Baan Manufacturing Routing

Transcription

1 Baa Maufacturig Routig Module Procedure UP089A US

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3 Documetiformatio Documet Documet code : UP089A US Documet group : User Documetatio Documet title : Routig Editio : A Date : July 1998 Copyright 1998 Baa Developmet B.V. All rights reserved The iformatio i this documet is subject to chage without otice. No part of this documet may be reproduced, stored or trasmitted i ay form or by ay meas, electroic or mechaical, for ay purpose, without the express writte permissio of Baa Developmet B.V. Baa Developmet B.V. assumes o liability for ay damages icurred, directly or idirectly, from ay errors, omissios or discrepacies betwee the software ad the iformatio cotaied i this documet. Routig

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5 Table of cotets 1. The Routig (ROU) module i BaaERP The fuctio of ROU i BaaERP The modules related to ROU ROU s fuctioal procedure The routig procedure The mai routig procedure The orm-table procedure The bill of critical capacities The sessios that are related to the routig procedure 2-6 Routig i

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7 About this documet Read this documet to get a overview of the Routig module s fuctioality ad to lear more about the fuctioal procedures that are related to ROU. You eed o detailed kowledge of the BaaERP software to read this documet. However, you are more likely to uderstad the cotets if you are familiar with: The overall structure of packages, modules, ad sessios withi the BaaERP software The geeral busiess procedures used i everyday busiess practice The basic cocepts of eterprise resource plaig For detailed descriptios of the module s sessios, refer to BaaERP s comprehesive olie Help. To use this documet Read Chapter 1, The Routig (ROU) module i BaaERP, if you wat to kow more about: The module s fuctioality The relatioship of the module with other modules The module s fuctioal procedures Read Chapter 2, The routig procedure, if you wat to kow more about: The sessios i the procedure The results of the procedure The sessios that are related to the procedure The optioal procedures that are related to the procedure Routig 1

8 Acroyms used i this documet BOM CCP CF COM CP CPR EMM HRA IBD INA IPD PCS ROU RPT SFC TRP Bill of Material Cetral Caledar Maagemet Cofigurator Commo Eterprise Plaig Cost Price Calculatio Eterprise Modelig Maagemet Hours Accoutig Item Base Data Ivetory Aalysis Item Productio Data Project Cotrol Routig Repetitive Maufacturig Shop Floor Cotrol Tools Requiremet Plaig Leged Madatory sessio Optioal sessio Madatory busiess object Optioal busiess object CF PCS PCS Idicates a madatory sessio Idicates a optioal sessio Idicates a madatory elemet i a fuctioal procedure Idicates a optioal elemet i a fuctioal procedure Idicates a package Idicates a module Idicates a module that is described i the module procedure Routig 2

9 1. The Routig (ROU) module i BaaERP This chapter provides iformatio o: The fuctio of the ROU module i BaaERP The modules related to ROU ROU s fuctioal procedures 1.1 The fuctio of ROU i BaaERP Stadard routig No-stadard routig The ROU module as iput for plaig A routig describes how a particulare item is maufactured. It cotais the (sequece of) operatios that eed to be performed, o which work ceters the operatios are performed, the setup times, ad the ru times. I Baa s ROU module, you ca create routigs for maufactured items. You must eter iformatio about the (sequece of) operatios i this module, but also data pertaiig to work ceters, machies, tasks, orm tables, ad critical capacities. See for more iformatio sectio 1.3. You ca distiguish betwee stadard routigs, ad o-stadard routigs. A stadard routig is a item-idepedet routig. It ca be used for multiple items. They are especially used i the followig productio eviromets: Stadard-to-order eviromets Multimodel flow (repetitive) eviromets A o-stadard routig is a routig that is uiquely liked to a specific item. I the ROU module, you caot create routigs for geeric items. However, you use Baa s Cofigurator to create geeric routigs for geeric items. I the Cofigurator also customized routigs occur, that are based o the geeric routigs. The ROU module gives iput to almost every plaig fuctio of productio maagemet. Based o the routig iformatio the followig is calculated: The lead time of productio orders The load o machies ad work ceters The cost estimate of a operatio The stadard operatio cost of a item Routig 1-1

