Certified Course Curriculum

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1 Sage ERP X3 Manufacturing Series Fundamentals STUDENT CURRICULUM SAGE UNIVERSITY Certified Course Curriculum

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3 Sage ERP X3 Manufacturing Series - Fundamentals CERTIFIED STUDENT CURRICULUM SAGE UNIVERSITY Curriculum Version 2.0

4 NOTICE This document and the Sage ERP X3 software may be used only in accordance with the accompanying Sage ERP X3 End User License Agreement. You may not use, copy, modify, or transfer the Sage ERP X3 software or this documentation except as expressly provided in the license agreement. Visit our website at or call to learn about training classes that are added throughout the year. Information in this document is intended solely as general information with respect to common business issues and is not to be construed as professional advice. It is always best to consult a tax or accounting professional for all tax and account related questions. THE INFORMATION HEREIN IS PROVIDED AS IS AND ALL WARRANTIES ARE EXPRESSLY DISCLAIMED, INCLUDING BUT NOT LIMITED TO ANY WARRANTY: OF MERCHANTABILITY; OF FITNESS FOR ANY PARTICULAR PURPOSE; OF NON-INFRINGEMENT OF ANY PROPRIETARY RIGHT OF ANY THIRD PARTY IN ANY COUNTRY; OTHERWISE ARISING OUT OF ANY PRODUCT, PROPOSAL, SPECIFICATION OR SAMPLE; AND ANY WARRANTY THAT THE DOCUMENT IS ERROR FREE. No license, express, implied, by estoppel or otherwise, to any intellectual property right is granted by this document. Sage Software may make changes to the information in this document at any time, without notice. Recipient is solely responsible for assessing the suitability of the information and assumes all risk of use Sage Software, Inc. All rights reserved. Sage, the Sage logos, and the Sage product and service names mentioned herein are registered trademarks or trademarks of Sage Software, Inc., or its affiliated entities. All other trademarks are the property of their respective owners. 11/2012

5 Contents Welcome and Introduction... 1 Understanding the Manufacturing Process... 3 Understanding the Manufacturing Flow... 4 Demand Forecasts MRP/MPS Planning Understanding Planning Concepts MRP Processing MPS and MRP Results Enterprise Planning Planning Workbench Order Grouping Inquiries Advanced MRP Concepts Understanding the MRP/MPS Process Defining MRP Parameters Working with MRP Data Reorder Policy BOM Explosion Low Level Code Suggestion Characteristics Production Orders Understanding Work Orders Setting Up Entry Transaction Parameters Work Order Creation Automatic Allocations Automatic Scheduling Multi-Level Planning Viewing the List of Work Orders Capacity Planning Understanding Capacity Planning Load Recalculation Load Inquiry Certified Student Course Curriculum - Version 2.0 Page i

6 Printing Production Documents Production Reporting/Tracking Production Tracking Work Order Status Work Order Close Work Order Reactivation Tracking Plans Reintegration Plan Tracking Plans Understanding Tracking Plans Time Tracking Material Tracking Plans Production Plan Reintegration Plan Technical Sheet Plan Managing the Tracking Plans Mass Updates, Closures, and Completions Mass Work Order Updates Mass Closures and Completions Production Costing Production Cost Inquiry WIP Cost Inquiry Cost Comparison Multiple Cost Comparison WIP Valuation WIP Finalization WIP Accounting Interface Reports Printing Manufacturing Reports Summary Page ii Certified Student Course Curriculum - Version 2.0

7 Lesson 1 Welcome and Introduction Welcome to the Sage ERP X3 Fundamentals of Manufacturing training class. This course provides information on specific concepts and is intended to provide you with a basic understanding of the functions and features of the manufacturing process in Sage ERP X3. This course will help you meet the following objectives: Learn about manufacturing concepts and processes. Learn about the manufacturing planning tools. How to set up manufacturing requirements. How to process material requirements planning and view the results. How to create work orders and perform allocations and scheduling. How to track the production process. How to view actual costs compared to planned costs. How to determine the production cost for a completed work order. Certified Student Course Curriculum - Version 2.0 Page 1

8 Welcome and Introduction (continued) How to Use This Curriculum The following table describes the conventions used in this curriculum Convention Step numbers versus Practice numbers Italic font in a Practice Courier font in a Practice Explanation Step numbers are not part of a Practice and are intended to provide you with the steps typically used to complete a task. Practice numbers appear in bold and are completed in class. Items that are part of a Practice and appear in an italic font indicate you need to select a task or perform a specific action to complete the step (for example, click OK). Items that are part of a Practice and appear in courier font indicate information you should enter (for example, at the Customer No. field, enter 01-ABS). Page 2 Certified Student Course Curriculum - Version 2.0

9 Lesson 2 Understanding the Manufacturing Process In the following topics, you will learn about the manufacturing flow, principles of manufacturing in Sage ERP X3, and demand forecasts. The topics in this lesson include: Understanding the Manufacturing Flow Demand Forecasts Certified Student Course Curriculum - Version 2.0 Page 3

10 Manufacturing Series - Fundamenta als Understanding the Manufacturing Flow Among other functions that Sage ERP X3 is capable of, it also provides a powerful computer integrated manufacturing (CIM) system resulting in a highly effective production process. It helps you reduce inventory investment and production costss resulting in higher customer satisfaction. The following diagram shows a high-level view of the CIM system available in Sage ERP X3. Page 4 Certified Student Course Curriculum - Version 2.0

11 Understanding the Manufacturing Flow (continued) The following diagram shows a high-level view of how the various entities and functions in the manufacturing process work together within Sage ERP X3. A manufacture/purchase product can be executed using a work order or a purchase order. Certified Student Course Curriculum - Version 2.0 Page 5

12 Understanding the Manufacturing Flow (continued) Manufacturing Principles in Sage ERP X3 Parameters set in Sage ERP X3 feed the most accurate information coming from the category, product, product site, bill of materials, and routing. Calculation algorithms (MRP Process), control tools (Planning Workbench), and checking tools (MRP Results) provide work orders. - These work orders have dates and quantities that match the components and production resource availability constraints. - These same work orders provide purchase orders to supply components and operation orders (OW*) to control load. If running under capacity constraint, you can launch finite capacity analysis (on OWS) before running material requirements. A production order is created as close as possible to the need. This avoids inventory build-up between the end of the production and its delivery downward. Two balances are considered in the manufacturing process: - Demand/supply: Fits resources to the needs (in terms of quantity/date). For example, a purchase order (resource or supply) is triggered by the need to produce a work order which uses it. If demand is greater than supply, a shortage occurs. If supply is greater than demand, excess inventory is created. Production orders are created as a way of authorizing the manufacture of products. Page 6 Certified Student Course Curriculum - Version 2.0

13 Understanding the Manufacturing Flow (continued) - Load/capacity: Fits capacities (hours needed to perform assembly) to the planned load. Forecasting is used to level under- or over-loaded periods. Load/capacity balance answers the questions: How? How long? and When? Certified Student Course Curriculum - Version 2.0 Page 7

14 Understanding the Manufacturing Flow (continued) The following diagram shows the priority planning and capacity planning logic used in Sage ERP X3. Real-life occurrences, such as machine breakdowns and illness results in the need to react to supplier delays, queue in front of machines, etc. and the need for short term control measures, such as work order reschedule, operations reschedule, operation sequencing, etc. The process flows from planning to execution (tracking). Page 8 Certified Student Course Curriculum - Version 2.0

15 Understanding the Manufacturing Flow (continued) Manufacturing Methods There are many different methods that manufacturing companies can use to produce goods: Engineer to order (ETO): Requires a unique design by the customer. With this method, there is a unique set of part numbers, bills of material, and routings for every customer. Make to order (MTO): Goods are produced as orders from the customer are received. Assemble to order (ATO): Products are custom built from basic components or subassemblies. Finished to order (FTO): The company uses a postponement strategy during order fulfillment. Finish-to-order occurs after the customer order is received. In this case, there may be an inventory of semi-finished goods in addition to a backlog of customer orders promised for future shipment. Make to stock (MTS): Typically used for high-volume products. Items are usually produced in batches and stock is inventoried before receiving orders from the customer. The following diagram shows the demand lead times and cumulative lead time constraints for the various manufacturing methods. Certified Student Course Curriculum - Version 2.0 Page 9

16 Manufacturing Series - Fundamenta als Demand Forecasts Use Demand forecastss (GESORZ) on the Manufacturing > Planning menu to enter and view the demand forecasts for a product at a given site. This task generates orders of the type SOS (suggested sales order). Forecasts can be entered manually period by period or automatically based on the distribution information which can include the seasonality curve linked to the product or by duplicating the forecasts for another product. Sales forecasts are used to drive MPS/MRP to make suggestions to cover a forecasted sales period so out-of-stock for resale and finished good items. occurrences are minimized. Forecasts are usually entered for purchase The following illustrates the demand and saless forecast concept in Sage ERP X3. Page 10 Certified Student Course Curriculum - Version 2.0

17 Demand Forecasts (continued) Forecasts can be defined in the following buckets: Weekly Every second week Every third week The last week of the month Combinations of the above To simplify the distribution of forecasts, a calculation process can be used to distribute a quantity over a defined period of time. Sage ERP X3 allows for one forecast to be entered per week to cover the week. At the Date range field, enter the start and end dates to run the forecast against. - The start date is initialized by the horizon end date for the request or by the current date if there is not one. Certified Student Course Curriculum - Version 2.0 Page 11

18 Demand Forecasts (continued) The request horizon, the seasonality curve, the economic lot, and the technical lot are loaded after selecting the product. On the grid, the quantities are detailed by week for each month. The last two columns specify the start and end dates for the month. - For each forecast line, the totals by month are displayed at the end of the line entry, and at the end of the general entry, the percentage information is displayed. - These forecasts can be modified directly in the grid, deleted, or modified. - If the firm and/or planned orders have been requested, they are inserted in the forecast succession. Grouping Criteria Click Criteria to group by different selection criteria. This allows you to: - Display the forecast for another product at the same site. - Display forecasts for the product on a different date range. - Display the customer orders, firm and/or planned. These orders are inserted amongst the forecasts. Page 12 Certified Student Course Curriculum - Version 2.0

19 Demand Forecasts (continued) If you selected to display the customer firm or planned orders, you can click the graph icon in the grid to view the information in graphical format as shown below. If you selected the Log check box, during the forecast validation, a log displays the demand forecasts entered, calculated, and not modified. You can also create a memo in order to save these settings for future use. Certified Student Course Curriculum - Version 2.0 Page 13

20 Demand Forecasts (continued) Regrouping Forecasts Click Regroup to group several forecasts within a period. First, indicate the start and end months for the regrouping. For the end month, you can select the End of grid check box to load the end month with the date of the last forecast. Next, select the grouping and rounding methods to use. Page 14 Certified Student Course Curriculum - Version 2.0

21 Demand Forecasts (continued) Calculating the Forecast Click Calculate to enter the information needed to run the calculation, such as: - The date range (the calculation period is pre-loaded with the horizon entered in the main window). - The quantity to be distributed (initialized by the total amount for each line). - The distribution method for this quantity in the horizon (week by week, all on week 1 of the month, all on week 2 of the month, all on week 3 of the month, or all on the last week). At the Trend profile field, you can associate a seasonality curve on this data. This is an allocation curve used to create forecasts, based on a seasonality variation structure. The forecast quantity is distributed according to the distribution method selected and the period defined. After clicking OK, the distributed forecasts can be viewed and adjusted in the Demand Forecast grid. Click Save to create the new forecast. A message displays indicating that the existing forecast will be replaced with the new one. Click OK. Certified Student Course Curriculum - Version 2.0 Page 15

22 Lesson 3 MRP/MPS Planning In the following topics, you will learn about the material requirements planning (MRP) and master production schedule (MPS) planning tools, how to work with enterprise planning and workbench tools, how to group orders, as well as how to view MPS and MRP inquiries and reports. The topics in this lesson include: Understanding Planning Concepts MRP Processing MPS and MRP Results Enterprise Planning Planning Workbench Order Grouping Inquiries Page 16 Certified Student Course Curriculum - Version 2.0

23 Understanding Planning Concepts Planning in manufacturing involves the process of using the tools to define the total level of the manufacture demand plan of production in order to support the firm sales and possible sales (forecasts). The following are used in Sage ERP X3 regarding planning in manufacturing. - The strategic plan Master Production Schedule (MPS) - The industrial plan Material Requirements Planning (MRP) - Behavior based on parameters Sage ERP X3 has an operational type planning comprising of the following functions: - Management of the forecasts - Management of the Master Production Schedulee - Calculation of the net requirements - Work order management The following diagram shows a high-level view of the planning sequence in a manufacturing system: S&OP = Sales & Operation Planning MPS = Master Production Scheduling MRP = Material Requirements Planning Certified Student Course Curriculum - Version 2.0 Page 17

