Shop Floor Control Overview

Transcription

1 Shop Floor Control Agenda Shop Floor Control Overview Setup Shop Floor Control Shop Floor Control Process Enter Work Order Commitment Work Order Processing Issue Material Record Hours and Quantity Work Order Completion Shop Floor Control Overview 1

2 System Integration Product Data Management Inventory Management DRP/MPS/MRP Payroll Procurement Sales Order Management RCCP/CRP Manufacturing Accounting Shop Floor Work Order Flow Create Work Orders Attach Parts List Attach Routing Instructions Generate shop paperwork Commitments - Availability Checking - Capacity Pick/Issue Materials Schedule Work Record Hours and Quantities Complete Work Orders Update Inventory Backflushing Post Labor 2

3 Shop Floor Management Setting Up Shop Floor Management Performing Shop Floor Processes Accounting Shop Floor Processes Setup Shop Floor Control 3

4 Define Manufacturing Constants Manufacturing Constants are branch-specific information which affects processing throughout the JD Edwards EnterpriseOne Manufacturing systems. Manufacturing Constants Shifts Commitment Control Costing Options 7 4

5 Define Shop Floor Calendar Define Working Day Weekend Holiday 5

6 Define Employee Labor Rate Employee Labor Rate is used to define employee labor rates that the system uses to calculate labor costs Employee Code/Address Book Number Employee Name Rate/Hour 6

7 Work Order Status Step/events In Process Work Order s - Run Work Order activity as needed - Partial Completions Complete adjusting manufacturing entries - Status to 95 - Manufacturing complete Manufacturing Accounting complete - Work Order Activity Variance Report Printed Variance Accounting complete - Purge Next Number 14 7

8 Shop Floor Process Shop Floor Processes Cycle Enter Compl etion Process Report Hrs & Quantity Invent Issue 8

9 Work Order Creation Manually Automatically - by acting on messages From Sales Order Define Item to create a certain quantity by a given date Create user-defined codes for type, priority, status Work Orders Sugar Whey Parts List Calcium Stearate Flavors Soybean Oil Routing 10 Mix 20 Add Liquids 30 Bake 40 Package 9

10 Attach Part List 1. Attach Manually 2. Automatic Attach Part List when Attach Routing (Define in Processing Option) 3. Automatic Attach Part List from Order Processing Program What happens when attach Part List and Routing 1. Specified Bill/Routing Type with Specified batch quantity 2. Specified Bill/Routing Type with Zero batch quantity 3. Bill/Routing Type M with Specified batch quantity 4. Bill/Routing Type M with Zero batch quantity 10

11 What happens when attach Part List and Routing Shrink, scrap, and operational yield. Parts List Generate Pats List automatically Override component requirements, commitments, and quantities Modify Parts List real-time Use substitute items if necessary 11

12 Attach Routing 1. Attach Manually 2. Automatic Attach Routing when Attach Part List (Define in Processing Option) 3. Automatic Attach Routing from Order Processing Program 12

13 Routing Instructions Generate routings automatically Use master routings Outside operation Item No*OP Operation Seq. Change work center, operation information Change sequence of operation steps Modify routings real-time 13

14 How calculate the start date Fixed Leadtime Request date = 15/10/10 Level leadtime = three days Start date = 12/10/10 Variable Leadtime {(Leadtime per unit x order quantity / TIMB (Item balance)) + setup + queue}/work hours per day Request date = 15/10/10 Leadtime per unit = 32 hours/1000 Units Work order quantity = 1000 Setup = 1 hour Queue = 9 hours Work Hour Per Day = 24 hours {(32 x 1000/1000) } / 24 = 2 day Start date 13/10/10 Commitments 14

15 Hard Vs. Soft Commit A hard commitment designates inventory to a specific inventory location or lot A soft commitment tentatively commits inventory to work order, although not tied to a location or lot Where commitments are made... Manufacturing Constants Backflush Option - Specified location for Work center or use commitment control Commitment Control 1. Primary location where work order originated 2. Branch/Plant boundaries may be crossed 3. Any location within a Branch/Plant 15

16 When hard commitments are made... Manufacturing Constants Hard/Soft Commit 1. Hard commit at creation of Parts List 2. Soft commit change to hard commit during work order pick list print process 3. Soft commit through inventory relief How hard commitments are made... Item Branch/Plant Commitment Method 1. Primary Location, then Location with the most quantity 2. Lot number starting with lowest 3. Lot expiration date, earliest first 16

17 Managing Commitments for Grade and Potency Controlled Items Not available Not available Valid Range low end high end Can be committed and issued 17

18 Managing Commitments for Grade require 800 and grade range A01-A03 Back Commitments for Potent Units Active ingredient in a product On Hand Requirement 40% (400 GA)(.40) = 160 GP 200 GP 80% (50 GA)(.80) = 40 GP 18

19 Managing Commitments for Potency require 500 GP 30 / 70% = 43 Back 470 Repost Work Order Commitments Clear outdated or invalid commitments Repost commitments and on-order quantities specified in a work order to current requirements Clear (set to zero) Quantity Commit to Work Order and Quantity on Work Order Repost Value in Quantity on Work Order from F4801 : Quantity on Order (Quantity Complete + Quantity Scrap) Repost Value in Quantity Commit on Work Order from F3111 : Quantity require Quantity issued 19

20 Shop Floor Processes Cycle Enter Compl etion Process Report Hrs & Quantity Invent Issue Process Work Order Generate Part List, Routing or both Update Status Code of Work Order Print Report - Shortage List, Shop Paper Work, Shop Packet Summary Issue Inventory automatic through a batch program (Preflush) Generate Purchase Order automatic for Outside Operation Calculate Standard Cost for Configured Item Substitute Item performed 20

21 Shop Floor Processes Cycle Enter Compl etion Process Report Hrs & Quantity Invent Issue Pick/Issue Relieve inventory using one of the following: Manual issue Preflush Relieve upon work order completion using: Backflush SuperBackflush 21

22 Pick/Issue Shop Floor Update Part List (F3111) 22

23 Production Scheduling Schedule work center production for work orders Compare planned against actual schedules Use the scheduling workbench to review and change schedules real-time Capacity Orders 23

24 Shop Floor Processes Cycle Enter Compl etion Process Report Hrs & Quantity Invent Issue Hours and Quantities Enter and track time and quantities by Work Order Employee Track resource usage by work center Compare standard Vs. actual Charge actual hours 24

25 Post Hours and Quantities Operation Hours Quantity Run Hours and Quantities Update program Interactively through Hours and Quantities entry Hour & Quantity Hour & Quantity (P311221) Shop Floor Write Time Transaction (F31122) Post Shop Floor Update Routing (F3112) 25

26 Review this Report and Run Update Hour by R31422 Update Hour Program 26

27 Shop Floor Processes Cycle Enter Compl etion Process Report Hrs & Quantity Invent Issue Completions to Inventory Partial completions as they occur Full completion when entire work request is satisfied Inventory Item Loctn Qty Candy Bin-X 2000 Complete

28 Complete Inventory Complete (P31114) Shop Floor Update Work Order Header (F4801) Process Manufacturing, Quantity Complete recorded in F