10 The Routig (ROU) module i BaaERP Figure 1 shows how the ROU module is positioed i BaaERP. Product Data Maagemet Productio ROU Plaig Sales Purchase Figure 1, The ROU module withi BaaERP 1.2 The modules related to ROU Figure 2 shows the modules ad packages that are related to the ROU module. TRP BOM RPT IBD IPD HRA CCP PCS CPR EMM CF ROU SFC INA CP CF Figure 2, The modules ad packages related to the ROU module Routig 1-2

11 The Routig (ROU) module i BaaERP The followig modules ad packages are the iput ad/or output of the ROU module: CPR The operatio rates that are defied i the Cost Price Calculatio (CPR) module are used i the ROU module whe the work ceters ad the tasks are defied. Data from the ROU module is used i the Cost Price Calculatio (CPR) module to calculate ad simulate the stadard cost of a item. HRA Employee data from the Hours Accoutig (HRA) module (ad the Commo (COM) package) is used i the ROU module. The work ceter of the backflush employee must have the same fiacial compay as the task s work-ceter. I this way, you ca lik oe backflush employee to multiple work ceters. CCP The caledars that are defied i the Cetral Caledar Maagemet (CCP) module are used i the ROU module. IBD ad IPD Routigs ca be defied for stadard ad customized items of item type Maufactured. The items are created i the Item Base Data (IBD) module ad the Item Productio Data (IPD) module. The lead time of a item is calculated i the ROU module, ad ca be updated i the productio-order data of this item. RPT The schedulig area that is defied i the Repetitive Maufacturig (RPT) module is liked to the routig codes whe you defie the routig operatios. The repetitive data is also used i the plaig of orders of repetitive items. TRP Toolig iformatio from the Tools Requiremet Plaig (TRP) module ca be liked to a machie, task, or operatio i the ROU module to specify the tool(s) that are eeded to perform the operatio. EMM For multisite purposes, a work ceter ca be liked to eterprise uits by the Eterprise Modelig Maagemet (EMM) module. CF Whe you defie a mix-model lie i the Cofigurator (CF) package (for assembly orders i the Shop Floor Cotrol (SFC) module), buffers ad lie statios are used that are defied i the ROU module. PCS You ca lik tasks (defied i the ROU module) to activities i the Project Cotrol (PCS) module. I the ROU module, you ca lik activities (defied i the Project Cotrol (PCS) module) to tasks. Routig 1-3

12 The Routig (ROU) module i BaaERP Master data ad prerequisites BOM The operatios that are defied i the ROU module are used to maitai a bill of material by operatio i the Bill of Material (BOM) module. Productio orders are plaed i the followig plaig modules ad packages: The Ivetory Aalysis (INA) module The Shop Floor Cotrol (SFC) module The Eterprise Plaig (CP) package The Cofigurator (CF) package These modules receive iput from the ROU module. The Cofigurator (CF) package uses the data of the ROU module for plaig purposes i a mixedmodel flow eviromet. Before you ca use the ROU module, you must set up certai master data: You must defie items of the item type Maufactured i the Item Base Data (IBD) module, because a routig ca oly be liked to a maufactured item. You must defie operatio rates i the Cost Accoutig (CPR) module. If you wat to set up repetitive data, you must defie schedule areas i the Repetitive Maufacturig (RPT) module. 1.3 ROU s fuctioal procedure The mai fuctioal procedure i the ROU module is the routig procedure. I the routig procedure, you record the operatios to maufacture stadard ad customized items. The sequece of operatios is defied as a routig. I additio, data pertaiig to work ceters, machies, tasks, ad orm tables are etered: Work Ceters A work ceter is a group of resource uits that is used as a fuctioal plaig uit. Resources (ma or machies) are liked to a work ceter. The operatio rate code that is liked to the work ceter ca be used to calculate the cost price of a item, or the estimated ad actual costs of a operatio. The capacity load o a work ceter ca be used i the productio plaig. Machies Machies are liked to work ceters ad are used to pla operatios. The rate defied for a machie ca be used to calculate the actual machie costs. The capacity load o a machie ca be used i the productio plaig. Routig 1-4

