INDEX: ENGINEERING CONTROLapps.qmuzik.com/Training/qm8pdf/Equipment Base.pdf · Equipment Base:...

EQUIPMENT BASE Course Assignment

REVISION 01

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View As

Built

View Serialized

Stock

View Product

Structure

Add Part

Operations

Build Product

Structure

Add Part

Master

Movement: Production

To Customer

Movement: Stores to

Order Requirements

Ship to Equipment

Base

Add Works Order

Movement: Stores to

Order Requirements

Movement: Production To Store

Add Customer Order

Explode Requirements

Is „Off‟

Serial Number Linking

Move Serialized Parts Per Number

View Requirements

Parts

Create Equipment

ID

Link Equipment

ID

Component Serial Number Determine

Parent Serial Number

View Equipment Base

Structure

EQUIPMENT BASE THROUGH WORKSORDERS

REPLACE COMPONENT

Receipt From

Equipment Base

Unlink Equipment

ID

Add Customer Order

(Optional)

Movement:: Stores to Order Requirements

Movement: Production

To Customer

Update Equipment

Status

Receipt From

Equipment Base

Release Created Repair

Order

Issue Requirements

Return Fixed Component To

Stock

Return To Equipment

Base

REPAIR COMPONENT

Movements: Requirements

To Stores

Movements: Customer to Production

Movements: Stores to

Requirements

Update History Add „Returned‟

To Equipment ID And Components

View Structure

Ship to Equipment base

Movements: Production to

Customer

Serial Number Linking

Unlink Equipment ID

Equipment base View Structure

REPLACE COMPONENT

Serial Number Un-Linking

Old Component New Component

Start „Repair/Scrap Procedure

Revision 01: 1 February 2006 Page 1

Equipment Base: Course Assignment

INTRODUCTION

The Equipment Base Course addresses the populating and maintenance of the Equipment Base. Where the Product Structure shows the components needed to build a product, the Equipment Base reflects which components (serial numbers) were uses to build and maintain the product. The Serial Number Linking function keeps the original As Build structure.

OBJECTIVES : You will learn how to:

EXERCISE 1 : View Parts

EXERCISE 2 : Add Works Order (Production Order)

EXERCISE 3 : Issue Required Components to the Works Order

EXERCISE 4 : Serial Number Linking

EXERCISE 5 : Receive Final Product into Stock

EXERCISE 6 : Create Customer Order (Explode Requirements „Off‟)

EXERCISE 7 : Issue the Stock to the Customer Order

EXERCISE 8 : Ship the Product

EXERCISE 9 : Replace Defective Component



EXERCISE 1

VIEW PARTS Use the Part Master function to view the parts that will be used during this course. The Product Master must have Equipment Base option set to on. Specify parts as Maintenance Significant Items. Select a repair type and select the Equipment Base option per part. See The Engineering course for more detail on adding parts.

TABLE 1.1

COMPONENT NUMBER

DESCRIPTION SERIAL NUMBER STORES NUMBER

LOCATION

MEI00001 MEI00002 MEI00003

TOP LEVEL PART COMPONENT LEVEL 1 COMPONENT LEVEL 1

CV01 CV02 CV03

FIGURE 1.1

VIEW A PART

NOTES:

Use the Part Master function to view parts.

The Part should be marked as either „Always‟ or „Record Later‟ in the Serialised Frame. Set the Equipment Base option on on LSA tab.

FIGURE 1.2

VIEW STRUCTURE

NOTES:

Use the Product Structure function to view the components needed to build the product number MEI00001.

The detail per components is visible in the column on the right.



FIGURE 1.3

VIEW AVAILABLE STOCK

NOTES:

Note in step 1 that although the part is flagged as serial controlled, there are no serial numbers. This is because the serialised option “record later” was selected.

There is a quantity on hand of two of every component preloaded.



EXERCISE 2

ADD A WORKSORDER (PRODUCTION ORDER) (Make to Stock)

The components are available. We will now create a works order to build the final product. Use the Order Master function to add a works order.

