new line created. The customer will then get credited for the percent of adjustment on the original line number. The net difference is that the customer is paying for the percent of the tread used on the old retread. Line #10 11R22.5 WHL 8.5 adjustment ($ 91.54) Credit Line #14 11R22.5 WHL 8.5 new retread $ Customer pays $ Reference retread 21

22 Initial Inspection Take the Primary Inspection option from the Retread Production Menu. Enter the inspector name. To reduce the use of the keyboard, bar codes could be created for each inspector and you would simply have to scan the correct bar code. 22

23 Scan the bar code on the casing. The line number will be displayed for the casing that you scanned into the system. Casing Grade can be input instead of NDI if control is set to Y. See the Maintenance Section for setup information. A Prompt function is available to select a code. If the casing passes inspection then you would enter a Y or scan the barcode for Pass Inspect. If the casing does not pass inspection, use the Prompt function for a list of rejection codes. Select the correct rejection code to insert the code. Enter to inspect the next casing. Note: Bar codes can also be created for the different rejection codes so you can just scan the correct code and enter to continue. The comment line entered during work order input is displayed above and will blink if control has a value of Y. The All Inspect function is available if control has a value of Y. The Change Tread function is available if control has a value of Y. If the control has a value of Y, then the system will automatically reject the casing in primary and final inspection when it is rejected in primary inspection. This will cause the system to print a finished label so the casing can be taken off of the line now. 23

24 CIA Inspection The CIA Inspection Station is an optional station. The CIA (Casing Integrity Analyzer or Surrographer) is a station that takes an image of the casing to look for separations. The casing can be rejected at this time. 24

25 Buffer Inspection Take the Buffer Inspection option from the Retread Production Menu. Enter the inspector ID as we did in Primary Inspection. Scan the bar code on the next casing to be buffed. The fields that are available for input are the tread design and grade. The casing circumference can be overwritten if control has a value of Y. The tread design field allows you to change the tread for this casing. The tread may be entered with no tread width at primary inspection. The buffer inspector will scan the bar code representing the proper tread or enter the proper tread width. If control has a value of Y, grade messages entered in control keys are displayed at the top of the screen. If control has a value of Y, then the All Inspection function is available. This allows changes to be made to all fields on this work order line number. After all valid information has been entered into the system you are ready to scan the next casing into the system. 25

26 Repair Station Take the Repair Station option from the Retread Production Menu. Enter the inspector ID as we did in Primary Inspection. Scan the bar code on the next casing to be repaired. 26

27 A screen will be displayed to allow you to enter the quantity of each type of repair performed on the casing. The sequence number entered for each repair in repair code maintenance controls the order in which the repairs are displayed. Enter the quantity of each repair performed. You can now scan the next casing bar code to continue. To reject the casing, take the Reject Line function to display the primary inspection window. Enter the correct rejection code. Control must have a value of Y to allow this feature to be available. 27

28 Build Station Take the Build Station option from the Retread Production Menu. Enter the inspector ID as we did in Primary Inspection. Scan the bar code on the next casing to be built. The intended use of the builder station is to allow the builder to see the tread width entered at the buffer station. The Change Tread function is available to edit the tread design if control has a value of Y. The Change Grade function is available to input/edit the casing grade if control has a value of Y. The Change Circum function is available to change the casing circumference if control has a value of Y. The technician will enter a Y to confirm the tread has been applied. The system will prompt you to scan the next casing to continue. 28

29 Envelope Station Inspection The Envelope Station is an optional station. The Envelope station allows you to barcode the envelopes and then scan the envelope for tracking. This information could then be tracked with a query over the file to see how many times an envelope was used. This also provides one more station to track the casing through the plant. 29