13 The Routig (ROU) module i BaaERP Tasks Tasks are used to describe the activities that take place o the shop floor. They are classified accordig to the ature of the work that is performed. Tasks ca be liked to operatio rate codes to calculate the cost price of a item, or the estimated ad actual costs of a operatio. Tasks are also used i productio plaig. Norm Tables Norm tables are used to calculate the productio rate of a operatio. After you defied a matrix for two physical characteristics (for example legth ad thickess), a set of stadard operatio times ca be maitaied for each combiatio of characteristics. The ru time ad productio rate ca be calculated by usig a orm table whe tasks ad routig operatios are defied. See for further iformatio sectio 2.2. Bills of critical capacities A bill of critical capacities idicates the work ceters that are regarded as critical i the master-plaig processes. Critical capacities are usually the bottleecks i a routig. See for further iformatio sectio 2.3. Figure 3 shows how the elemets i the routig procedure are related. Work Ceters Bill of Critical Capacities Operatios Machies Tasks Norm Tables Figure 3, The elemets of the routig procedure Routig 1-5

14 The Routig (ROU) module i BaaERP Routig 1-6

15 2. The routig procedure This chapter describes: The mai routig procedure The orm table procedure The bills of critical capacities The sessios that are related to the routig procedure 2.1 The mai routig procedure The procedure s results I the routig procedure you defie the sequece of operatios that is eeded to produce a specific item, ad the elemets (work ceters, machies, tasks) that are used i the operatios. For more iformatio about these elemets that are used i operatios, see sectio 1-3. The routig procedure is part of the data setup process. If you wat to calculate the ru time ad the productio rate of a operatio by usig orm times, you must carry out the orm-table procedure (see sectio 2-2). If you wat to determie the bill of critical capacities, see sectio 2-3. The result of the routig procedure is the routig for a particular maufactured item. The routig procedure gives iput to almost every plaig fuctio of productio maagemet. Figure 4 shows the steps i the routig procedure. 1 Work Ceters (tirou0501m000) 2 Machies (tirou0502m000) A Norm Tables (tirou3501m000) 3 Tasks (tirou0503m000) B Norm Times (tirou3510m000) 4 Routig Codes by Item (tirou1501m000) C Calculate Norm Times (tirou3201s000) 5 Routig Operatios (tirou1502m000) 6 Calculate Bottleeck Work Ceter & Productio Rate (tirou1201m000) Figure 4, The routig procedure Routig 2-1