24 Understanding Planning Concepts (continued) MRP and MPS Planning Tools There are two main planning tools available: Material Requirements Planning (MRP) and Master Production Schedule (MPS). MRP: The primary goal of MRP is to consider current demand for a given period, attempt to cover that demand using existing resources (firm work order), or to make a replenishment suggestion to cover the demand while maintaining inventory levels above the safety stock minimum. - MRP calculates the results based on the parameter settings of both the productsite record and the requirement parameters. - MRP calculates the net requirements by site concerning the products subjected to dependent demand. MRP uses bill of material and inventory information, and the Master Production Schedule (MPS) to calculate the requirements for materials. - Suggestions are then made to release replenishment orders for material and to reschedule open orders as needed. - The following diagram shows the logical flow for the calculation of net requirements in MRP: Page 18 Certified Student Course Curriculum - Version 2.0

25 Understanding Planning Concepts (continued) - The following diagrams show an MRP calculation example: Departure = 0 diagram = 35 hours Certified Student Course Curriculum - Version 2.0 Page 19

26 Understanding Planning Concepts (continued) MPS: MPS calculates the requirements for finished goods, generating a proposed production schedule. Net requirements are calculated by site concerning products that are subjected to independent demand, such as customer orders and commercial forecasts. - The MPS process is usually set up in batch to run each evening. - Planning is done on a daily basis and the MPS results are reviewed to react to any scheduling changes. Order Types Orders can affect the supply and demand balance in manufacturing. Demand/needs: - Customer - Internal - Inter-site (inter-company) Supply/resources: - Supplier - Internal - Inter-site (inter-company Page 20 Certified Student Course Curriculum - Version 2.0

27 Understanding Planning Concepts (continued) Orders can be identified by three letters comprising of a document type and status. - A document type: two letters (WO, SO, PO) - A status: one letter (F, P, S) The following diagrams further define the order types available in Sage ERP X3: S = Suggested, P = Planned, F = Firm N = Need R = Resource S = Suggested, P = Planned, F = Firm N = Need R = Resource Certified Student Course Curriculum - Version 2.0 Page 21

28 Understanding Planning Concepts (continued) S = Suggested, P = Planned, F = Firm N = Need R = Resource The following diagram shows the affects created by firm resource (WOF), planned resource (WOP), and suggested resource (WOS). Use the Automatic Release task accessed from Manufacturing > Batch processes to change the status of work orders in mass from suggested to planned or from planned to firm. You can use a formula or filters to select groups of work orders. - WOS becomes WOP - WOP becomes WOF Page 22 Certified Student Course Curriculum - Version 2.0

29 MRP Processing As mentioned previously, Material Requirements Planning (MRP) is a process for defining the component requirements with respect to the demand for parent products. MRP makes it possible to draw the difference between component and parent product requirements (independent and dependent requirements). It is run separately for each warehouse. MRP processing is also used to issue suggestions (ordering, manufacturing) on requirements, which will be scheduled over time and quantified with respect to the established rules and parameters. MRP processing in Sage ERP X3 is multi-site, successive regeneration processing that uses a special routing and BOM (MRP type code). Depending on the various parameterizations, it can generate a load, draw up a suggestion analysis, submit a rescheduling message, and generate various suggestions (over-stock analysis, expiry date). MRP processing deals with the various requirements that generate various resources. Requirements and resources can be of Suggested, Planned, Firm type. Only those products associated with a reorder mode by MRP are taken into account (requests or requirements) by the calculation. The following parameters must be assigned: Scheduling parameter MRP parameterr The reorder policy mentioned on the product-site record The management rules described on the product-site Certified Student Course Curriculum - Version 2.0 Page 23

30 MRP Processing (continued) Use MRP processing (FUNMRPG) on the Manufacturing > Planning menu to enter the information for the MRP calculation, such as the start date and which site to run the calculation against. All the orders to be processed showing a date earlier than the reference date are assigned to this date. - Based on the calculation periods and the start date, the number of periods will be readjusted. If a problem arises during the MRP calculation, select the Display progression check box to display the product being processed. Page 24 Certified Student Course Curriculum - Version 2.0

31 MRP Processing (continued) After clicking OK to run the calculation, a log similar to the following is displayed. The log shows a recap of how parameters were set up when MRP was run. - Be sure to review the log for any errors that may have occurred during processing. - You may need to scroll down to view all the information in the log. - Click Delete to permanently delete the log (optional). Certified Student Course Curriculum - Version 2.0 Page 25

32 Manufacturing Series - Fundamenta als MPS and MRP Results Use MRP results (CONSSCBPD1) and MPS results (CONSSCBCB1) on the Manufacturing > Inquiries > Reorder results menu to view the MRP and MPS results for a specific product and site. The inquiries are for single site and products only. It provides a way to track MRP results on a product by product basis. Use the header section to specify the main selection criteria for the inquiry, such as the site, product, category, date calculated. MRP MPS Results Tab For the product selected, the system reproduces the principal information concerning the management method for the product for the reorder, with BOM having served as an aid to the following: - Requirements calculation - Management method - Suggestion type reproduced by the MRP - Possible coverage - Reorder site - Reorder strategy for the product - Demand horizon and firm horizon Page 26 Certified Student Course Curriculum - Version 2.0

33 MPS and MRP Results (continued) - Starting stock taken into account by the calculation - Percentage loss for the product The system also reproduces the principal stock data for the product: total internal stock, stock waiting put-a-way, total loaned stock, total stock at sub-contractor, cumulative allocated quantities, and cumulative suspended stock. In the MRP MPS results grid, you can view the following for each order: - The document number - The requirement date, end date, start date - The requirement or resource quantity - This quantity is negative when it is a requirement, it is positive when it is a resource. - The projected stock that makes it possible to see the progress of the stock - The remaining quantity represents the quantity taken into account in the MRP process (resources, demands) - The allocated quantity on the firm resource or the firm demand - The order and the order number with the requirement source - Source product - The MRP message - The MRP date (end date calculated at the time of analysis with re-planning, uniquely in simulation) - The MRP quantity (quantity calculated at the time of analysis with re-planning, uniquely in simulation) Buttons Click Search to view the results of the MRP. Click Criteria to access and set additional selection criteria. Click WIP to view the status of the order in process. Click Site stock to view the stock total for the product. This launches the Stock by Site Report task. Click Re-order policy to view the reorder policy for the product. This launches the Replenishment policy task. Click Product to view the product information. This launches the Products task. Click Product site to view the product site information. This launches the Product - site task. Certified Student Course Curriculum - Version 2.0 Page 27

34 MPS and MRP Results (continued) Understanding MRP Messages The following table shows the possible MRP messages and suggested actions. Message from MRP MRP suggests the following action No Action Advance Delay Increase Reduce Cancel Advance/Increase Advance/Reduce Delay/Increase Delay/Reduce Delay Firm Horizon Obsolete Product (end of life) Overstock Late Shortage No action required. This means that No extraordinary action is required. Change the date to an earlier date. Change the date to a later date. Increase the quantity. Reduce the quantity. No longer necessary and can be deleted. Change the date to an earlier date and increase the quantity. Change the date to an earlier date and reduce the quantity. Change the date to a later date and increase the quantity. Change the date to a later date and reduce the quantity. Late compared to the objective date. Expired product Stock level is over the maximum level (the option Maximum stock level must be selected in Inventory Requirement Parameters). Associated with SOF if not shipped out on time. Associated with SOF if insufficient stock. Page 28 Certified Student Course Curriculum - Version 2.0

35 Enterprise Planning Enterprise planning is a tool for decision making provided to planners, schedulers, and material managers. The main objectives of the Enterprise planning task is to highlight the critical events and act on MRP messages for orders subjected to re-planning. This is the big picture view of MRP using all products, warehouses, sales orders, etc. The Enterprise planning workbench serves as a work queue for the planner. This allows the planner to review work order suggestions generated from MRP to make planning decisions for the manufacturing process. The planner can also make production decisions based on material shortages, current inventory levels, and current demand. The following functionality is also available: The definition of profiles differing according to the role of the manager (planner, supplier, buyer, etc.). Offers a multi-site and multi-product view of all the activity to be managed over a given period of time. Allows action on the restored orders. Use Enterprise planning (FUNGBENCH) on the Manufacturing > Planning menu to view critical events and act on MRP messages. After the selecting Enterprise planning, a Transaction Selection windoww is displayed allowing you to select the transaction template to use. Certified Student Course Curriculum - Version 2.0 Page 29

36 Enterprise Planning (continued) After selecting the transaction template, the following window appears. The End date field makes it possible to filter the orders to be loaded. Page 30 Certified Student Course Curriculum - Version 2.0

37 Enterprise Planning (continued) Viewing Results Click Search in Enterprise planning to view the results based on the selection criteria. Certified Student Course Curriculum - Version 2.0 Page 31

38 Enterprise Planning (continued) Selecting Additional Criteria Click Criteria in the Enterprise planning task to access additional selection criteria to filter the results on. Page 32 Certified Student Course Curriculum - Version 2.0

39 Enterprise Planning (continued) Creating Purchase/Delivery Requests or Purchase Orders Click Repl in Enterprise planning to create a purchase request, delivery request, or purchase order. - The delivery request or the purchase order can be of inter-site or inter-company type depending on the selected supplier. - Click Suggest to create suggested procurement orders. Certified Student Course Curriculum - Version 2.0 Page 33

40 Enterprise Planning (continued) Creating Work Orders Click Manufacturing in Enterprise planning to create a new work order, planned (WOP) or firm (WOF). - Click Suggest to create suggested procurement orders. Creating Sub-Contract Orders Click Subcontract in Enterprise planning to create a sub-contracting order. Page 34 Certified Student Course Curriculum - Version 2.0

41 Enterprise Planning (continued) Accessing the Product Workbench Click Planning workbench in Enterprise planning to access the product workbench to view the projected stock information. Accessing the Grouping Workbench Click Regroup in Enterprise planning to access the grouping workbench. For example, this feature can be used to identify products purchased from the same supplier and consolidate them into the same lines. For more information, see Order Grouping in this lesson. Certified Student Course Curriculum - Version 2.0 Page 35

42 Enterprise Planning (continued) Viewing Component Availability You can right-click the suggested work order line in the Enterprise planning grid, and then select Stock inquiry to view the component availability. Page 36 Certified Student Course Curriculum - Version 2.0

43 Enterprise Planning (continued) You can also check the availability of the finished good and review the current inventory levels by right-clicking the line in Stock by site and selecting Available stock. - The Available stock task displays the following information for you to view: Current inventory levels Existing resources Total demand for the item Available to promise amount Certified Student Course Curriculum - Version 2.0 Page 37

44 Enterprise Planning (continued) Generating a Work Order After a work order suggestion (WOS) is reviewed and verified for production by the planner, a work order can be generated from the workbench. Steps for generating a work order: 1. In Enterprise planning, right-click the work order suggested (WOS) line and select Plan/Initiate. 2. Select the All (Full entry) entry transaction. 3. You can modify the quantity and change the requirement date as needed. 4. Accept the default BOM and routing codes. 5. Click Release to make a firm work order (WOF). 6. Review all the work order suggestions in the workbench and repeat these steps until all planning is completed. Deleting a Work Order When reviewing the MRP results, a planner can make a decision on whether to manufacture an item or remove the suggested work order from the work queue. Steps for deleting a work order: 1. In Enterprise planning, right-click the work order suggested (WOS) line and select Plan/Initiate. 2. Click Delete. 3. A confirmation window appears followed by a second deletion confirmation. 4. The work order suggestion is now removed from the planning window. Note: If there are demand requirements for the item being planned, the work order suggestion is re-created the next time MRP is processed. Page 38 Certified Student Course Curriculum - Version 2.0

45 Planning Workbench The planning workbench helps in the decision-making process by further filtering data to provide a snap shot of the projected stock by product and by site over a given period. When entering additional criteria to filter the results on, you can enter formulas that use the WIP, product, and product-site In contrast to Enterprise planning, Planning workbench only tables. Unlike MRP results, orders are acted on and updates are made instantly. uses one warehousee and one product. It is similar to Enterprise planning, but on a smaller scale. Use Planning workbench (FUNDBENCH) on the Manufacturing > Planning menu to view the projected stock. Certified Student Course Curriculum - Version 2.0 Page 39

46 Planning Workbench (continued) After selecting the transaction template, the following window appears. Page 40 Certified Student Course Curriculum - Version 2.0