30 Final Inspection Take the Final Inspection from the Retread Production Menu. Enter the inspector ID as we did in Primary Inspection. Scan the bar code on the next casing to be final inspected. This is the final step in the production process. The final inspection station is critical because the final inspector is responsible for verifying the retread is satisfactory and that all data entered up to this point is correct. The primary inspection field is open to edit if control has a value of Y. This may be used if you are not using all stations in the process. The final inspector may be responsible for rejecting the casing after primary inspection if the casing was not retreaded. This is critical to make sure entries to the inventory and general ledger post correctly. The Add/Change repairs function is available. The Change Tread function is available if control is set to Y. If control is set to Y, the All Inspection function allows changes to be made to all fields on this work order line number. If all data is correct, enter a Y to pass inspection. If the casing does not pass inspection, enter a valid rejection code to reject or a valid rerun code to rerun the casing. Note: You can use the Prompt function for a list of valid rejection and rerun codes. 30

31 Reject a Casing at Final Inspection Station If a rejection code is entered at final inspection, the tread design will be replaced with REJECT as the tread design. The system will print a rejected label for the casing if control has a value of Y. If a casing passed inspection at primary but was rejected at final, the system will relieve the correct raw material from inventory and make the proper GL posting during the update. Note: If the casing was never retreaded, then you need to reject the casing in the primary inspection field so that the raw material inventory is not relieved incorrectly. Rerun a Casing If the retread does not pass inspection but can be rerun, enter or prompt for the proper rerun code. The system will relieve the correct raw material from the inventory and make the proper GL posting during the update after the casing has been final inspected. Rerun the casing through the production process again. The casing will now show that the rerun number is 01 at all stations. When the casing is final inspected this time, the last rerun code entered and the number of rerun will be displayed next to the final inspection field. Enter a Y or the proper rejection/rerun code. 31

32 Retread Finished Goods Label If control has a value of Y, then a retread label is printed whenever a retread is passed or rejected at final inspection. A label will also print for a casing rejected at primary if control have a value of Y The retread label gives you the information that you need to identify the retread and handle it efficiently. The information that is printed on the label is (1) customer name, (2) dealer customer, (3) work order and line number, (4) tread description, (5) casing size, (6) casing manufacturer, (7) product number and (8) a bar code. For more information that can be printed on the label, see the next page. 32

33 The following information can be printed on the retread label if the control keys below are set up and answered If Y the product number is printed as a bar code at the bottom of the label. If W then the work order line number is printed as the bar Contains the actual hold message to be printed on the label when a hold label is printed in primary If Y the company name is printed in the header of the label. If N the value of control is printed. If you have your company name preprinted on the label header, then you would answered N The name of the company to print in the If Y the serial number will print, if N the brand number will print on the If Y the casing grade rating will print on the If Y the casing circumference will print on the If Y up to six lines of repairs will print on the If Y the number of times the casing has been retreaded will print on the If Y the total number of lines on the work order will print. The work order and line number would print as of - Contains the description for the route code **, where ** is a route code assigned to a If Y the salesman, route code and mounted information will print. If N then the value will Contains the description to print when a casing credit is processed through the retread system. Customer casing Y and Adjustment is C. Retread labels can be purchased online from First Tape and Label. 33

34 Pending Scrap Tires To turn this feature on, set control with a value of a valid Pending Scrap rejection code. This feature will allow you to pick up tires that you already know are scrap, but flag them as pending to review at a later time before disposing of the casings. 34

35 Flag as Pending Scrap By setting the Initially Scrap field with a Y during work order input, the Primary (Initial) inspection field is automatically set with the Pending Scrap code. The above casing is flagged as PENDING SCRAP. These tires can be staged to be inspected at a later time. 35

36 Inspect Pending Scrap Casings When you want to inspect the pending scrap casings, go into Final Inspection and scan or enter the tag number or work order/line number to pull up the Pending Scrap casing. Enter the correct scrap/rejection code or use the Prompt function and select the correct code from the list. This will get written into the Primary and Final inspection fields. The Scrap Report has been added as a new option to the Retread Report Package. This report will now include the lines that are flagged as PENDING SCRAP. 36