16 The routig procedure Step 1 Step 2 Step 3 Step 4 The routig procedure cosists of the followig steps. Work Ceters (tirou0501m000) Use the Work Ceters (tirou0501m000) sessio to defie work ceters. You must defie the critical capacity type (Ma Capacity or Machie Capacity) for each work ceter alog with the umber of resource uits ad the capacity. You ca lik operatio rates to a work ceter if you set the Type of Operatio Rates field to Work Ceter Rate i the CPR Parameters (ticpr0100s000) sessio. If the Use of WIP Warehouses check box is selected i the SFC Parameters (tisfc0100s000) sessio, a work-i-process (WIP) warehouse ca be liked to a work ceter, allowig material issues for the operatio to the WIP warehouse. You ca also lik a backflush employee to a work ceter i the Work Ceters (tirou0501m000) sessio. A backflush employee facilitates the backflushig of hours for operatios that are plaed i the work ceter. Machies (tirou0502m000) Use the Machies (tirou0502m000) sessio to defie machies. For each machie, the machie rate, basic capacity, ad the ma-to-machie ratio is defied. The machie is also liked to a work ceter. The machie data is used to calculate the estimated ad actual costs of productio orders. Tasks (tirou0503m000) Use the Tasks (tirou0503m000) sessio to defie tasks. Tasks are used to describe activities that take place o the shop floor. They are classified accordig to the ature of the activity. Both machie tasks ad o-machie tasks ca be used i defiig the routig. You ca lik a operatio rate code to a task if you eter Task Rate i the Type of Operatio Rates field i the CPR Parameters (ticpr0100s000) sessio. Routig Codes by Item (tirou1501m000) Use the Routig Codes by Item (tirou1501m000) sessio to defie a routig code, ad lik it to a item. If you defie a routig code for a ope (blak) item code, the it is a stadard routig code. A stadard routig ca apply to multiple items. You ca lik oe or more routigs to a item, ad each routig ca be depedet o a specific order quatity of the item. The result is, for example, that the operatio order for a small order differs from the operatio order for a large order. To lik a quatity-depedet routig to a item, the two followig coditios must be met: You must select the Order Quatity Depedet Routig check box i the Item Productio Data (tiipd0101s000) details sessio. Routig 2-2

17 The routig procedure Step 5 Step 6 You must eter the maximum order quatity for which the routig is valid i the Up to Order Quatity field i the Routig Codes by Item details (tirou1101s000) sessio. If o routig has bee defied, the default routig that is defied i the ROU Parameters (tirou0100s000) sessio is selected. Routig Operatios (tirou1502m000) A series of operatios must be performed to maufacture a item. Use the Routig Operatios (tirou1502m000) sessio to defie a sequece of operatios for a routig code. For each operatio you defie the task, the work ceter, the machie, the ru time, ad the set-up time. A item s routig code ca be liked to a stadard routig. The routig will the re-use all the operatio data of the stadard routig. If the Use Productio Rates check box is selected i the ROU Parameters (tirou0100s000) sessio, you ca both use the Productio Rate field ad the Ru Time field i the Routig Operatios (tirou1102s000) details sessio. Eter the productio rate, ad BaaERP will automatically calculate the correspodig ru time. If the Use Productio Rates check box is cleared i the ROU Parameters (tirou0100s000) sessio, you ca oly eter a value i the Ru Time field. You ca use the Calculate Rate butto to calculate the correspodig productio rate. Calculate Bottleeck Work Ceter ad Productio Rate (tirou1201m000) Use the Calculate Bottleeck Work Ceter ad Productio Rate (tirou1201m000) sessio to determie the bottleeck work ceter for (a rage of) repetitive items, ad to calculate the productio rate. A bottleeck work ceter is a work ceter that govers the productio rate of a item. The productio rate of the bottleeck work ceter is used to calculate the productio order quatity of repetitive items. The work ceter data ad the routig of a item are used to determie the bottleeck work ceter ad the productio rate. If you eter a percetage of the set-up time i the Percetage Setup Time for Rate Calculatio RPT Items field i the ROU Parameter (tirou0100s000) sessio, the set-up time that is defied for a operatio is also used i the calculatio. If the productio rate is calculated, also the value i the Rate Factor for Plaig field i the Item Productio Data (tiipd0101s000) details sessio is take ito accout. Routig 2-3