47 Enterprise Planning (continued) Selecting Additional Criteria Click Criteria in Enterprise workbench to access additional selection criteria to filter the results on. Filters The options in the Filters section are used for. Ignore pending issues: Select this check box so that suspended transactions are not subtracted from the available starting stock. Include the stock under QC: Select this check box so that controlled stock is included in the available stock. Ignore previous lost sales: Select this check box to ignore sales forecasts of which the date is before the current date. Apply % loss: Select this check box if the remaining quantities of work orders must be reduced in the percentage of product-site loss. Suggestion Filter Use the Suggestion Filter options to filter the suggestions based on MPS, MRP, or both. Display Use the Sort Criterion to select to display the criteria by date or requirement date. Certified Student Course Curriculum - Version 2.0 Page 41

48 Manufacturing Series - Fundamenta als Order Grouping Use Grouping (FUNMPICK) on the Manufacturing > Planning menu to group and cover the requirements with a single reordering order. This completes the order in the planning workbench and global planning. Depending on the template you select, the fields in the transaction entry window will be different. Select a transaction and click OK. The header section is used to select the current orders that are being grouped. Page 42 Certified Student Course Curriculum - Version 2.0

49 Order Grouping (continued) Double-click the Pick field to enter a check mark, which selects the product for grouping purposes. The Qty. taken in STK field is the quantity to be taken into account in the grouping process. The Start date and End date fields identify the first and last days of the period over which an allocation is defined. - You can define up to 53 periods. - Periods must be consecutive and without gaps. - The curve must be defined from 01/01 to 12/31. The Planned quantity field indicates the planned quantity, expressed in sales unit, for this contract product. This field is for information purposes and is used during price list searches. The Quantity Allocated field indicates the quantity allocated to the order line. The Shortage field indicates the shortage quantity. The Total actual quantity field is the total quantity carried out, including the rejected quantity. This quantity is expressed in operation units. The Priority field is used to assign a priority to the supplier in the selections. The BOM Code field identifies the single product reference that is used by several BOMs. These codes are used to: - Manage structures of different products according to their use - Requirement calculations - Sales order entry - Production At the Operation Number field, the components can be linked to routing operations according to the manufacturing process requirements. The Planner/approv. field is used to activate actions on the work orders. At the Buyer field, enter the operator in charge of reordering the product for the considered site. Several processes refer to this code: - Buyer s product planning workbench - Supplier order entry Certified Student Course Curriculum - Version 2.0 Page 43

50 Order Grouping (continued) Nature of Generated Order The nature of the generated order depends on the role assigned to the transaction on which the grouping is based, whether it is a planned or firm work order, planned or firm sub-contracting order, purchase request, or planned or firm inter-site replenishment order. A work order or sub-contracting order covering sales orders or production or subcontracting requests increments the "Quantity taken into account at release" field of these orders. The production release is made according to the release transaction dedicated to the automatic release, a transaction based on the current Enterprise Planning Workbench transaction, and in its absence on a general parameter. The selected scheduling method is the one planned at the level of the automatic release transactions and it cannot be modified. The sub-contracting release is made according to the release transaction dedicated to the automatic release, a transaction based on the current Enterprise Planning Workbench transaction, and in its absence on a general parameter. The creation of a planned or firm purchase order is carried out with the following groupings: - A firm delivery request is generated for each planned delivery request - A firm purchase order by supplier - An order line by product / project. Note : In order to keep a log of the requirements taken into account, a planned work order (WOP) coming from a grouping is of type WOP* and can no longer be the object of a grouping to a planned order. Grouping Grid Use the grid to enter the following: The document number and line identify the source of the stock movements, such as: - Supplier receipt - Customer delivery - Work order - Receipt movement Page 44 Certified Student Course Curriculum - Version 2.0

51 Inquiries There are many inquiries and reports available in Sage ERP X3 for viewing manufacturing information. These inquiries and reports contain a wealth of information. Viewing Inquiries The MRP/MPS inquiries are located under the Manufacturing > Inquiries menu. Certified Student Course Curriculum - Version 2.0 Page 45

52 Lesson 4 Advanced MRP Concepts In the following topics, you will learn about Material Requirements Planning (MRP) concepts beyond what you learned in the Manufacturing Fundamentals course. Classified as a proactive approach, MRP uses Bill of Materials to calculate requirements. MRP provides relevant results in maintaining the due dates and also provides information for reducing inventories. The topics in this lesson include: Understanding the MRP/MPS Process Defining MRP Parameters Working with MRP Data Reorder Policy BOM Explosion Low Level Code Suggestion Characteristics Page 46 Certified Student Course Curriculum - Version 2.0

53 Understanding the MRP/MPS Process The purpose of MRP is to propose suggested orders for manufacture and purchase (provider, inter-sitee provider, or sub-contract provider) in order to ensure that the considered demands (sales orders, forecasts, etc.) are satisfied. The orders are dated to allow for the timely flow of materials from suppliers, through the production process and to the finished stock or customer. MRP examines each selected product, either in time buckets, or by demand order, and considers the following questions: Every piece of information and setting is examined and influences the answers to these questions. MRP principals are usually short term and determine what is needed to meet existing schedules. MPS (Master Production Schedule) is the process of applying MRP principles to a business plan, in order to ensure the practicality of the plan while also considering all business constraints. We will start by looking at the settings and controls that influence the MRP/MPS process. These settings and controls are located throughout Sage ERP X3 and are accessible to the correct users (buyers, planners, inventory control managers, etc.) Certified Student Course Curriculum - Version 2.0 Page 47

54 Understanding the MRP/MPS Process (continued) Some of the controls include: - The requirements planning parameters - The product site planning settings - The reorder policies - The general parameters Page 48 Certified Student Course Curriculum - Version 2.0

55 Defining MRP Parameters MRP is a shared tool between the planner and the buyer; therefore, they should agree on the settings in Requirements parameters (accessed from the Setup > Inventory menu). As you learned in the Manufacturing Fundamentals course, Requirements parameters is made up of four tabs for both MRP and MPS parameters. As MRP and MPS are similar in their processing, they share similar settings. Note that they are not set on the same lead time and not set with the same requirements and supplies. Certified Student Course Curriculum - Version 2.0 Page 49

56 Defining MRP Parameters (continued) - Two of the tabs are dedicated to MRP: MRP calculation, and MRP calculation 1, and two of the tabs are dedicated to the MPS. The Management variables are identical to the MRP tabs. You should regularly run the Low-level codes resynchronization task to maintain the accuracy of the BOM tree structure. It identifies changes to the lowest levels of the BOM structure allowing for the most accurate MRP and MPS processing. MRP and MPS needs to determine where the lowest levels of the tree are in order to know where to start identifying material requirements. For more information, see Low Level Code in this document. MRP Calculation Tab Use the MRP Calculation tab to define all the processing parameters. Processing Section The following provides information about the settings in the Processing section in Requirements parameters. Weekly structure: This is the time period the facility is operational. The weekly structure applies to the population of produced goods. The purchased goods are subjected to calendar lead times. Common settings are 085 for 5-8 hour days or 165 for 5-16 hour days with 2 shifts. BOM code: This is the BOM code that will be used for developing the dependent demands for a suggested work order (MW*). - The same value will be applied to all products. - The selected value must allow MRP (or MPS) processing. - A TPOP (Time Phased Ordered Point) dedicated to purchase-sold products, can be run with a BOM code, even if the product does not need a BOM code. - Note: The MRP calculation is based on a unique BOM code. Page 50 Certified Student Course Curriculum - Version 2.0

57 Defining MRP Parameters (continued) Replanning analysis: - An order that the end date exceeds the last day of the horizon (expressed in weeks) is not replanned. - A back to back order is not replanned. - From a production point of view, the replanning analysis manages neither the By Order management coming from the product file (a WOF linked to a SOF can be replanned), nor material availability (unless its component is replanned managed), nor a possible overload that may occur during a work order replanning. Load calculation: Load calculation uses routings and schedule loads. At each work center, a load profile is established based on MRP suggestions (blue color for suggested load, green for planned, and orange for firm). - Material need dates, in the MRP process with load calculation, match the operation start date. The process uses the routing during load calculation. In the case where the component is linked to an operation in the BOM, the process can update material (sub-part) need date. After the load calculation horizon, the MRP bases its calculation on the product-site procurement or manufacturing lead time. - The buckets delimit the MRP processing horizon (priority planning). Use caution when a load calculation (CRP; capacity planning) is run for a certain horizon (scheduling parameter in Setup > Manufacturing > Scheduling), you must fit priority planning buckets with capacity planning buckets. Remember that the CRP is coupled to the MRP release. - The following illustrates a load calculation. If a number of weeks is set on the Load calculation field on the MRP calculation tab, it triggers OWS. If it is set on the MPS calculation tab, it triggers ORS in Sage ERP X3. Certified Student Course Curriculum - Version 2.0 Page 51

58 Defining MRP Parameters (continued) Maximum stock analysis: Maximum stock analysis triggers VRS ORDERS records only visible in the MRP (MPS) result. The MRP quantity for the VRS indicates the level of the projected stock at the end of a bucket if this level is higher than the maximum + technical lot. - Maximum stock and technical lot are defined in Product category or Product sites (Planning tab). - These can be reported from the table, CBNDET, selecting WIPTYP = 11, MRPMES = 13. Product selections: Only products managed in stock on this site could be analyzed by the MRP processing. It depends on the Product sites reordering mode being MRP or MPS. - Select the MPS and MRP products check box to process all MPS and MRP management products. Warning: Previous suggestions and replanning messages will be erased and replaced for all processed products. - Normally, all products will be process, taking into account all MWS (either generated from the MRP process, or remaining from the MPS process. - Suggestions are only passed to ORDERS according to the selections. - The following illustrates the processing that occurs with the MPS and MRP products check box cleared and the Exclusive selection check box cleared: Page 52 Certified Student Course Curriculum - Version 2.0

59 Defining MRP Parameters (continued) - If the MPS + MRP products check box is selected, MPS products will display an MRP origin because the calculation processes them in the same say as the MRP reorders. If the MRP has been released beforehand, the gross requirements on the MRP population will be doubled. Additionally, if you select the Exclusive selection check box, the system will only place one suggested resource facing the one whose origin in now MRP (and not two that would be incorrect). Therefore, it is highly recommended that whatever happens, the Exclusive selection check box remains selected. - The following illustrates the processing that occurs with the MPS and MRP products check box selected and the Exclusive selection check box cleared: - Two changes occur if the Exclusive check box is selected: o Only the selected products are processed. o Where a WOS remains from another process on a product included in this process, its MWS will not be considered as dependent demands. o Exclusive selection respects the product s MPS origins. The MRP traditionally exploits MPS type MWS requirements. This means that MRP suggestions will be determined through the requirements (MWS) emitted by independent products with an MPS origin. Certified Student Course Curriculum - Version 2.0 Page 53

60 Defining MRP Parameters (continued) - The following illustrates the processing that occurs with the MPS and MRP products check box selected and the Exclusive selection check box selected: - When a RCCP has run before MRP, manufacturing lead times for MPS product are unfortunately based on product load profile. The MPS and MRP products check box should be selected in order to have realistic lead times (based on routing). - You should regularly run the lowest code level resynchronization task. Buckets Section Refer to Understanding Time Buckets in this lesson. Page 54 Certified Student Course Curriculum - Version 2.0

61 Defining MRP Parameters (continued) Starting Stock Section The following provides information about the settings in the Starting stock section in Requirements parameters. Starting Stock: Starting stock is the site physical stock (according to the following selections), less the allocations. Allocated requirements (MWF, SOF) are not considered as demands. Dock stock and subcontract stock are considered available for MRP, unless the subcontract stock is allocated. Note: If you want to exclude subcontract stock from starting stock, you can use the entry point STRSTO in MRP processing. You can create the STODISSCO general parameter linked to the global variable GSTODISSCO. If the value is set to 1, the subcontract stock will no longer be included in starting stock. - On hand: Select On hand to specify if the physical stock must be included in the calculation starting stock. If selected, allocations will be deducted from the starting stock. - QC: Each quality control (QC) request is analyzed and a VRF (miscellaneous resource) is created in the CBNDET table for the quantity/end date. This setting specifies whether: o The stock under control must not be included in the starting stock. o The stock under control must be thoroughly included in the starting stock. o The stock under control must be included to the available stock at the control end date. - Rejected: Specifies if the starting stock must include the rejected stock. - Transfers: Specifies it the current transfers must be included in the starting stock of the calculation. - Stock phantoms: Select this check box if the calculation must take the phantom product stock into account. Certified Student Course Curriculum - Version 2.0 Page 55

62 Defining MRP Parameters (continued) Requirements Section The following provides information about the settings in the Requirements section in Requirements parameters. Select from: - Sales orders (SO*) and Transfer demands (TPx) can be included or excluded. - Work order material requirements (MWP and MWF) are always included. - Suspended transactions can be included or excluded. - Sales forecasts (SOS) can be offset. Resource Section The following provides information about the settings in the Resource section in Requirements parameters. Select from: - Work orders (WO*): Then the work order material requirements suggested (MWS) are included in the requirements. - Purchase orders (PO*) - Transfers (TR*) Page 56 Certified Student Course Curriculum - Version 2.0