37 Selecting Retreads to Bill If control has a value of Y then that work order line number will be added to the plant s retread billing file when it is final inspected. This is the recommended setting to use whether you are manually selecting retreads to bill or you are using the MaddenCo scan billing process. If control has a value of W then the work order and line number will be printed as a bar code at the bottom of the label. This allows us to scan the label to select the lines to be billed. This is a much more accurate way of making sure the retreads that were shipped were billed and that only the retreads billed were shipped. This gives us a lot greater control to keep our billing and inventory accurate. Note: Reference the Scan Billing document for more information on this feature. Customers with retreads to bill Retreads are billed through Point of Sale. To inquire on which customers have retread work orders with lines available for billing, take the Retreads to Bill function from the Work with Estimates, Work Orders and Invoices screen. 37

38 Select customer by status code You can isolate down which customers you have retread transactions to bill by the Show Only Status field. Prompt for a list of status codes. This is helpful if you only want to work with customers with outstanding casing credits, for example. 38

39 Billing retreads While on the Work with Work Order screen from within a POS invoice, take the function to Bill from Scan/Retread. The available retread transactions are listed for the customer. If Scan Billing is turned on, (SCANBILL is set to a Y), then you are taken to the Compare Scanned Tires to Ordered screen. From here you will need to use the Bill Nonscanable Items function to continue to the Select Retreads to Bill screen. 39

40 Retreaded tires are usually listed by work order, in work order line number order. If control is set to T, then the retreads will be displayed by tag/barcode number. (See above) Furthermore, if control is set to P, then retreads will be displayed in product number then tag number order. If this key is set to T, then the retreads are displayed in tag number order. The Show Only field has been added to the Select Work Order Lines to Bill screen as well. Prompt to display a list of the valid options. You can also display only complete work orders by flagging the Show only completely produced orders with a (Y) above. Select the work order/lines or tag numbers to bill or take the Bill Entire WO function to bill all available lines. A confirmation screen is displayed when the function is used. If control has a value of N, and you are using our plant scan selection of tags to add to the billing file, then by setting control is set to Y, casing credits and adjustments (nonscannable lines) are automatically added to the billing file at final inspection time. These can be selected for billing here. If control is set to Y, retread billing will check the cross reference file to get the product number to use when billing a casing credit. The tread design for this is specifically CASINGCREDIT. This way casing credits can be billed using different product numbers by casing size and casing grade, if using casing grades. If the cross reference for the size is not found, the value of control will still be used. This was added to handle Penske requirements for Bridgestone delivery receipts. 40

41 Line items added to ticket The line items are added to the ticket. For intercompany transfers from the plant, the end user customer will print on the invoice if control is set to a Y. If control is set to Y, then you can restrict a retread from being billed/transferred to another store until it has been billed/transferred to the original store. Set control key PCSCNOxx to a Y where xx is a product class to restrict customer retread products from being billed without selecting them from the retread billing file or scanning them onto a ticket. This will help ensure that the customer s billing file is accurate. Stock retreads resulting from a casing credit can be flagged as STOCK when they are final inspected, so that they can be billed to any store or customer from the plant, if control has a value of Y. If you are using the MaddenCo scan billing feature to bill retreads, if control is set to Y, then when a stock retread is scanned that was associated to a customer casing credit, only the stock retread will be billed. Modifications have been made in retread billing allowing casing credits to be transferred from store to store. In the manual transfer function, option C has been added allowing the casing credit only to be transferred, not including the associated stock tire. Option 1 will still only transfer the stock tire, except if new control is set to Y. If this is set then both the casing credit and the stock tire will be transferred. This control record also applies to scanning transfers. If you scan a casing credit, both will be transferred. 41

42 Retread line item detail If you display the retread product, the work order/line and tire ID (Barcode tag) is shown. This work order/line will now be displayed as billed to the above POS ticket and a time stamp record is added to the retread work order inquiry. 42