18 The routig procedure 2.2 The orm-table procedure The determiatio of a task s ru time ca be complicated. For example, the ru time of a drillig operatio depeds o may factors, such as the spidle speed of the drill (that is, the revolutios per miute), the thickess of the plate, the diameter of the hole, ad so o. As a result, the ru time varies depedig o all these variables. Norm tables are used to determie the ru time ad the productio rate of a operatio. Whe the ru time depeds o two variables, a matrix ca be set i BaaERP to defie several possible values for the combiatios of the two variables values. After a matrix is defied for two physical characteristics (for example, legth ad thickess), you ca maitai a set of stadard operatio times for the combiatios of the variables values. Norm tables are also used i the followig parts of BaaERP: The Project Cotrol System (PCS) module: to budget customized routigs ad routig sheets. The Cofigurator (CF) package: to calculate the ru time ad the productio rate i a geeric routig. Figure 5 shows the steps i the orm-table procedure. 1 Work Ceters (tirou0501m000) 2 Machies (tirou0502m000) A Norm Tables (tirou3501m000) 3 Tasks (tirou0503m000) B Norm Times (tirou3510m000) 4 Routig Codes by Item (tirou1501m000) C Calculate Norm Times (tirou3201s000) 5 Routig Operatios (tirou1502m000) 6 Calculate Bottleeck Work Ceter & Productio Rate (tirou1201m000) Figure 5, The orm-table procedure Routig 2-4

19 The routig procedure Step A Step B Step C The orm-table procedure cosists of the followig steps. Norm Tables (tirou3501m000) Use the Norm Tables (tirou3501m000) sessio to defie a orm table ad its structure. You ca eter two physical characteristics (for example, legth, thickess) that effect the ru time ad the productio rate. You must also eter the correspodig values of the two characteristics. For example, the values for the characteristic legth ca be 2, 3, 4, ad 5; the values for the characteristic thickess ca be 0.1, 0.2, ad 0.3. Norm Times (tirou3510m000) Use the Norm Times (tirou3510m000) sessio to defie the task s rutimes give the values of the variables that you defied i the Norm Tables (tirou3501m000) sessio. Whether you defie the times i miutes or i hours depeds o the settig of the Productio Rate Time Uit field i the ROU Parameters (tirou0100s000) sessio. Calculate Norm Times (tirou3201s000) Use the Calculate Norm Times (tirou3201s000) sessio to calculate the ru time or productio rate.you ca start this sessio i the ROU module from the Ru Time field or the Productio Rate field i the Tasks (tirou0503m000) sessio ad the Routig Operatios (tirou1502m000) sessio. 2.3 The bill of critical capacities A bill of critical capacities idicates the work ceters that are regarded as critical for a specific pla item. Critical capacities are usually the bottleecks i a routig. The Baa Eterprise Plaig package uses the bill of critical capacities for plaig purposes. It geerates the rough capacity requiremets for critical capacities. The followig sessios are used i the Routig (ROU) module to determie the bill of critical capacities: Bills of Critical Capacities (tirou2530m000) sessio Use the Bills of Critical Capacities (tirou2530m000) sessio to list the bills of critical capacities for items that meet the followig coditios: The items are pla items (that is, they are items with order system Plaed, as defied i the Item Order Data (tcibd2500m000) details sessio). The work ceter is defied as Critical i Master Plaig i the Work Ceters (tirou0101s000) details sessio. This sessio allows you to gai isight ito the future bottleecks i the productio process. Routig 2-5