63 Defining MRP Parameters (continued) MRP Calculation 1 Tab As you learned in the Manufacturing Fundamentals course, the MRP calculation 1 tab is dedicated to replanning rules, display of messages aimed at optimizing resources already positioned, and various adjustments concerning data set in the product site and the reordering policy. For more information, refer to your Manufacturing Fundamentals curriculum. Certified Student Course Curriculum - Version 2.0 Page 57

64 Manufacturing Series - Fundamenta als Working with MRP Data Settings within many tasks in Sage ERP X3 affect MRP processing. This topic explains some of these settings in Products and Product sites. The Material Requirements Planning program may be processed on a site of the following types: Manufacturing Stock (a BOM code is mandatory despite the lack of BOM for bought-sold products). Product site managed stock Products Use Products from the Common data > Products menu to make settings affecting the MRP process. - Management mode: Affects By Orderr or Available Stock. - QC management: Influences the stock status. This has an impact on the reservations and the stock available take into account in the MRP process. - Expiration management: Reserved to the product with lot management. This influences the stock status and has an impact on the reservations and MRP. This can trigger VDS orders to plan the issue of the lot from the stock available (only in the inquiry MRP results or MPS results). Product - sites Use Product - sitess from the Common dataa > Products menu to make settings affecting the MRP process. - Firm horizon: The horizon (in weeks or months) is used to set a frozen zone for planning reasons during which MRP cannot place any suggestion. - Demand horizon: Inside the demand horizon, the forecasts are ignored and beyond the maximum (SOP + SOF, SOS) is considered.. - Trend profile: The trend profile is used to adapt to a producedd good or purchased good in MRP (see the STO > REA > MRPDYNSAF general parameter) or to build calculated forecasts. - Production, QC, purchasing lead time: Variables taken into account in the MRP process and order management. - Digressivity factor: The digressivity factor is used to adapt the order lead time in proportion to EOQ. It is used in the MRP process and the work order (technical lot). Corrected lead time = DR*(1+ (quantity/lot 1)* *coefficient/ 100). Page 58 Certified Student Course Curriculum - Version 2.0

65 Working with MRP Data (continued) - Multi-level lead time: This is the cumulative lead time. The Multi-level planning task can calculate this lead time (Manufacturing > Planning > Multilevel planning). - Assignment rule: Does the component need to be linked with its parent? Does the finished good need to be linked with the sales order? - Reordering policies: The products are able to be reordered according to the reorder point, re-completion, or MRP/MPS methods. If the choice is MRP or MPS, a re-ordering policy is entered. - Coverage: Each bucket triggers a suggested order with a quantity equal to the sum of the x next week s needs (SOP/F, MWP/F ), even if the system is demand/supply balanced. It is called Time Period Safety Stock. - Suggestion type: The nature of the planned order created by MRP/MPS depends on this choice. If the suggestion is inter-site, the reordering site must be entered. - Safety stock: The safety stock defined is taken into account in MRP according to two conditions: o The reorder policy defines that it must be taken into account o The parameter of the MRP - Reorder point: The reorder point can be entered if the ROP method has been chosen. - Maximum stock: The maximum stock can be entered if periodical replenishment was chose. - EOQ: The economic lot can be an external, internal, or economical constraint. o External: Supplier capacity o Internal: Profitability of a mold or of a tank refill, for example o Economical: The economic lot can be used in a reorder policy specific to each product. The Wilson formula as shown below is a formula that is also used to refine the calculation of a manufacturing or purchase lead time. If my reorder requirement is 300 quantities will it take me 5 to 10 days knowing that my lead time is 5 days for a lot of 150? D = Requests over a certain period (year) CI = Release cost Unit cost t = rate of carrying cost o You can adjust the size of the economic lot considering several points: warehouse size, handling considerations, spoilage, whether there is enough staff (such as craftsmen for setup), and whether to round for tool wear and tear. Certified Student Course Curriculum - Version 2.0 Page 59

66 Working with MRP Data (continued) - Technical lot: The technical lot is subject to a technical constraint. It is used in the MRP as much for purchased products as manufactured products, but also and especially in manufacturing releases. The technical lot is a subdivision of the economic lost and offers the possibility of splitting up the reorder suggestions into multiple lots. For example: A manufacturing order of 1,000 is given by MRP, while the economic lot is 500 and the technical lot is 100. The system can display 10 suggestions of Protection in process (replan): the orders in process can be excluded from replanning. General Parameters GPNLFLT: Sage ERP X3 tests the field (Planner / Buyer) for the creation of WOP, WOF, or POP. - Yes: If no planner, the workbenches display all orders. - Yes exclusive: If no planner, nobody can reorder. BUYFLT: Tests the field buyer for the creation of POFs. - If BUYFLT is Yes and no buyer is entered in the product site, everybody can reorder. - If BUYFLT is Yes and a buyer is entered in the product site, only this buyer can reorder. Page 60 Certified Student Course Curriculum - Version 2.0

67 Reorder Policy Products are able to be reordered according to the reorder point, periodic, or MRP/MPS methods. If the choice is MRP or MPS, a re-ordering policy is entered. Reorderr policies are used exclusively with MRP/MPS methods. They are not considered if the reorder method is ROP or periodic. The reorder policy is a set of rules that modify how MRP/MPS behaves with respect to the product it is associated with. A reorder policy is associated with the product on the product site record (Planning tab) the reorder policy can be different for each product at each site. Use Reorder Policy on the Common data > Product tables menu to define the reordering policies used in the MRP and MPS processes. This allows for distinctive management of quantities to be manufactured or purchased per product. The reordering policies are used for a given product to specify certain details during the requirements calculations (MRP and MPS) to identify the suggestion type, the reorder quantity, the splitting, safety stock, use of the loss percentage, and the replanning analysis. Certified Student Course Curriculum - Version 2.0 Page 61

68 Reorder Policy (continued) The reorder quantity field has the following options: - Net quantity: The suggestion is the same quantity as the demand. It is normally important to use this for products whose management mode is By Order. - Minimum quantity without rounding: Any quantity equal or greater than the EOQ. - Minimum quantity with rounding: Equal to the EOQ by a multiple of technical lot. The Splitting field has the following options: - No splitting: One suggestion per period or demand. - Parallel splitting: One suggestion per technical lot, all on the same dates. - Successive splitting: One suggestion per technical lot, distributed across the lead time. Example: EOQ = 500, Technical lot = 100 The following table shows suggestion based on needed quantities, whether or not splitting is used and whether new quantity, minimum quantity without routing or with routing is used. Reorder Qty Splitting Need = 450 Need = 650 Net quantity No splitting 1 suggestion = suggestion = 650 Splitting 4 suggestions of suggestion = 50 6 suggestions of suggestion = 50 Minimum No splitting 1 suggestion = suggestion = 650 quantity Splitting 5 suggestions of suggestions of without 1 suggestion = 50 rounding Minimum quantity with rounding No splitting 1 suggestion = suggestion = 700 Splitting 5 suggestions of suggestions of 100 The safety stock entered in Product sites may or may not be subject to replanning. Additionally, the product that assigns replanning analysis may or may not be subject to replanning. Page 62 Certified Student Course Curriculum - Version 2.0

69 BOM Explosion The principle of BOM explosion is to analyze the upper level of the BOM in order to know the component needs. Component purchase orders are anticipated because of its dependent demand on the parent product in a work order. The work order start date (suggested, planned, or firm) is used as the due date (expected receipt date) for the procurement. The following illustrations indicate the suggestions thatt occur with and withoutt pegging. Note: Pegging indicates the relationship between supply and demand. It determines the quantities needed for the components by the parents and also the schedule for which they are needed. Suggestion with MRP Pegging: BOM explosion analyzes the upper level of the BOM in order to determine the component needs. Component purchase orders are anticipated because of its dependent demand on the parent product in a work order. - It is important to define the most-used BOM for every product under the same BOM code. Certified Student Course Curriculum - Version 2.0 Page 63

70 BOM Explosion (continued) Suggestion without MRP Pegging: This could be useful if the planner wants to base the semi-finished and component analysis after the creation of a planned or firm work order on the finished good. - With this kind of organization, the scheduling is done per low level code, and the MRP is run many times. In this example, the scheduling of all the finished goods is done in the first stage. Then, a new MRP is run on the dependent demand on component (MWP/F - and the semi-finished goods are scheduled). A last new MRP is run on dependent demand on component (MWP/F and finally the raw materials are purchased). MRP Pegging Only: This is used for phantom product. The following table shows the types of suggestions: Table MRP Work File CBNDET Planning Orders Type of suggestion WOS MWS WOS MWS No suggestions Yes No No No Parent and components Yes Yes Yes Yes (suggestions with MRP pegging) Parent Only Yes No Yes No Components Only (MRP pegging records only) Yes Yes Yes, zero quantity Yes The normal setting is parents and components. - Parent only: The finished good is make to order (MTO) managed and its MRP suggestions respond to firm sales orders. Its components are make to stock (MTS) managed with MRP suggestions responding to forecasts. Therefore, the MRP pegging triggered by the upper level must not be taken into account for suggestion generation. SOS and MWS cannot be accumulated in that case. Or, the planner or buyer may want to wait before the WOS is validated into a WOP or WOF before planning (if there is a semi-finished good involved) or before buying (for raw materials). As a WOS is transformed into a POF or can be validated on a different BOM code, the requirement on the component can be changed completely, so there is a risk to planning and buying before the WOS validation. - Components only: is useful in an engineer to order (ETO) environment where work orders are released manually. It is also used for a phantom with this expected behavior: no WOS on the phantom product but a requirement on its component. The work order should not be created until the BOM is complete. While the designers are adding components to the BOM, this ensures that MRP will procure the components without any possibility of accidently releasing a work order which is not linked to the sales order. Page 64 Certified Student Course Curriculum - Version 2.0

71 Low Level Code Before carrying out an analysiss of a product, make sure to generatee all the dependent demands that affect it; therefore, creation or modification of bills of material maintains an absolute low level code for each product. This represents the lowest level at which it appears in any BOM. Within a BOM, all components must be at a lower level than the parent. The low level code is an important part of the key to reading the products to process. Low level code is held in the ITMBOMM table. The low level code defines the order of the product analysis. Note: The cost calculation uses the same low level code to define the orderr of the product analysis, but in reverse order (the highest low level code first to the lowest low level code at the end). Low level code of A, E, F = 0. Low level code of B=2. Certified Student Course Curriculum - Version 2.0 Page 65

72 Low Level Code (continued) Use Recovery from the Common data > BOMs > Low level codes menu to recalculate low level code that is no longer synchronized (in the case where many changes occur in the BOM). Page 66 Certified Student Course Curriculum - Version 2.0

73 Suggestion Characteristics All the characteristics of a suggestion can be manually modified before validation: End / start date Quantity Order type Supplier (for purchase order) BOM code and routing (for work order) Flow Sales Order Purchasing Manufacturing Material working for Subcontracting Material for subcontracting Inter-company or inter-site provide Inter-company or inter-site required Suggested (S)* SOS Forecast POS Purchase order suggested WOS Work order suggested MWS Depends on WOS EOS External order suggested MSS Depends on EOS TPS Depends on TRS TRS Transferr required suggested Planned (P) SOP Shipment request planned Quotes POP Purchase request planned Purchase requests WOP Work order planned MWP Depends on WOP EOP External order planned MSP Depends on EOP TPP Depends on TRP TRP Transferr required planned Firm (F) SOF Shipment request firm Sales order firm POF Purchase request firm Purchase order firm WOF Work order firm MWF Depends on WOF External EOF order firm MSF Depends on EOF TPF Depends on TRF TRF Transferr required firm Certified Student Course Curriculum - Version 2.0 Page 67

74 Suggestion Characteristics (continued) The many document types can be grouped into two types: - Requirements ( represented with an R in the table on the previous page). - Supply (represented with an S). Note: A work order represents an S but to make the work order, it may generate downstream documents MWS, MWP, or MWF, which are R types (requirements for the work order). The product category allows the type of flow for each product: - Manufactured - Subcontracted - Purchased - Sold The same product can be linked to many flows (such as manufactured + purchased + sold). Then, in Product-sites (Planning tab), it is possible to set the order type suggested by the MRP. - Note: A suggestion can also be manually validated into another order type (such as WOS to POF only if the product is set as manufactured + purchased). Page 68 Certified Student Course Curriculum - Version 2.0