43 Retread Work Order Inquiry Note: Refer to Billing Retreads from the Advanced Point of Sale document for detailed information on how this is done. Also refer to the Scan Billing document to learn more about using wireless Ethernet scanners for billing and taking physical inventories. Handling the retread billing and inventory with greater accuracy will keep your company s money in the bank instead of going down the road. Don t forget to see Customer pricing on how to set up and maintain correct pricing for your customer s retreads and repairs. 43

44 Setting up a New Tread Design There are seven records that need to be set up for a retread product. 1. Tread product number A product number needs to be set up for the tread rubber to be used as a raw material. 2. Finished product number A product number needs to be set up for the finished product. 3. Cap and casing product number A product number needs to be set up for the cap and casing as a single product number if you inventory the product as a single number. 4. Raw casing product number The raw casings will probably already be in the system. 5. Finished casing product number The finished casings will probably already be in the system. 6. Cross reference file A cross reference will need to be set up for each casing size that is to be retreaded with this particular tread design. 7. Bill of material file A bill of material will need to be set up for each tread design and width. This will show what raw materials are used and the quantity that is used. In the case of a tread or the cushion gum, this quantity is the weight per linear inch of the raw material. Retread Maintenance Menu To get to the Retread Maintenance Menu from the starting menu take the Tire Dealer System option, then the Retread Menu option and then Retread Maintenance Menu. We are going to cover Cross Reference, Bill of Material and Product Maintenance in this document. 44

45 Product Maintenance Add Tread Product Number Go to Product Maintenance and show only the product class set up for tread rubber. 45

46 Use the Copy option for a similar product or use the Add Product function to start with a blank product screen. Note: You will reduce the amount of data that needs to be set up if you copy a similar product. Enter the product number of the new product that we want to set up. Now we will change the description and whatever fields that need to be changed for this new product. In this case we are going to leave the class code and vendor alone. We will change the manufacturer product number. Since every thing else is the same. 46

47 A new window will pop up with the product cost and pricing fields. Change the costs and any other fields that may need to be changed on this screen. Continue to set up all the new tread product numbers. Finished product numbers Set up the new finished product numbers the same as we did for the treads. Choose a similar product to copy and make the necessary changes. Repeat this for the cap and casing product numbers as well. Note: Once you have set up the finished product numbers, copy those to create your cap and casing product numbers. This will make it even easier for you. Remember that the class code and vendor code may be different for cap and casings. Casing product numbers Unless there have been some new casing sizes added to the retread products, the casing product numbers are probably already in the system. 47

48 Retread Cross Reference File The cross reference file is on the Retread Maintenance Menu as the Cross Reference Maintenance option. If you enter a size and tread design of a similar tread you can use the Edit option to show you how other similar cross reference records are set up. Cross Reference records can be set up by casing manufacturer. This allows you to designate different finished product numbers if you want to differentiate between casing manufacturers. 48

49 Add New Cross Reference Record Use the Add Cross Reference function to add a new cross reference record. Enter the casing size and tread design for the new cross reference record that you want to create. Note: this is where you would enter a casing manufacturer if you want to set up the cross reference by casing manufacturer. If control is set to a Y, then the cross reference file is a combination of Size, Tread and Casing MFG. If this key is set to a G, then the Cross Reference file is accessed by Size, Tread and Casing Grade. 49

50 Cross Reference Detail Enter the finished product number for the retread, the finished casing product number, the raw casing product number and the cap and casing product number if you are using a single product number for cap and casing. If all the product numbers are found in the product file, then the descriptions will show on the screen for a second and the system will take you back to add the next record. Note: If a product number is not found in the product file the system will display product not found next to the item that is missing. You will not be able to go any further until the product is added to the product file. 50

51 Bill of Material File From the Retread Maintenance Menu take the Bill of Material Maintenance option. Add a New Bill of Material Record Use the Add Tread Design function to add a new Bill of Material record Enter the tread design for which we will be creating this record. Remember that this is what we will enter into the system during work order input and is not necessarily the same as the tread product number. For example the tread may be D438.5 but the product number for this tread may be D Next enter in the product number for this tread design and the weight per inch for this tread. This can be calculated from the Material Weights and Measure book. Take any size casing for this tread and width, then, divide the total weight of this tread by the casing circumference to get the weight per inch. You may also be able to get a file that contains the weight per foot. Just divide this by 12 to get the weight per inch. 51

