ADempiere User Manual

Part C

Manufacturing

Copyr i gh t

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All trademarks within this guide belong to their legitimate owners.

Author s

Heinz-Günter Siebert (Oscar)

FeedbackMaintainer of this document: Heinz-Günter Siebert Please direct any comments or suggestions about this document to:authors @adempiere.org

Pub l i ca t ion date and so f tware ver s ion

Published: 4 th June, 2008. Based on Adempiere Version 3.5.1a Revision 5331 – Doc.Version 0.1

Table of Content 0 Introduction......................................................................................................................................5

0.1 Change Notice...........................................................................................................................5 0.2 BOM Change Notice................................................................................................................6

1 Engineering Management.................................................................................................................7 1.1 Resource Manufacturing...........................................................................................................7

1.1.1 Resource Type...................................................................................................................7 1.1.2 Manufacturing Resource...................................................................................................7 1.1.3 Questions...........................................................................................................................8

1.2 Manufacturing Workflow..........................................................................................................8 1.2.1 Manufacturing Workflow setup........................................................................................8 1.2.2 Manufacturing Workflows................................................................................................9

1.2.2.1 Questions...................................................................................................................9 1.2.3 Workflow Editor..............................................................................................................11

1.3 Bill of Material & Formulas..................................................................................................12 1.3.1 Workflow Editor..............................................................................................................12 1.3.2 Bill of Material & Formula.............................................................................................13 1.3.3 BOM & Formula Info.....................................................................................................13 1.3.4 Multi Level BOM & Formula Detail..............................................................................14 1.3.5 Multiple Components Change........................................................................................14 1.3.6 Product Configuration BOM...........................................................................................15

2 Planning Management....................................................................................................................16 2.1 Planning Management Setup..................................................................................................16 2.2 Product Data Planning............................................................................................................16

2.2.1 Product Planning.............................................................................................................16 2.2.2 Create Product Planning..................................................................................................17 2.2.3 Forecast...........................................................................................................................18

2.3 Material Resource Planning – MRP.......................................................................................19 2.3.1 Material Requirement Planning setup.............................................................................19 2.3.2 Calculate Low Level.......................................................................................................19 2.3.3 Create Record MRP........................................................................................................20 2.3.4 Calculate Material Plan...................................................................................................20 2.3.5 MRP Info.........................................................................................................................21 2.3.6 MRP Notice.....................................................................................................................21 2.3.7 MRP Details....................................................................................................................22 2.3.8 Planned Order Approval..................................................................................................22

2.4 Capacity Requirements Planning - CRP.................................................................................23 2.4.1 Capacity Requirement Planning Setup...........................................................................23 2.4.2 Calculate Capacity Plan..................................................................................................23 2.4.3 Resource Load View.......................................................................................................24 2.4.4 CRP Info..........................................................................................................................24

2.5 Distribution Resource Planning - DRP...................................................................................25 2.5.1 Distribution Resource Planning Setup............................................................................25 2.5.2 Calculate Distribution Plan.............................................................................................26 2.5.3 DRP Details.....................................................................................................................26

3 Production Management.................................................................................................................27 3.1 Discrete Manufacturing..........................................................................................................27

3.1.1 Discrete Manufacturing Setup .......................................................................................27 3.1.2 Manufacturing Order.......................................................................................................28 3.1.3 Manufacturing Orders Review........................................................................................29 3.1.4 Component Check...........................................................................................................29

3.1.5 Print & Release Order.....................................................................................................30 3.1.6 Order Receipt & Issue.....................................................................................................31 3.1.7 Inventory in Process........................................................................................................31 3.1.8 Order Transactions..........................................................................................................32 3.1.9 Management Maintenance..............................................................................................32

3.2 Shop Floor Control.................................................................................................................33 3.2.1 Activity Control Report...................................................................................................33 3.2.2 Shop Floor Transaction Details.......................................................................................33

4 Distribution Management...............................................................................................................34 4.1 Distribution Management Setup.............................................................................................34 4.2 Distribution Network..............................................................................................................34 4.3 Freight Category.....................................................................................................................35 4.4 Shipper....................................................................................................................................35 4.5 Distribution Order...................................................................................................................36 4.6 Generate Movement - Manual................................................................................................37 4.7 Generate Movement - Process................................................................................................38 4.8 Inventory Move.......................................................................................................................39

5 Quality Management.....................................................................................................................41 5.1 Quality Specifications.............................................................................................................41 5.2 Bill of Materials & Formula...................................................................................................42 5.3 Print Test Results....................................................................................................................42

6 Quality Management.....................................................................................................................43 6.1 Create Doc Type to Manufacturing.........................................................................................43 6.2 Create Element........................................................................................................................43 6.3 Product Costing.......................................................................................................................44 6.4 Copy Price to Standard Cost...................................................................................................44 6.5 Workflow Cost Roll-Up..........................................................................................................45 6.6 Cost Workflow & Process Details..........................................................................................45 6.7 Bill of Material & Formula Cost Roll-Up..............................................................................46 6.8 Cost Collector.........................................................................................................................46

0 Introduction

0.1 Change Notice

0.2 BOM Change Notice

1 Engineering Management

Engineering Management is the process, which delivers ...