20 The routig procedure Geerate Bills of Critical Capacities (tirou2230m000) sessio Use the Geerate Bills of Critical Capacities (tirou2230m000) sessio to geerate a bill of critical capacities o the basis of the bill of materials (BOM) ad the routig data. To geerate a bill of critical capacity, BaaERP takes ito accout the effectivity dates ad expiry dates of the BOM compoets. A bill of material (BOM) explosio is carried out up to the ext critical pla item. Durig the explosio, BaaERP computes the capacities of the work ceters that you defied as critical. These capacities are the icluded i the bill of critical capacities, for that specific critical pla item. 2.4 The sessios that are related to the routig procedure Update Number of Resource Uits by Work Ceter (tirou0201m000) Use the Update Number of Resource Uits by Work Ceter (tirou0201m000) sessio to update the umber of resource uits that you etered i the Work Ceters (tirou0501m000) sessio. If the Critical Capacity Type field i the Work Ceters (tirou0501m000) sessio is Ma Capacity, the updated umber of resource uits equals the umber of employees that is liked to the work ceter. If the Critical Capacity Type field i the Work Ceters (tirou0501m000) sessio is Machie Capacity the updated umber of resource uits equals the umber of machies i a work ceter. Update Order Lead Times (tirou1202m000) Use the Update Order Lead Times (tirou1202m000) sessio to update order lead times. The order lead time of a item is etered i the Item Productio Data (tiipd0501m000) sessio.to update the order lead time, a routig is used. Which routig is used depeds o the Order Quatity Depedet Routig checkbox i the Item Productio Data (tiipd0501m000) sessio: If the Order Quatity Depedet Routig check box is cleared, the default routig (defied i the ROU Parameters (tirou0101s000) sessio) is used to calculate the order lead times. If the Order Quatity Depedet Routig check box is selected, ad the item s order method is Fixed Order Quatity or Ecoomic Order Quatity, the routig that is liked to that item is used to calculate the order lead time. If there is o routig liked, the default routig is used. The item s order quatity is defied i the Item Orderig Data (tcibd2500m000) sessio. Routig 2-6

21 The routig procedure Calculate Bottleeck Work Ceter ad Productio Rates (tirou1201m000) Use the Calculate Bottleeck Work Ceter ad Productio Rates (tirou1201m000) sessio to determie the bottleeck work ceter ad to calculate the productio rate of the work ceter. A bottleeck work ceter is the work ceter that govers the productio rate of a item. The productio rate of the bottleeck work ceter is used to calculate the productio order quatity of repetitive items. The work ceter data ad the routig of the item are always used to determie the bottleeck work ceter ad the productio rate. Other data that ca be used i the calculatio are: The set-up time that is defied for a operatio (provided that the Use Productio Rates check box i the ROU Parameter (tirou0101s000) sessio is selected). The percetage of the set-up time that is etered i the Percetage Setup Time for Rate Calculatio RPT Items field i the ROU Parameter (tirou0101s000) sessio. The value of the Rate Factor for Plaig field (for repetitive data) i the Item Productio Data (tiipd0501m000) sessio. The calculated productio rates ad the bottleeck work ceters are displayed i the Routig Codes by Item (tirou1501m000) sessio. Assembly Lies (tirou1506m000) To maufacture FAS (Fial Assembly Schedule) items, you must set up a assembly lie i the Baa Cofigurator package. A assembly lie is subdivided ito a umber of lie segmets. A lie segmet cosists of a umber of lie statios, ad oe buffer (at the ed). Lie statios ad buffers ca be cosidered as work ceters. Items are maufactured by passig them from lie statio to lie statio, ad by carryig out operatios at each lie statio. You ca use the Assembly Lies (tirou1506m000) sessio to get a overview of your assembly lies. From the Specific meu you ca start the followig sessios: The Cycle Times by Effectivity Data (tirou1507m000) sessio to display the time betwee completio of two separate uits of productio. The Lie Segmets (tisfc7521m000) sessio to display the lie segmets that are part of the assembly lie. Cycle Times by Effectivity Data (tirou1507m000) You ca use the Cycle Times by Effectivity Data (tirou1507m000) sessio to display the time betwee completio of two separate uits of productio o a assembly lie. Routig 2-7

22 The routig procedure Toolig per Operatio (tirou1510m000) You ca use this sessio to get a overview of the tools ad tool kits that are eeded to perform a operatio. You ca also eter data i the Toolig per Operatio (tirou1110s000) details sessio to lik the tools ad the tool kits to a specific operatio. The data etered i this sessio are used i the availability plaig of tools that is performed before productio orders are plaed. You ca oly eter this sessio if the Toolig Implemeted check box i the Compay Data (tccom0500m000) sessio is selected. Routig 2-8