75 Suggestion Characteristics (continued) MRP is Backward Only The MRP calculation is performed based on the procurement lead time (purchase or manufactured lead time) to determine when the order will be released. This can be a purchase order, work order, inter-site order, or an external order. MRP uses only the lead time. The MRP suggestions are made in infinite capacity logic. The following is an example of when to start/finish each order. (Note: MRP is backward.) The company that works in MTO needs to define the first available date (forward logic), then it is possible to use the multi-level plan to meet this requirement. - Once the first available date is set as the shipment date, the MRP is able to generate the correct suggestions. Digressivity Factor The digressivity factor is applied to the manufacturing lead time (or to the purchasing lead time). - The digressivity factor is used to adapt the order lead time in proportion to the EOQ. It is used in the MRP process and the work order (technical lot). Example: Lead time = 5 days for a lot of 150 Suggestion = 300 LT coeff = 100% LT = 10 days = = 5*(1 + 1*100%) Suggestion = 300 LT coeff = 60% LT = 8 days = 5*(1 + 1*60%) Suggestion = 300 LT coeff = 0% LT = 5 days = 5*(1+1*0%) Formula: Corrected lead time = LT*(1 + (quantity/lot - 1)*coefficient/100) Certified Student Course Curriculum - Version 2.0 Page 69

76 Suggestion Characteristics (continued) Multi-Level BOM Example The following is a multi-level BOM example that illustrates when to start and finish each order. - FG1 lead time is 10 days - SF1 lead time is 5 days - B1 lead time is 10 days - B2 lead time is 13 days - B3 lead time is 25 days Note: For inter-sites, a TRS has an offset equal to the lead time (purchase lead time) set on the product site corresponding to the time transit between the two sites. - A TPS (Transfer Provide) is generated automatically on the provider site. This order represents a need to produce or purchase; therefore, it can trigger a supply order (such as POS or WOS). - Inter-site runs with two sites declared as Customer and Provider. - If the lead time is shortened between the two sites, you can set in transit stock available for the MRP. - Inter-site contracts can be set up. Page 70 Certified Student Course Curriculum - Version 2.0

77 Lesson 5 Production Orders In the following topics, you will learn about work order concepts and how to create work orders suggested from MRP. You will also learn how to automatically allocate and schedule several work orders at one time. The topics in this lesson include: Understanding Work Orders Setting Up Entry Transaction Parameters Work Order Creation Automatic Allocations Automatic Scheduling Multi-Level Planning Certified Student Course Curriculum - Version 2.0 Page 71

78 Manufacturing Series - Fundamenta als Understanding Work Orders Bill of materials, routing, and product information is used when creating a work order. A work order is a document like a sales order that represents the approval to produce a good or subassembly. It is given to production to manufacture the product. After a work orderr is created, the data involved, such as bill of materials and routing are duplicated. At that point, changes made to the theoretical bill of materials and routing have no effect on an existing work order. A work order can comprise of several different documents, such as a paper work order, routing sheet, materials list, QA sheets, etc. Some companies, however, print a combined document with this information. Page 72 Certified Student Course Curriculum - Version 2.0

79 Understanding Work Orders (continued) Work orders can be generated from many different sources: Certified Student Course Curriculum - Version 2.0 Page 73

80 Understanding Work Orders (continued) Features of a Work Order The following diagram shows a high level view of the features of a work order. The site must be a production site. The work order can be manual. The release can be: - Complete release - Partial release (materials and operations only) Page 74 Certified Student Course Curriculum - Version 2.0

81 Understanding Work Orders (continued) Lifecycle of a Work Order in Manufacturing The following diagram shows a high level view of the complete flow of a work order in the manufacturing process. Work order flow: - WO Planned is not a mandatory step. - Scheduling is not mandatory and can be performed automatically at work order creation. - Allocation can be performed automatically at work order creation (firm only). This can be mandatory depending on general parameters. - Printing can be performed automatically at work order creation. This can be mandatory depending on general parameters. - Time tracking can be performed automatically at the time tracking of the following operation or at the work order closure. - Material tracking can be performed automatically at the time tracking, the production tracking, or at the work order closure. - Time tracking can be performed automatically at the time tracking or at the work order closure. - Work order closure can be re-opened. - Work order cost can no longer be modified. Certified Student Course Curriculum - Version 2.0 Page 75

82 Understanding Work Orders (continued) Possible Work Order Flows in Sage ERP X3 The following diagram shows the different work order flows possible in Sage ERP X3 for managing the manufacturing process. The first flow has a stock change point. This refers to the location change you can do to provide the component from the stock area to the manufacturing production area. The second flow shows a different way to do the tracking and is more appropriate if each tracking is recorded in mass at the same time. The last flow shows the simplest flow you can do in Sage ERP X3. After the first tracking, even if it is a partial one, you can generate the missing tracking at the closure. Page 76 Certified Student Course Curriculum - Version 2.0

83 Understanding Work Orders (continued) Work Order Statuses The following diagram shows the three possible statuses of a work order during the manufacturing process. The Planned status has the following consequences: - The components cannot be allocated. - The operations impact the load and can be scheduled. - The lot number can be set (defined). - There is impact on MRP and MPS. - The WOP can be optimized. - The work order shop packet cannot be printed. - The re-planning analysis can be applied on WOP. The Firm status has the following consequences: - The components cannot be allocated. - The technical data can be updated according to the RELUPD general parameter. - The shop packet can be printed. - The operations impacting the load can be scheduled. - The lot number can be set (defined). - There is impact on MRP and MPS. - WOF can be optimized. - The re-planning analysis can be applied on WOF. Closed means no more tracking. Certified Student Course Curriculum - Version 2.0 Page 77

84 Understanding Work Orders (continued) Line Statuses The following diagram shows the line statuses possible during the work order flow. Line statuses: - Pending = Work order created - Suspended = No load - Printed = Work order shop packet printed - In progress = At least one tracking has been done - Competed = No more WIP (load, allocation, MWF = Material Requirement, WOF = incoming receipt, WIP costed). New tracking or modification is still possible. - Close and costed = No modification can be done Page 78 Certified Student Course Curriculum - Version 2.0

85 Understanding Work Orders (continued) Time Fences and Horizons The following diagram depicts the concept of time fences and possible actions you can take. DTF = Demand Time Fence PTF = Planning Time Fence LT = Lead Time Certified Student Course Curriculum - Version 2.0 Page 79

86 Understanding Work Orders (continued) The following diagram depicts the short term and long term horizon logic. Page 80 Certified Student Course Curriculum - Version 2.0

87 Setting Up Entry Transaction Parameters You can use the Setup > Manufacturing > Entry transactions menu to define the screens for the following tasks. How you set up the entry transaction parameters has an impact on work flow and data entry. There are many entry transaction tasks as listed below: Work Orders Production tracking Enterprise planning Planning Workbench Grouping Time tracking Material tracking plan Production plan Reintegration plan Technical sheet plan Managing the tracking plans These tasks are used to control all aspects of work order and production tracking data. Some are mentioned in this course. For more information working with entry transaction tasks, refer to your Common Tools course materials. Certified Student Course Curriculum - Version 2.0 Page 81

88 Manufacturing Series - Fundamenta als Work Orderr Creation Use Work orders (GESMFG) on the Manufacturing > Planning menu to manually create a work order. To use this task, you must first have the following setup or defined: A product and product site set up for finished goods and raw materials A bill of materials defined A routing defined Work orders can be created either from suggestions generated from MRP or entered manually. In certain cases, it may be necessary to create a work order manually. Page 82 At the Order statuss field, selecting Firm allows for allocation and scheduling of a work order; whereas, selecting Planned does not allow for material allocation. At the Release mode field, enter the code that defines the release mode. - Complete: The material requirements and the operation loads are generated. - Materials only: No operation loads are generated. Certified Student Course Curriculum - Version 2.0

89 Work Order Creation (continued) - Operations only: No material requirements associated with the release are generated. Header Tab Use the Header tab to assign a priority to the work order, enter the planned start and end dates of the work order, and enter the scheduling mode. LT In the LT section, enter the following options. At the Scheduling Mode field, select from the following scheduling methods. The method selected is usually backward scheduling. - Backward scheduling: Requires an end date with the start date being calculated according to the routing times. - Forward scheduling: Requires a start date with the end date being calculated according to the routing times. The Start date field makes the components and operations present in the order according to their validity date (if the order is not scheduled). The duration (manufacturing lead time) is first taken from the product site. It can be adjusted by the digressivity factor, a factor that has impact on the lead time). Secondly, as soon as the routing code is known, this duration can be set by the scheduling. - Note: If the transaction is set with automatic scheduling, the work order is scheduled at the time of its creation. Certified Student Course Curriculum - Version 2.0 Page 83

90 Work Order Creation (continued) Inter-operation times can be reduced or increased depending on the workshop situation. The compressed factor can be entered or not depending on the transaction. Planned lead time calculated by MRP can be adjusted by this factor. The % LT Reduction field is used to apply an increase or decrease of the slack times to all the operations of the work order. The Priority field entry affects the finite scheduling. This field defaults to Normal and is used for batch allocation of work orders. Routing In the Routing section, the routing information belonging to the associated routing alternative is displayed with the bill of materials alternative set up on the Products Released grid. The Routing code is the product released code or Production routing according to the product-site parameter settings. If the release is multi-product, the routing of the first released product is proposed. Page 84 Certified Student Course Curriculum - Version 2.0

91 Work Order Creation (continued) Components Tab The Components tab lists the components required for the manufacturing of the released product. The Expected Quantity field provides the quantity that is expected to be produced. The Producable Quantity field indicates the maximum of a product that can be produced with the resources available. The list of the generated materials when creating the work orders is translated into the WIP as gross material requirements, MWF, and MWP type orders. The BOM Sequence field, which is the BOM sequence of a component in the work order line, is null if the component was added after the order was created. Certified Student Course Curriculum - Version 2.0 Page 85

92 Work Order Creation (continued) Operations Tab The Operations tab lists the operations. The list of operations generated upon work order creation is translated into the workload as OWF and OWP type orders. Operation-related data is initialized based on the routing data. Page 86 Certified Student Course Curriculum - Version 2.0

93 Work Order Creation (continued) Documents Tab Use the Documents tab to print the documents for the traveler packet. The following shows the five documents associated with work orders: Title Crystal Report Content Usual number Material Issue Slip BSM Lists all materials Routing Sheet FICHSUI Lists all operations Job Ticket BONTRV Detail of operation Production Slip RECETTE Detail of operation with materials Technical Sheet FICHUI Questions of technical sheet 1 per order 1 per order 1 per operation 1 per operation I per operation with technical sheet Certified Student Course Curriculum - Version 2.0 Page 87

94 Work Order Creation (continued) Printing the Work Order Packet Steps for printing the work order packet 1. In the Work orders task, select the work order from the left list. 2. From the Report menu, select Documents. 3. Accept all the defaults and click Print. 4. Each report displays in preview mode. 5. To send a report to the printer, click the Printer button on the toolbar and select the report. Material Allocation Status Work orders to be released should be scheduled and allocated. When a work order is created, the materials components can be set to automatically allocate to the work order (setup can be changed to not allocate). Click Allocation in the Work Orders task to view the work order allocation status. If the status is complete, the materials are allocated without shortages. - You can look at the inventory in the warehouse to determine if you have enough material to complete the work order. - This method is used for allocating one work order at a time. Scheduling Status When work orders are created, the work orders can be scheduled automatically. (However, in Transaction Entry, this can be changed so the work orders are not scheduled automatically). View the schedule by clicking Scheduling in the Work Order task. The scheduling dates for each operation can then be viewed. Page 88 Certified Student Course Curriculum - Version 2.0

95 Automatic Allocations Use Allocation (FUNMAUTA) on the Manufacturing > Batch processes > Allocation/deallocation menu to allocate several work orders at one time. Certified Student Course Curriculum - Version 2.0 Page 89

96 Automatic Allocations (continued) After selecting your criteria and clicking OK, a log similar to the following is displayed. Page 90 Certified Student Course Curriculum - Version 2.0

97 Automatic Allocations (continued) Other Ways to Automatically Allocate You can also set parameters to force documents to automatically allocate. - In Setup > Inventory > Inventory, click the Backorder Management tab, and then select the Auto process shortages check box. - This allows for automatic allocation the moment it becomes available. Certified Student Course Curriculum - Version 2.0 Page 91

98 Manufacturing Series - Fundamenta als Automatic Scheduling Use Scheduling (FUNMAUTJ) on the Manufacturing > Batch processes > Scheduling/descheduling menu to track scrap and work order efficiency through routing to determine how long and when to start producing. Page 92 Certified Student Course Curriculum - Version 2.0

99 Multi-Level Planning Use Multi-level planning (MULTIWOX) on the Manufacturing > Planning menu to view different levels of the BOM structure. This is a planning tool for the master production schedule beyond short term planning, whichh can also be used this if you are not using MRP. Multi-level planning is discussed in more detail in the Manufacturing Beyond the Basics course. Click OK to display the orders that are being proposed to the BOM levels. Certified Student Course Curriculum - Version 2.0 Page 93