52 Use the add function again to add another raw material for this tread design, such as the cushion gum, if needed. Enter the product number for the cushion gum and the weight per inch. The weight per inch is calculated the same as the tread. 52

53 Bill of Material Detail This record is complete. Exit the record and then use the add function to add another record. You have now set up all records that are needed for the new tread design. 53

54 Retread Casing Grade You can enter different products based on casing grade. Your casing grades must first be entered using Casing Grade Maintenance which is available on the Retread Maintenance Menu. Set up the casing grades and description in Casing grade Maintenance. 54

55 To set up different products by casing grade in Retread Cross Reference Maintenance, set control to a G. This will display the Grade instead of the MFG field. 55

56 At all the retread stations, the NDI has been replaced by casing grade or GRD. The Grade field will be open for entry if control is set to Y. It will be mandatory to enter the grade if control is set to Y. When control is set to Y and the cross reference product for the retread has the Driver field set to Y, control keys are checked whether to display a warning message. If control where x represents a grade, is set to Y, a warning message is displayed for this grade. Control where x represents the casing grade, contains the warning message text and can be up to 32 characters. For example, when Grade B is entered at this station the message warns that this should be driver quality. This is based on control = Y (check for = Y (B represents grade) display warning message for this grade when driver is = warning message GRADE B FOR A DRIVER...REALLY??? The label print programs will print the casing grade instead of the NDI. Set control = 'Y' to print casing grade on label where NDI was printing with description of GRD: instead of NDI: 56

57 To use the Change Grade function to change the casing grade at the Builder, Repair and Envelope stations, set control to a value of Y. The Casing Supplier Analysis report will display information by casing grade instead of NDI. You can choose which 2 casing grades will be broken out in detail. Use these control keys for this = 'A' (or a valid grade) Grade that will be in first column of Casing Supplies Analysis = 'B' (or a valid grade) Grade that will be in second column of Casing Supplies analysis report. 57

58 The other casing grades will be added to the column OTHR, and the ones with no casing grade will be in the NONE column. The label print programs will print the casing grade instead of the NDI. Set control with Y to print casing grade on the label where NDI was printing with description of GRD: instead of NDI: 58

59 Service Codes You can enter a quantity for service codes at the Service Station Inspection if service items need to be added after a work order line has been through final inspection. Your service codes must first be entered using Service Code Maintenance, which is available on the Retread Maintenance Menu. Use the Add Code function to enter service codes. The Edit option allows the description, sequence and quantity to be changed. Use the Delete option to remove a code. 59

60 Use the Service option from Service Inspection Station or from the All Inspection screen. 60

61 Enter the quantity for each service listed. If you set a maximum quantity in the service code file and enter an amount greater than that value, you will receive a message. When the line item is billed through Point of Sale, the Service Codes are added to the invoice. 61

62 Rework Codes You can enter a Rework Code at the Final Inspection rather than rejecting the retread. Your rework codes must first be entered using Rework Code Maintenance, which is available on the Retread Maintenance Menu. Use the Add Code function to enter codes. The Edit option allows the description to be changed. Use the Delete option to remove a code. 62

63 During final inspection, use the Prompt function on the final inspection field. Set the Selection Inquiry to find the RW codes and select a code. This will flag the retread as a Rework such as a missed spot repair. This will allow the casing to be sent back down the line for the rework. This does not relieve any raw materials as waste as a Rerun does. 63

64 Retread Inquiry All retread inquires have been moved to an Inquiry Menu. 64

65 Retread Reports All reports can be directed to a printer and put on hold. The default printer is highlighted above the printer id. They can also be ed if you are using the feature. See the Data Exchange document for setup information. 65