FIGURE 2.1

ADD A WORKSORDER HEADER NOTES:

Use the Order Master function to load a works order.

The Final Product is assembled against a Works Order (Production Order).

A Customer Order (Demand) does not necessary exist for the product yet. If it did and no stock for MEI00001 existed, MRP would have created a planned works order.

FIGURE 2.2

ADD WORKSORDER LINE

NOTES:

Ensure that the line status is „Released‟.

After adding the line click on the requirements tab to view the components needed to build the product.

Note the quantity to be manufactured equals 2.

FIGURE 2.3

VIEW REQUIREMENTS



EXERCISE 3

ISSUE REQUIRED COMPONENTS TO THE WORKSORDER Use the Stores to Order Requirements Movement to issue the required components to the works order from the store.

FIGURE 3.1

STORES TO ORDER REQUIREMENTS

NOTES:

Issue the Serialised Components one by one. This is because the serial numbers need to be allocated to the parts flagged as serialised record later.



EXERCISE 4

SERIAL NUMBER LINKING The Product Structure does not include the serial numbers of the actual component parts. Use the Serial Number Linking function to link components with their serial numbers to a parent with its serial number. The Product Structure is a Logical Structure while this exercise creates a Physical (As Build) Structure.

If the system setting “Serial And Lot Tracking To End Item Level” is set, the As Build configuration must be defined before the finished goods can be received through the Production to Store Movement.

FIGURE 4.1

SERIAL NUMBER LINKING

NOTES:

Step 4 selects the component part number to be linked.

Step 5 is the specific serial number of the part to be linked and step 6 the parent serial number it must link to.

Follow the steps in fig 4.1. for both parents.



EXERCISE 5

RECEIVE FINAL ASSEMBLY INTO STOCK When the final products are assembled it is moved back into stock. Use the Production to Stores Movement to achieve this.

FIGURE 5.1

RECEIVE BACK INTO STORE

NOTES:

Follow the steps in fig 5.1 to receive both parent parts.

Step 5: Through multiple select both parents can be received simultaneously.

If numbers appear in serial number list box select from there in step 6.

FIGURE 5.2

VIEW AS BUILD

NOTES:

Follow the steps in fig 5.2 to view parent parts as build.



EXERCISE 6

ADD A CUSTOMER ORDER Use the Customer Order function to add a Sales Order for the products build in exercise 5. For more information see the Customer Order Course.

FIGURE 6.1

ADD A CUSTOMER ORDER

FIGURE 6.2

ADD CUSTOMER ORDER LINE

NOTES:

Explode Requirements is „Off”

Step 4 : Quantity Ordered = 2

Click on the Requirements tab once the line is added.

FIGURE 6.3

VIEW REQUIREMENTS

NOTES:

Because Explode Requirements is „Off”, the final product is the only requirement.



EXERCISE 7

ISSUE THE PRODUCTS TO THE CUSTOMER ORDER Use the Stores to Order Requirements Movement to issue the final products to the Sales Order.

FIGURE 7.1

ISSUE FINAL PRODUCT

NOTES:

Products can be issued one by one per Serial number or multi selected as in this example.



EXERCISE 8

SHIP THE CUSTOMER ORDER

Use the Production to Customer Movement to ship the Customer Order.

FIGURE 8.1

SHIP ORDER TO CUSTOMER

NOTES:

The shipping line includes both serialised end items (products).

Step 5 opens the Shipping To Equipment Base tab.

FIGURE 8.2

SHIP LINE

NOTES:



FIGURE 8.3

SETUP EQUIPMENT BASE FOR

FINISHED PRODUCTS

NOTES:

FIGURE 8.4

SETP WARRANTY PARTICULARS IF

APPLICABLE

NOTES: Every Time the equipment status changes you may amend the warranty particulars.