100 Multi-Level Planning (continued) Planning and Process Use the Planning and Process sections to choose which status to generate the work order with (Planned or Firm) and what quantity to release. You must also specify the BOM alternative as well as the routing to use in the releases. Page 94 Certified Student Course Curriculum - Version 2.0

101 Viewing the List of Work Orders Use List of WOs (CONSMFG) on the Manufacturing > Inquiries menu to view a list of work orders according to the criteria entered, such as status, start and end date, work order number, released product, routing, project, original document, component, and work center. The grid displays lines by work order for the criteria selected. - If the Materials detail or Operations detail check boxes are selected, the grid displays the materials or operations for each work order. The color codes of the work order lines are as follows: - Green: Firm work orders - Grey: Planned work orders - Red: Closed work orders The Criteria button allows you to access additional selection criteria, such as BOM codes, routing codes, original document type, and work order status. Certified Student Course Curriculum - Version 2.0 Page 95

102 Lesson 6 Capacity Planning In the following topics, you will learn about capacity planning and how load affects capacity. You will also learn about tools to recalculate the load as well as view the load for a site and verify the available capacity. The topics in this lesson include: Understanding Capacity Planning Load Recalculation Load Inquiry Printing Production Documents Page 96 Certified Student Course Curriculum - Version 2.0

103 Understanding Capacity Planning In capacity planning, you can look at the entire site and judge the capacity to determine if the manufacturin g system has enough people and machines for a given period of time. Work order allocation and scheduling occurs automatically either when the work order is created or through an automatic batch process. Production orders are scheduled according to infinite capacity, meaning that when the load against a work center is scheduled, it takes into account the available capacity for each work center for the work order to schedule the load. It does not consider other work orders that are already scheduled. The load for each work center can be viewed and smoothed out according to the available capacity by manipulating work order dates. Loads are managed in two ways: The Workload table has a bucket for each work center per load period. This table holds capacity and load for scheduled orders only. - This allows for load/capacity comparisons. The Operations table holds every operation, including: - Firm and planned, scheduled and un-scheduled - Suggested within the load calculation horizon - This allows total load inquiries, whatever the status or situation of the order, but not as a comparison to capacity. Certified Student Course Curriculum - Version 2.0 Page 97

104 Understanding Capacity Planning (continued) With finite loading, there is an assumption that there is a definite limit to capacity at any work center. Infinite loading, on the other hand, assumes the capacity is infinite at any work center. Understanding the Capacity Planning Structure As learned in the Manufacturing Fundamentals class, capacity is the capability of a work center to produce output during a given period of time. Capacity planning helps you determine if resources will be available to support the master production schedule. - It is important to check for constraints in order to determine if the system will fail or succeed. If needed, the plan can then be altered. In the following diagram, the operation times are entered in a routing operation in hours. The maximum time (waiting, post-operation) is taken into account in the scheduling. Page 98 Certified Student Course Curriculum - Version 2.0

105 Load Recalculation The load recalculation process rebuilds the load buckets according to the period breakdown. - Load Recalculation should be run regularly, particularly if the load buckets are progressively sized. - The reference date is considered as the new start date for any orders that are unfulfilled. - You can select whether orders that are in arrears should be automatically re- scheduled and whether operations with force dates are modified. The reference date is considered the new start date for any orders that are in arrears. The following diagram is an example of load and finite scheduling. - Work Center 1 - Number of resources = 5 - Hours per day = 7 Certified Student Course Curriculum - Version 2.0 Page 99

106 Load Recalculation (continued) Use Recalculate loads (FUNMIWL) on the Manufacturing > Batch processes menu to recalculate the load. This process is important to load management. It also allows you to reschedule all past orders relative to the reference date used for the recalculation. The work center represents an entity for which the load needs to be planned and/or the production times need to be tracked. - Each work center is associated with an assignment site. Page 100 Certified Student Course Curriculum - Version 2.0

107 Load Recalculations (continued) After clicking OK, a window similar to the following is displayed allowing you to view the load recalculation information. Certified Student Course Curriculum - Version 2.0 Page 101

108 Manufacturing Series - Fundamenta als Load Inquiry Use Loads (CONSMWK) on the Manufacturing > Inquiries > Loads menu to display the available load for a given site and to verify there is available capacity. You can also filter the results based on work center, work center group, and date criteria. The load represents the load generated during the creation of a work order (firm or planned) or generated during the launch of MRP with load calculation. This load may be scheduled or not. The un-scheduled order load is displayed by operation start and end dates that correspond to the start and end dates of the work order. Before using this task, you should have defined work centers, routings, and scheduling parameters. For more information about the scheduling and load parameters, see Scheduling/Load (LOA Group) in the Understanding Manufacturing Parameters lesson. The load for each work center can be viewed and smoothed out according to the available capacity by manipulating the work order dates. The date range is used to view the load and list out all the jobs thatt are scheduled to start in the week being planned. Page 102 Certified Student Course Curriculum - Version 2.0

109 Load Inquiry (continued) Loads Tab By default, the grid on the Loads tab displays some information for the site, such as order type, operation number, work center, start and end dates, the planned quantity, the achieved quantity, and the various times (setup, running, etc.). Viewing the Load and Capacity in Graphical Format Click the graph icon to view the load and capacity information in graphical format. The graph creates a view of the current load against the available capacity for the work center. - The graph identifies periods that are overloaded and need smoothing, as well as periods that have available capacity. Certified Student Course Curriculum - Version 2.0 Page 103

110 Load Inquiry (continued) - If additional resources are available, capacity adjustments can be made on the work centers and the load can be recalculated. - Reschedule work orders as necessary to adjust the work center load. Smoothing Bottlenecks In the load results window, you can determine which jobs need to be moved. This can be done by analyzing the periods that are overloaded, viewing the jobs that are scheduled for that period and making a determination of which jobs to move. Page 104 Certified Student Course Curriculum - Version 2.0

111 Printing Production Documents Use the Production documents task accessed from the Reports > Prints/group > Manufacturing menu to provide team leaders at each workstation with various manufacturing documents, such as job tickets, material issue notes, routing sheets, technical sheets and answers, and production slips. This provides the team leaders with information about what to perform for the day. You should review the job packet and Dispatch Report with the shop manager. Then, you can adjust the loads and capacity to meet the unexpected changes to the schedule. The job packet is placed in jackets and moves with the job during the production process. The Material issue notes (Pick List) is sent to the warehouse to pull the needed materials. Certified Student Course Curriculum - Version 2.0 Page 105

112 Printing Production Documents (continued) The following is an example of a production slip. Page 106 Certified Student Course Curriculum - Version 2.0

113 Lesson 7 Production Reporting/Tracking In the following topics, you will learn how to track released work orders, complete and close firm work orders in process, and reactivate a closed work order,. The topics in this lesson include: Production Tracking Work Order Status Work Order Close Work Order Reactivation Tracking Plans Reintegration Plan Certified Student Course Curriculum - Version 2.0 Page 107

114 Manufacturing Series - Fundamenta als Production Tracking Use Production tracking (GESMTK) on the Manufacturing > Production Tracking menu to track the work orders released to the workshop. You can also view production times, material consumption, and production reports. It is not possible to work with a work order until it is firm and allocated (at least globally). Production Tracking was designed to optimize the automation of the work order tracking; however, you can also manually track work orders. Sage ERP X3 also has mass work order tracking functions to allow you to track several work orders at the same time as well as perform production tracking without a work order. If the transaction selected allows you to use several tracking types, (material and operation tracking, production reporting), a check box and a tab are activated for each tracking type. In the event of material consumption and production reporting, the corresponding stock transactions are posted on the tracking date. Page 108 Certified Student Course Curriculum - Version 2.0

115 Production Tracking (continued) - The system validates that the entered date falls in a period for which stock update is authorized. Operations Tab Use the Operations tab to enter the time devoted to the operations of a work order. All the fields that can be entered on this tab are pre-loaded by the transaction. In automatic tracking, the quantity carried out by each operation is loaded by default with the quantity remaining to be produced in the work order. The operation completion is proposed by default. If the information in the grid is acceptable, all that is needed is to create the tracking record by recording the time spent. If the information in the grid is not acceptable, the actual quantity, actual rejected quantity, unitary time, operation time, setup time, completion, ID number, messages, and scrap messages can be assigned. Production times are automatically adjusted. The actual quantity is the total quantity produced for the operation. It includes the rejected or under quality control quantity coming from the operation. If a rejected quantity is entered, you can associate up to 15 different reject messages by right-clicking the Rejected quantity and Reject message fields. Certified Student Course Curriculum - Version 2.0 Page 109

116 Production Tracking (continued) Manufacturing Tab Use the Manufacturing tab to carry out the receipt of stock of production. This stock movement uses the parameters of the tracking transaction. All the fields in the grid are pre-loaded by the tracking transaction. - The lot, sub-lot, status, serial number, and transaction description fields are accessible, if needed, according to the tracking transaction used. Page 110 Certified Student Course Curriculum - Version 2.0

117 Production Tracking (continued) Components Tab Use the Components tab to carry out material stock issues. Backflushing Backflushing is the process that assumes a certain amount of raw material consumption based on the quantity of the finished goods produced. For example, if you are an automobile manufacturer and need to produce 100 automobiles, you can conclude that you will need 400 tires. Enter the needed information into Sage ERP X3 and the system calculates how much of a component is needed for the finished goods. Certified Student Course Curriculum - Version 2.0 Page 111

118 Manufacturing Series - Fundamenta als Work Orderr Status Use Work order statuss (FUNMSITU) on the Manufacturing > Production tracking menu to view a summary of the work order progress, including released products, materials, and operations. Page 112 Certified Student Course Curriculum - Version 2.0

119 Work Order Status (continued) General Tab Use the General tab to view the work order header information, as well as view a summary of general information. The Scheduling mode field specifies the scheduling method. - The production lead-time is calculated based on the product data. This lead-time is applied at the start or end date of the work order. Certified Student Course Curriculum - Version 2.0 Page 113

120 Work Order Status (continued) Products Tab Use the Products tab to view information about the released product, such as the status regarding the availability of the product. Note: Several BOMs can be defined for the same product reference. You can view planned and completed quantity information for products in graphical format. - You can also click a bar to display options allowing you to remove a component or export the information in the graph to Microsoft Excel. Page 114 Certified Student Course Curriculum - Version 2.0

121 Work Order Status (continued) Components Tab Use the Components tab to view work order material information. You can view the required and consumed information for components in graphical format. Certified Student Course Curriculum - Version 2.0 Page 115

122 Work Order Status (continued) Operations Tab Use the Operations tab to view work order operation information. You can view the expected quantity and total achieved quantity information for operations in graphical format. Page 116 Certified Student Course Curriculum - Version 2.0

123 Work Order Close Use Work order close (FUNMCLOSE) on the Manufacturing > Production tracking menu to complete and close the firm work orders in process which have been tracked beforehand. The Complete function specifies the status Completed for each operation, material, and product line released. - The WO status field changes automatically from In processs to Completed. - It is possible to continue tracking a work order completed but not yet closed. The Close function changes the work order status from Firm to Closed. It is normally impossible to save consumption or work movements when the status is Closed; however, the WO Reactivation task can be used to continue tracking a work order, provided that no price cost has been calculated for this work order. Certified Student Course Curriculum - Version 2.0 Page 117

124 Work Order Close (continued) General Tab Use the General tab to view information, such as the work order status (pending, printed, in process, completed), and last tracking and the closing dates. Page 118 Certified Student Course Curriculum - Version 2.0

125 Work Order Close (continued) Products Tab Use the Products tab to view a summary of the information related to the work order concerning the released products. Certified Student Course Curriculum - Version 2.0 Page 119

126 Work Order Close (continued) Components Tab Use the Components tab to view summary information regarding the work order components, including the component status and required date. Page 120 Certified Student Course Curriculum - Version 2.0

127 Work Order Close (continued) Operations Tab Use the Operations tab to view summary information regarding the work order operations, including the operation line status (Pending, In progress, Ordered, Received or Closed), work center and work center group, and type of work center, such as machine, labor, or sub-contract. Certified Student Course Curriculum - Version 2.0 Page 121

128 Work Order Close (continued) After clicking Close, the Production Cost Calculation log may appear if you clicked Yes at the Production Cost Calculation message. Page 122 Certified Student Course Curriculum - Version 2.0

129 Work Order Reactivation Use WO reactivation (FUNMREACT) on the Manufacturing > Utilities menu to reactivate a closed order. The reactivation of the work order consists in changing the status of (the work order switches from the Closed status to the Firm status) in order to authorize additional tracking. This reactivation can only take place on work orders whose cost price has not been calculated yet. Certified Student Course Curriculum - Version 2.0 Page 123