1.1 Resource ManufacturingThe intention of Resource Manufacturing define Resource Types and Manufacturing Resources.

1.1.1 Resource Type

1.1.2 Manufacturing Resource

1.1.3 Questions● What is the meaning of Resource Type ?

○ man --> consultant

○ machine ?

○ Why are Product and Tax Category required ?

● What is the meaning of the checkbox IsManufacturingResource ?

1.2 Manufacturing WorkflowThe idea of the manufacturing workflow is

1.2.1 Manufacturing Workflow setup

The Manufacturing Workflow consists of four nodes:

● Resource Type

● Warehouse & Locators

● Manufacturing Resource

● Manufacturing Workflows

1.2.2 Manufacturing Workflows

1.2.2.1 Questions● What does have Data Access Level and Entity Type to do with the user's action ?

● Why is the Operation-Tab not called Node-Tab ?

1.2.3 Workflow Editor

This Menu item does provide an interface to serach for specifc workflow to be edited.

1.3 Bill of Material & Formulas

1.3.1 Workflow Editor

1.3.2 Bill of Material & Formula

1.3.3 BOM & Formula Info

1.3.4 Multi Level BOM & Formula Detail

1.3.5 Multiple Components Change

1.3.6 Product Configuration BOM

2 Planning ManagementBefore the manufacturing process will be started, it is necessary to plan all activities which are required to deliver all required components and material in time. Planning Management does answer the question: What is the optimal input for manufacturing to fullfil sales orders in time and keep warehosue costs at a minimum.

2.1 Planning Management Setup

2.2 Product Data Planning

2.2.1 Product Planning

2.2.2 Create Product PlanningIn order to facilitate to load planning data of similiar products, one can run teh process „Create Product Planning“ and this process will create the data planning register for every product, which fits the parameters: Product Category, Warehouse and Resource. One must indicate the planning parameters defined in the last section for every Product Category, Warehouse and Resource Set. Every Product which does fit with these three parameters will hava a data planning record with the same data planning values you enter in this form.

2.2.3 Forecast

2.3 Material Resource Planning – MRPMRP is a set of techniques which uses Bills of Meterial, Inventory Data and Master Production Schedule (MPS) to calculate requirements for materials. It does create planned manufacturing orders to balance demand and supply for products and it does issue recommendations to receipt material with the right quantities and just in time to satisfy the MPS in teh most efficient way.

2.3.1 Material Requirement Planning setup

2.3.2 Calculate Low Level

2.3.3 Create Record MRP

2.3.4 Calculate Material Plan

2.3.5 MRP Info

2.3.6 MRP Notice

2.3.7 MRP Details

2.3.8 Planned Order Approval

2.4 Capacity Requirements Planning - CRPThe process of Capacity Plan Calculation allows us to know the available time in each manufacturing resource, as well as teh required time to satisfy the Master Production Schedule (MPS). It is a set of techniques which uses the planned manufacturing orders by MRP, open manufacturing resources and the workflows to calculate the required time for each resource along with the available time. With this information, we are able to balance teh time demand with the available time. Though the knowledge of the required and available capabilities it is possible to adjust the MPS until we arrive at a realistic time.

2.4.1 Capacity Requirement Planning Setup

2.4.2 Calculate Capacity Plan

2.4.3 Resource Load View

2.4.4 CRP Info

2.5 Distribution Resource Planning - DRP

2.5.1 Distribution Resource Planning Setup

2.5.2 Calculate Distribution Plan

2.5.3 DRP Details

3 Production Management

3.1 Discrete Manufacturing

3.1.1 Discrete Manufacturing Setup Once the production planning process is completed1, the production control process allow the check the execution activities in order to garantuee to hold the material plan. Each time one needs to release a manufacturing order, the required components, material, man and machines are completely available in the warehouse. This is achieved by tracking the manufacturing release and due dates for every component, required to fullfil the initiating sales order. This is easy to get, using the shortage reports from this (?) module.

This module is responsible to answer the question: What do I need to accomplish the Master Production Schedule (MPS) ? If one cannot cover the MPS as planned, this module provides information required to decrease the negative effects on costs (reduce warehouse costs) and customer service (deliver in time).

1 Checklist ??

3.1.2 Manufacturing Order

3.1.3 Manufacturing Orders Review

3.1.4 Component Check

3.1.5 Print & Release Order

3.1.6 Order Receipt & Issue

3.1.7 Inventory in Process

3.1.8 Order Transactions

3.1.9 Management MaintenanceWhat are the Spare Parts for ?

3.2 Shop Floor Control

3.2.1 Activity Control Report

3.2.2 Shop Floor Transaction Details

4 Distribution Management

4.1 Distribution Management Setup

4.2 Distribution Network

4.3 Freight Category

4.4 Shipper

4.5 Distribution Order

4.6 Generate Movement - Manual

4.7 Generate Movement - Process

4.8 Inventory Move

5 Quality Management

5.1 Quality Specifications

5.2 Bill of Materials & Formula

5.3 Print Test Results

6 Quality Management

6.1 Create Doc Type to Manufacturing

6.2 Create Element

6.3 Product Costing

6.4 Copy Price to Standard Cost

6.5 Workflow Cost Roll-Up

6.6 Cost Workflow & Process Details

6.7 Bill of Material & Formula Cost Roll-Up

6.8 Cost Collector