FIGURE 8.5

SHIP ORDER TO CUSTOMER

NOTES:



FIGURE 8.6

SHIPPING

NOTES:

FIGURE 8.7

VIEW SHIPPING DETAILS

NOTES:



EXERCISE 9

REPLACE DEFECTIVE COMPONENTS

FIGURE 9.1

RECEIPT OF DEFECTIVE PART

NOTES:

The selected equipment is defective and sent back by the customer. To the very right is a check box to indicate if a part must be removed from the equipment structure or not. This is used for a component that is defective.

In “Create Order”, „none‟ was selected. Other options were to create either a maintenance or repair order if applicable.

In step 1 we could have selected a component that was returned instead of the whole equipment. In that case we first add a new equipment status before doing the Receipt from Equipment Base movement.

FIGURE 9.2

VIEW EQUIPMENT

NOTES:

Note in step 1 that the status changed to returned and in step 2 an indication that equipment is currently not ready for use.



FIGURE 9.3

VIEW MOVEMENT HISTORY

NOTES:

FIGURE 9.4

VIEW MOVEMENT HISTORY

NOTES:

Notice the unplanned receipt movement created by the Receipt from Equipment Base function.

FIGURE 9.5

ADD CUSTOMER ORDER

NOTES:

A component is defective and needs to be replaced. Create a spare sales line (step 1).

Due to the warranty there is no sales price associated as shown in step 4.

If a component was simply fixed and replaced we could do a Return to Equipment Base movement and do not need customer orders and production to customer movements.



FIGURE 9.6

ISSUE SPARE TO CUSTOMER

ORDER LINE

FIGURE 9.7

EQUIPMENT BASE

NOTES:

The old link is made inactive.

FIGURE 9.8

SHIPPING TRANSACTION

NOTES:



FIGURE 9.9


NOTES:

FIGURE 9.10

VIEW MODIFIED EQUIPMENT

STRUCTURE

NOTES:

Show that an existing equipment parent is to be updated in step 1.

FIGURE 9.11


NOTES:



FIGURE 9.12

MODIFY EQUIPMENT STRUCTURE

NOTES:

FIGURE 9.13


STRUCTURE

NOTES:

FIGURE 9.14

ADD NEW EQUIPMENT STATUS

NOTES:



FIGURE 9.15


STRUCTURE

NOTES:

Note that equipment is shown as ready for use again.



LESSON SUMMARY

On completion of the Equipment Base course the students will have a basic understanding of how the Equipment Base functionality works.

TO DO THIS

View Parts Use the PART MASTER function Use the PRODUCT STRUCTURE function Use the PRODUCT STRUCTURE NAVIGATION function

View Stock Use the PART MASTER function

Create a Works Order Use the ORDER MASTER function

Issue stock to the Works Order Use the MOVEMENT: STORES TO ORDER REQUIREMENTS

Receive assembled stock back in Store Use the MOVEMENT: PRODUCTION TO STORES

Ship Stock to Customers Use the MOVEMENT: STORES TO ORDER REQUIREMENTS and then PRODUCTION TO CUSTOMER

Link the Serial Numbers Use the SERIAL NUMBER LINKING function

Build the Equipment Base Use the MOVEMENT: PRODUCTION TO CUSTOMER to ship the stock. Use the SHIPPING TO EQUIPMENT BASE function to populate the Equipment Base. Use the EQUIPMENT BASE function to create the Equipment Base structure. Use the STRUCTURE MAINTENANCE tab on the EQUIPMENT BASE function to create the structure and link the Equipment ID‟s to the structure.



PRESENTER’S NOTES

1. Ensure that enough serialised parts and quantity on hand‟s exists for all students. 2. Ensure that a product structure exists including those serialised parts. 3. Ensure that at least one part operation exists against the parent part and that a succesful cost

generation has been run for the product structure. 4. All student must have security profiles with full rights to the following functions: a. Part Master b. Part Operation c. Product Structure d. Product Structure Navigation

e. Equipment Base f. Serial Number Linking g. Movement rights to the specific store.

INDEX: ENGINEERING CONTROLapps.qmuzik.com/Training/qm8pdf/Equipment Base.pdf · Equipment Base:...

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