130 Work Order Reactivation (continued) General Tab Use the General tab to select the product site. The site associated with the user is displayed by default. Page 124 Certified Student Course Curriculum - Version 2.0

131 Work Order Reactivation (continued) Products Tab Use the Products tab to view information about the released product, such as the released quantity and line status (Active, Development, On hold, Not renewed, Expired, and Not usable). Certified Student Course Curriculum - Version 2.0 Page 125

132 Work Order Reactivation (continued) Components Tab Use the Components tab to view the component details of the product, such as component type (Normal, Sub-product, Text, and Valuation), required date, and quantity allocated. Page 126 Certified Student Course Curriculum - Version 2.0

133 Work Order Reactivation (continued) Operations Tab Use the Operations tab to view the operation lines for the product. You can view information such as the line status, the planned work center and work center group, and type of work center (machine, labor, or sub-contract). Certified Student Course Curriculum - Version 2.0 Page 127

134 Manufacturing Series - Fundamenta als Tracking Plans Use the Managing the tracking plans task accessed from the Manufacturing > Production tracking menu to track time, material, manufacturing, reintegration, and technical sheet plan information. These tasks can also be accessed directly from the Production tracking menu as shown below. Note: These tracking plans are discussed in more detail in the Manufacturing Beyond the Basics course. Page 128 Certified Student Course Curriculum - Version 2.0

135 Reintegration Plan Use Reintegration plan (FUNBENCHR) on the Manufacturing > Production tracking menu to record the reintegrationn of a group of materials either on a work order or on a bill of materials (without work order). For example, you can take off some materials from the work order and place them back into stock. Certified Student Course Curriculum - Version 2.0 Page 129

136 Lesson 8 Tracking Plans In the following topics, you will learn about the tracking plans available in Sage ERP X3. The topics in this lesson include: Understanding Tracking Plans Time Tracking Material Tracking Plans Manufacturing Plan Reintegration Plan Technical Sheet Plan Managing the Tracking Plans Page 130 Certified Student Course Curriculum - Version 2.0

137 Understanding Tracking Plans As learned in the Manufacturing Fundamentals course, tracking can be generated from many different sources: - BOM tracking for completed quantity or material tracking. - Routing tracking for time tracking. - Work center tracking for time tracking. Tracking without a work order can only be created through the tracking plan tasks. Modifications are only possible throughh Production Tracking. Tracking can be combined or done automatically as illustrated below. - From the Time Tracking Plan, you can combine a time tracking with a production tracking and/or material tracking. You can also generate a production or material tracking from your time tracking. - From the Manufacturing Plan, you can combine a material tracking. You can also generate a material plan from your manufacturing plan. - From the closure, you can generate time tracking and/or a production and/or material tracking (only if the work order is already in progress). Certified Student Course Curriculum - Version 2.0 Page 131

138 Understanding Tracking Plans (continued) Use Managing the tracking plans (FUNBENPLT) on the Manufacturing > Production Tracking menu to track time, material, manufacturing, reintegration, and technical sheet plan information. These tasks can also be accessed directly from the Production Tracking menu as shown below. Page 132 Certified Student Course Curriculum - Version 2.0

139 Time Tracking When work orders have been created, at some point, the reporting of labor hours needs to occur. Time tracking allows you to track labor times for one or more work orders simultaneously. Unlike Production tracking, different types of time can be entered using Time Tracking, such as: Time spent on an operation for a released work order. Time spent on a routing operation without a work order. Miscellaneous time (unproductive time). The following diagram shows the main features of a time tracking plan. The time type is linked to the origin of the tracking: - Work Orderr Origin = Work Order Number - Product Origin = Routing + Alternate - Miscellaneous Origin = blank Depending on the setup of the time transaction, material can also be back flushed when reporting time against an operation on a work order. Finished goods reporting can also be transacted. Time tracking allows you to enter the production times or other times at one time. Certified Student Course Curriculum - Version 2.0 Page 133

140 Time Tracking (continued) Setting Up Transaction Entries for Time Tracking First, you may want to set up the transaction entry window to tailor the way you enter time tracking information. This can be done in the Time tracking entry transaction window. Use the Time tracking (GESMOL) entry transaction window (accessed from the Setup > Manufacturing > Entry transactions menu) to define your transactions to track by work order or by routing. Time tracking relies on transaction entry windows to determine the type of time that is to be entered (with or without work order and miscellaneous) and if the time entry should be associated with a consumption of material, a production reporting, or should be manual and/or automatic. In the Material consumption section you can define the tracking to perform for material issues linked to the time entry: - No: No material consumption. - Yes manual: Save the consumption of associated materials. - Yes automatic: The consumption of associated materials is automatically carried out on validation. Page 134 Certified Student Course Curriculum - Version 2.0

141 Time Tracking (continued) - Yes automatic and manual: Manually track the associated materials. If the associated materials were not manually tracked, they are upon validation. Use the Stock issuing method section to define the material consumption mode for this transaction entry. You can select the mode according to the immediate planned quantity, the ranged produced quantity, or the progressive produced quantity. The check boxes in the Filter section are used to specify an automatic tracking options on materials completed, not completed, or on both criteria. The Completed quantity section determines whether the transaction allows the production statement on the associated products. - No: No production statement. - Yes manual: It is possible to save the production statement of the associated end product. - Yes automatic: The production statement of the associated end products. - Yes automatic and manual: Manually declare the production of associated products. The production statements that were not created manually are automatically created upon validation. Input Tab Use the Input tab to determine the following: Specify whether the personnel ID number can be assigned. Define specific stock receipt rules and stock issue rules for some transactions. For example, expert users could authorize a receipt to stock of goods with a status of A using a dedicated transaction; whereas, for all other users, the goods would have a status of Q. - Note: This is only possible for product categories authorizing this type of receipt rules and having the appropriate move code. Determine whether to print the document or not for this transaction. You can also specify whether to be able to enter the number of print jobs for the document. The movement code is used to define specific stock receipt rules and stock issue rules for some transactions. Activate or deactivate the modification of the operation unit. Filters/Sort Tab Use the Filters/Sort tab to determine the following: Determine the default value at the Filter field (Not closed, Close, or All). This affects the filter of the operations appearing on the plan. Determine if the Filter field can be entered, displayed, or hidden. Determine the sorting criteria for posting. Activate or deactivate the modification of the operation unit. Certified Student Course Curriculum - Version 2.0 Page 135

142 Time Tracking (continued) Display Tab Use the Filters/Sort tab to determine the following: Determine the default value at the Filter field (Not closed, Close, or All). Determine if the Filter field can be entered, displayed, or hidden. Determine the sorting criteria for the grid. Entering Time Tracking Information Use Time tracking (FUNBENCHO) on the Manufacturing > Production tracking menu to view the production times and the actual quantities for operations. If the global time is entered, it is broken down over the different operations of the selection according to the planned times. Use the Selections section to enter the start and end work order product numbers, operations, released product numbers, routings, alternate routing, and work centers. This information is used to refine the results that display in the grid. The End date field determines the horizon to use. Page 136 Certified Student Course Curriculum - Version 2.0

143 Time Tracking (continued) Grid Entry The grid is loaded with routing or work order operations according to the selection criteria. Many of the fields in the grid provide an opportunity to enter more precise information. The posting date for the transaction is defaulted to the current date. You can reenter this date to a prior date on the condition that the date is in an open period. You cannot enter a date that is later than the current date. The Time type field can take the following values: - WO: The declared time regarding the work order operation. The work order to be tracked can come from the selection criteria or added manually in the grid. - Product: This is for information purposes and is not associated with a work order. - Miscellaneous: The declared time regarding non-productive time, such as cleaning, maintenance, etc. on a work center. The Order no. field is the work order number allowing for a unique identifier. This number is generated automatically at each creation. If WO is the time type, you can modify the Actual Work Center and the Actual Labor W/C fields. The Personnel ID field is used for collecting information about the personnel or team. The Tot achieved qty field is the total quantity completed for the operation. It includes the rejected quantity or the quantity under control coming from the operation. To minimize the entry and if the transaction set up allows it, the completed quantity for each operation is loaded by default with the remaining quantity for the work order. The operation closure is proposed by default. The Operation UOM field is the unit of measure in which the production is occurring. The Message field allows you to assign a message to an operation tracking. This also allows you to create new messages during tracking. Certified Student Course Curriculum - Version 2.0 Page 137

144 Time Tracking (continued) Click Validation and review the log that is displayed. Page 138 Certified Student Course Curriculum - Version 2.0

145 Material Tracking Plans Use Material tracking plan (FUNBENCHM) on the Manufacturing > Production tracking menu to record the consumption of a group of materials either on a work order or on a BOM (without work order). All the columns displayed in the grid depend on the type of tracking. The current date displays at the Date field by default, but can be changed. - You can enter an earlierr date than the current date, but not a later date. - The stock issues are carried out on this date. - The system validates that the entry falls in a period for which stock updates are authorized. You can enter the tracking type, which can be of type work order or BOM. - Work order: Consumption deals with a material related to the product work order. - BOM: Consumption deals with a material related to a BOM. At the Order no. field, a unique work order number is automatically generated. The BOM field contains the bill of materials code for the product. Certified Student Course Curriculum - Version 2.0 Page 139

146 Manufacturing Series - Fundamenta als Production Plan A Manufacturing plan provides a way to prepare for resources, people, and facilities for the operations and manufacturing processes. Setting Up Transaction Entries for the Production Plan First, you may want to set up the transaction entry windoww to tailor the way you enter manufacturing plan information. This can be done in the Production Plan entry transactionn window. Use the Production plan (GESMIL) entry transaction window (accessed from the Setup > Manufacturing > Entry transactions menu) to enable/disable work order tracking, select the default quantity to use during tracking, determine if materials can be back flushed, and determinee how material issues will be managed. The options in the Filter section are used to specify automatic tracking on materials completed, not completed, or on both criteria. Page 140 Certified Student Course Curriculum - Version 2.0

147 Manufacturing Plan (continued) Filters/Sort Tab Use the Filters/Sort tab to make the following settings: Determine if the filter can be modified during tracking. Define the sort criteria for selected lines (by date, by work order, or by product). Enter the transaction groups and movement codes associated with the issue and receipt transactions. Entering Production Plan Information Use Production plan (FUNBENCHI) on the Manufacturing > Production tracking menu to record the production of a set of products jointly with a material consumption. This can be done either on the basis of a work order or a BOM without a work order. The columns displayed in the grid are the released products and sub-products linked to the work orders of the selection and/or the products manufactured on the selected BOMs. Certified Student Course Curriculum - Version 2.0 Page 141

148 Manufacturing Plan (continued) The current date displays by default, but can be changed. You can enter an earlier date than the current date, but not a later date. - Receipts to stock and potential joint stock issues are posted on this date. The system validates that the entry falls in a period for which stock updates are authorized. The grid also displays the tracking type, work order code, BOM, actual quantity, and whether the work order is closed. If not all the information required to complete the stock entry displays automatically, the product is displayed in red, indicating that the remaining information needs to be entered manually. The Production Plan is set up to back flush materials when production is reported into inventory. By reporting a quantity into inventory, the Manufacturing Plan consumes all materials required to produce end items according to the bill structure. Labor is not a factor and will not be tracked when performing this type of reporting. The usefulness of this process is for manufacturing environments that produce the same item on the same line each day without interruption. The Production Plan also allows a range of end products to be transacted simultaneously. Page 142 Certified Student Course Curriculum - Version 2.0

149 Reintegration Plan A Reintegration Plan allows the return of stock of materials associated with or without a work order. This is done without affecting the product produced (received into inventory). Setting Up Transaction Entries for the Reintegration Plan First, you may want to set up the transaction entry window to tailor the way you enter reintegration plan information. This can be done in the Reintegration plan entry transaction window. Use the Reintegration plan (GESMRE) entry transaction window (accessed from the Setup > Manufacturing > Entry Transactions menu) to set up the Reintegrationn plan transaction entry screens. At least one reintegration plan transaction entry is installed with the software and can be modifiedd or deleted. You can specify whether to track on the work orderr and/or BOM. Certified Student Course Curriculum - Version 2.0 Page 143

150 Reintegration Plan (continued) Entering Reintegration Plan Information Use Reintegration plan (FUNBENCHR) on the Manufacturing > Production tracking menu to record the reintegration of a group of materials either on a work order or on a bill of materials (without work order). For example, you can take off some materials from the work order and place them back into stock. The Work Order range fields are used to set a filter on the work orders to be processed by the reintegration plan. This filter is only accessible if the tracking type WOW is planned by the transaction. Page 144 Certified Student Course Curriculum - Version 2.0

151 Reintegration Plan (continued) The Operation range fields are used to set a filter on the materials to be processed by the reintegration plan. This filter is only accessible if the tracking type WOW is planned by the transaction. The Release Product and Alternate range fields are used to define a filter on the BOMs to be processed. The Material range fields are used to filter the materials to be processed among the selected work orders and BOMs. The columns available on the grid depend on the type of tracking that needs to be carried out. If the location is not entered and the product is managed by location, the stock window displays. Right-clicking the grid allows you to view the material quantities (Tracking Report), material detail, the work order, and stock movement information associated with the material. You can also enter receipts (Enter Detailed Quantities). Certified Student Course Curriculum - Version 2.0 Page 145

152 Manufacturing Series - Fundamenta als Technical Sheet Plan Use Technical sheet plan (FUNBENCHT) on the Manufacturing > Production tracking menu to create and modify the answers to the technical sheets within the framework of operation trackings created previously. Operation trackings display based on the selection criteria. The tracking number is automatically generated and provides a unique identifier. Right-click a line to manage the tracking and technical sheet for the transaction. Operation trackings within the Tracking date range display in the grid. The Routing field indicates the reference identifying the product, which is generated by a sequence number counter. Several routings can be definedd for a single product reference. The codes at the Alternate field: - Manage different operation processes according to their use, such as detailed calculation of costs or global costs, use of different machines, etc. - Manage different routings by site. The routing is described by means of operation numbers. Each operation corresponds to a task carried out on a given resource with given times. Page 146 Certified Student Course Curriculum - Version 2.0

153 Technical Sheet Plan (continued) The standard operation is a "template" operation used to create or modify the routing operations. - The definition of the fields of a standard operation is very similar to that of a routing operation. The Type field indicates whether the type is machine, labor, or sub-contracting. Certified Student Course Curriculum - Version 2.0 Page 147

154 Manufacturing Series - Fundamenta als Managing the Tracking Plans Use Managing the tracking plans (FUNBENPLT) on the Manufacturing > Production tracking menu to launch the Managing the tracking plans task after selection of the work orders with the status of Firm, Not suspended, Pending, In process, or Completed. This is a general process that can perform many actions. The actions you can perform are: Time tracking plan Material tracking plan Manufacturing plan Re-integration plan Technical sheet plan Page 148 Certified Student Course Curriculum - Version 2.0

155 Managing the Tracking Plans (continued) After entering your search criteria, click the Search button. The grid displays results similar to the following. Certified Student Course Curriculum - Version 2.0 Page 149

156 Managing the Tracking Plans (continued) - Double-click the Pick field adjacent to the work order(s), and then click one of the buttons in the lower right corner to. In the following example, we have clicked the Time button. Page 150 Certified Student Course Curriculum - Version 2.0

157 Lesson 9 Mass Updates, Closures, and Completions In the following topics, you will learn how to perform mass updates, closures, and completions on work orders. The topics in this lesson include: Mass Work Order Updates Working with Mass Closures and Completions Certified Student Course Curriculum - Version 2.0 Page 151

158 Manufacturing Series - Fundamenta als Masss Work Order Updates Use Levelling WO (FUNMAUTP) (accessed from the Manufacturing > Batch Processes > Work orders menu > Upgrade), to update a planned and/ /or firm work order when the bill of material (BOM) or routing has been modified. There is also a new parameter, RELUPD, that is used to determine if the work order should be updated automatically when being converted from planned to firm. This task is used to carry out a mass update of the pending work orders from the routings and BOMs. - Alll the changes carried out on the technical data from the creation of the work orders can be carried forward. There are three level updates available: - Routing: Take into account the modifications carried out on the routing. - BOM: Take into account the modifications carried out on the BOM. - Routing and BOM: Take into account the modifications carried out on the routing and on the BOM. Page 152 Certified Student Course Curriculum - Version 2.0

159 Mass Work Order Updates (continued) You can choose to ignore or keep unplanned elements: - Ignore: If a work order contains unplanned elements (materials, operations), you can ignore these orders. - Keep unforeseen elements: The routing/bom in these orders will be updated keeping all the unplanned elements. - Discard unforeseen elements: The routing/bom in these orders will be updated and the unplanned elements will be deleted. Certified Student Course Curriculum - Version 2.0 Page 153

160 Manufacturing Series - Fundamenta als Masss Closures and Completions Use Mass closure/completions (FUNTDUCLO) on the Manufacturing > Production tracking menu to perform mass completions and closures of selected works orders. Only in-process firm works orders (those having been the object of a production booking) can be completed/closed. The first window is used to select the work orders to be processed. You can block closures or completions by selecting the appropriate check box in the Block section. - If at least one sub-con ordered/in progress: The work order in question has a sub-contractor operation and it is on order or in the process of being received. Even if this check box is cleared, the operation cannot be completed and the closure of the work order cannot be carried out. In this case, a message displays in the log file. This check box only has an effect on the completion. - If at least one oper. is not complete: The current work order has at least one operation where the production tracking status is Pending. If an attempt to close the work order occurs, the result depends on the general parameter CTLCLE value. In this case, a message displays in the log file. Page 154 Certified Student Course Curriculum - Version 2.0

161 Mass Closures and Completions (continued) - If at least one rel. prod not produced: The current work order has at least one product launched where the production tracking status is Pending. - If at least one material not consumed: The current work order has at least one material where the production tracking status is Pending. If an attempt to close the work order occurs, the result depends on the general parameter CTLCLE. In this case, a message displays in the log file. - If the completed qty < planned qty: At the time of the closure, if the quantity produced is less than the planned quantity, you can choose to block the closure. Use the options in the Automatic Functioning section to control the automatic tracking of materials and operations. - Track automatic materials: At the time of completion or the closure of a work order, if the production of the launched product has started, you can automatically backflush the consumption of the materials. You must select the check box to carry out the material tracking. - Automatic tracking of operations: At the time of completion or the closure of a work order, if the production of the launched product has started, you can automatically complete the operations according to the quantity produced of the launched product. You must select the check box to carry out the tracking of operations. - Production Cost Price: Select this check box to automatically run the work order cost calculation. This allows the system to automatically calculate production costs following a work order closure. Work order finalization is run for each work order and each work order is closed. You can view the results by accessing Costing > Production Cost > WIP Cost Inquiry. Certified Student Course Curriculum - Version 2.0 Page 155

162 Mass Closures and Completions (continued) After clicking OK, the following window is displayed. You can right-click a line to view the work order detail and tracking information. Page 156 Certified Student Course Curriculum - Version 2.0

163 Lesson 10 Production Costing In the following topics, you will learn how to view the breakdown by cost type of the production cost price, work order valuation information, how to value the production WIP for one or more work orders or sub-contract orders, view variances between actual and standard cost, and how to pass the work order information to the accounting module. You will also learn how to compare multiple costs. The topics in this lesson include: Production Cost Inquiry WIP Cost Inquiry Cost Comparison Multiple Cost Comparison WIP Validation WIP Cost Finalization WIP Accounting Interface Certified Student Course Curriculum - Version 2.0 Page 157

164 Manufacturing Series - Fundamenta als Production Cost Inquiry Use Production cost inquiry (GESMFC) on the Costing > Production cost menu to view the breakdown by cost type of the production cost price for a work order. Page 158 Certified Student Course Curriculum - Version 2.0

165 WIP Cost Inquiry Use WIP cost inquiry (GESMWI) on the Costing > Production cost menu to view the work order valuation information and to compare the actual costs with those that were planned at the time of the release. Certified Student Course Curriculum - Version 2.0 Page 159

166 Manufacturing Series - Fundamenta als Cost Comparison Use Cost comparison (COMPCOUT) on the Costing > Performance analysis to compare two provisional costs or production costs that have been calculated for a single site or two different sites. You can measure the variances for material, machines, labor costs, subcontracts, and overhead Page 160 Certified Student Course Curriculum - Version 2.0

167 Multiple Cost Comparison Use Multiple cost comparison (COMPCOUTM) on the Costing > Performancee analysis to view multiple costs. The settings in this task allow you to compare the costs for a selection of products from two different warehouses or costs from a different source within the same warehouse. A report is generated comparing the many costs based on the criteria entered. Certified Student Course Curriculum - Version 2.0 Page 161

168 Manufacturing Series - Fundamenta als WIP Valuation Use WIP valuation on (ORDWIPVAL) the Costing > WIP menu to value the production WIP for one or more work orders or sub-contract orders, according to the calculation parameters. The production WIP corresponds to the value of the products in production for which the raw material has been consumed, time has been entered, and stock receipts have been carried out. Page 162 Certified Student Course Curriculum - Version 2.0

169 WIP Finalization Use WIP finalization (FUNWIPMFC) on the Costing > Production cost menu to determine the production cost price (PCP) for a completed work order and to underline a variance between the actual cost and the standard cost (cost based on the dataa in the BOM) or the cost based on the work order data. You can right-click the Order no. field to filter on work orders. (Right-click and select WO filter.) Certified Student Course Curriculum - Version 2.0 Page 163

170 Manufacturing Series - Fundamenta als WIP Accounting Interfacee Use In-process posting (WIP accounting interface) (FUNWIPACC) on the Costing > WIP menu to pass the work order WIP records that have resulted from production tracking, as well as any variance or adjustmentt records generated during the production cost calculation to the accounting module. It is possible to transfer the WIP records to accounting for work orders that have not yet been closed. It is also possible to transfer the WIP generated from reporting without work order. All elements from production are transferred to the accounting module by this method, including material issues, stock receipts, operational expenses (machine, labor and sub- are contractor) ), and overheads. Stock movements coming from production management therefore not posted by the stock interface. After selecting the needed criteria and clicking OK, a log window similar to the following appears. Page 164 Certified Student Course Curriculum - Version 2.0

171 Lesson 8 In the following topics, you will about some of the key reports available in Manufacturing. The topics in this lesson include: Printing Manufacturing Reports Reports Certified Student Course Curriculum - Version 2.0 Page 165

172 Manufacturing Series - Fundamenta als Printing Manufacturing Reports There are several reports available on various menus under the Reports menu that detail information on settings and transactions entered in Manufacturing. Reports > Reports There are various reports available in this task including routings and work centers, job tickets and technical sheets, MRP and MPS suggestion lists, work order cost detail, cost dimensionn listing, and analysis lists, as well as the single-level BOM cost report, to name a few. The technical data reports that you can print include standard operations, routings, weekly structure listings, and work center listings. - You can also print these reports from the Technical data task on the Reports > Prints/group > Manufacturing menu. The production documents that you can print include job tickets, material issue notes, routing sheet, technical sheet, and production slip. - You can also print these reports from Production documents task on the Reports > Prints/group > Manufacturing menu. The reorder reports that you can print include MRP and MPS suggestion lists and reorderr policy listing. The valuation reports that you can print include work order cost detail and cost dimension listing. The analysis report that you can print include lead-time, list or work orders, tracking list, material yield, operating yield, resource yield, late order analysis, time analysis, resource utilization, and work load listing. Reports > Prints/group > Manufacturing There are several different tasks that categorize the reports specific to technical data, production documents, reorder, valuation, and analysis. The Technical dataa task includes reports that are specific to reports or forms that are used for routings and work centers. They include such reports/forms as the Standard operations listing, Routings, Weekly structure listing, and Work center listing. The Production documents task includes reports that are specific to production such as Job tickets, Material issue notes, Routing sheet, Technical sheet, and Production slip. The Reorder task includes reports that are specific to MRP and MPS. They include the MRP suggestion list, MPS suggestionss list, Suggestion list ex-mrp, and Reorder policy listing. Page 166 Certified Student Course Curriculum - Version 2.0

173 Printing Manufacturing Reports (continued) The Valuation task includes reports that are specificc to work order cost and cost dimension. They include the WO cost detail and Cost dimension listing. The Analyses task includes reports providing information on lead time and material, operating, and resource yield. They include the Lead-time analysis, List of WOs, WO detail list, Tracking list, Material yield, Operating yield, Resource yield, Late order analysis, Time analysis report, Resource utilization report, and Work load listing. Reports In this Practice, take a few moments to view different reports. 1. From the menus and tasks discussed on the previous page, preview various reports. 2. When completed, close all windows until you are returned to the main Sage ERP X3 desktop. Certified Student Course Curriculum - Version 2.0 Page 167

174 Manufacturing Series - Fundamenta als Summary You have learned: About manufacturing concepts and processes. How to process material requirements planning and view the results. How to create work orders and perform allocations and scheduling. How to track the production process. How to view actual costs compared to planned costs. How to determine the production cost for a completed work order. Page 168 Certified Student Course Curriculum - Version 2.0

175 Sage ERP X3 Training Classroom Training Anytime Learning Training (Online) Realtime Learning Training (Online) Virtual Hands-on Labs Lunch and Learn Sessions Private Training Visit Sage University for your training needs.