Shop Floor Control Overviewintranet.kbs.co.th/blog/itblog/3-KBS_SHOP.pdfBackflushing Post Labor. 3...
Transcript of Shop Floor Control Overviewintranet.kbs.co.th/blog/itblog/3-KBS_SHOP.pdfBackflushing Post Labor. 3...
1
Shop Floor Control Agenda
• Shop Floor Control Overview
• Setup Shop Floor Control
• Shop Floor Control Process
• Enter Work Order
• Commitment
• Work Order Processing
• Issue Material
• Record Hours and Quantity
• Work Order Completion
Shop Floor ControlOverview
2
System Integration
Product Data Management
DRP/MPS/MRP
Procurement
Inventory Management
Payroll
Sales Order Management
RCCP/CRP Manufacturing Accounting
Shop Floor Work Order Flow
Record Hours and Quantities
Create Work Orders� Attach Parts List� Attach Routing Instructions� Generate shop paperwork
Schedule WorkPick/Issue Materials
Commitments - Availability Checking - Capacity
Complete Work Orders� Update Inventory� Backflushing� Post Labor
3
Shop Floor Management
Setting Up
Shop Floor
Management
Performing
Shop Floor
Processes
Accounting
Shop Floor
Processes
Setup Shop Floor Control
4
Define Manufacturing Constants
Manufacturing Constants are branch-specific information
which affects processing throughout the JD Edwards
EnterpriseOne Manufacturing systems.
�Manufacturing Constants
� Shifts
� Commitment Control
� Costing Options
7
6
Define Employee Labor Rate
Employee Labor Rate is used to define employee
labor rates that the system uses to calculate labor
costs
�Employee Code/Address Book Number
�Employee Name
�Rate / Hour
7
590
In Process Work Order’s - Run Work Order activity as needed - Partial Completions
9095
Complete adjusting manufacturing entries- Status to ‘95’- Manufacturing complete
9596
Manufacturing Accounting complete- Work Order Activity96
97 Variance Report Printed
9799
Variance Accounting complete- Purge
Step/eventsWork Order Status
Next Number
14
8
Shop Floor Process
Shop Floor Processes Cycle
Enter WO
WO Process
Invent Issue
Report Hrs &
Quantity
WO Completion
9
Work Order Creation� Manually
� Automatically - by acting on messages
� From Sales Order
� Define Item to create a certain quantity by a given date
� Create user-defined codes for type, priority, status
Work Orders
Routing
10 Mix
20 Add Liquids
30 Bake
40 Package
Parts List
Sugar
Whey
Calcium Stearate
Flavors
Soybean Oil
10
Attach Part List
1. Attach Manually
2. Automatic Attach Part List when Attach Routing
(Define in Processing Option)
3. Automatic Attach Part List from Order Processing
Program
What happens when attach Part List and Routing
1. Specified Bill/Routing Type with Specified batch
quantity
2. Specified Bill/Routing Type with Zero batch quantity
3. Bill/Routing Type M with Specified batch quantity
4. Bill/Routing Type M with Zero batch quantity
11
What happens when attach Part List and Routing
� Shrink, scrap, and operational yield.
Parts List
� Generate Pats List
automatically
� Override component
requirements, commitments,
and quantities
� Modify Parts List real-time
� Use substitute items if
necessary
12
Attach Routing
1. Attach Manually
2. Automatic Attach Routing when Attach Part List
(Define in Processing Option)
3. Automatic Attach Routing from Order Processing
Program
13
Routing Instructions
� Generate routings automatically
� Use master routings
� Outside operation
Item No*OP Operation Seq.
� Change work center, operation information
� Change sequence of operation steps
� Modify routings real-time
14
How calculate the start date
� Fixed Leadtime
Request date = 15/10/10
Level leadtime = three days
Start date = 12/10/10
� Variable Leadtime
{(Leadtime per unit x order quantity / TIMB (Item balance)) + setup + queue}/Work hours per day
Request date = 15/10/10
Leadtime per unit = 32 hours/1000 Units
Work order quantity = 1000
Setup = 1 hour Queue = 9 hours
Work Hour Per Day = 24 hours
{(32 x 1000/1000) + 1 + 9} / 24 = 2 day
Start date 13/10/10
Commitments
15
Hard Vs. Soft Commit
� A hard commitment
designates inventory to a
specific inventory location or
lot
� A soft commitment
tentatively commits
inventory to work order,
although not tied to a
location or lot
Where commitments are made . . .
Manufacturing Constants
Backflush Option - Specified location for Work center or use
commitment control
Commitment Control
1. Primary location where work
order originated
2. Branch/Plant boundaries may be
crossed
3. Any location within a
Branch/Plant
16
When hard commitments are made . . .
Manufacturing Constants
Hard/Soft Commit
1. Hard commit at creation of
Parts List
2. Soft commit change to
hard commit during work
order pick list print process
3. Soft commit through
inventory relief
How hard commitments are made . . .
Item Branch/Plant
Commitment Method
1. Primary Location, then
Location with the most
quantity
2. Lot number starting with
lowest
3. Lot expiration date, earliest
first
17
Managing Commitments for Grade and Potency Controlled Items
Not available
low end high end
Can be committed and issued
Not available
Valid Range
18
Managing Commitments for Grade WO require 800 and grade range A01-A03
Back
Commitments for Potent Units
Active ingredient in a product
On Hand Requirement
200 GP
80% (50 GA)(.80) = 40 GP
40% (400 GA)(.40) = 160 GP
19
Managing Commitments for PotencyWO require 500 GP
30 / 70%
= 43 Back
470
Repost Work Order Commitments
� Clear outdated or invalid commitments
� Repost commitments and on-order quantities specified
in a work order to current requirements
� Clear (set to zero) Quantity Commit to Work Order and
Quantity on Work Order
� Repost Value in Quantity on Work Order from F4801 :
Quantity on Order – (Quantity Complete + Quantity Scrap)
� Repost Value in Quantity Commit on Work Order from F3111 :
Quantity require – Quantity issued
20
Shop Floor Processes Cycle
Enter WO
WO Process
Invent Issue
Report Hrs &
Quantity
WO Completion
Process Work Order
� Generate Part List, Routing or both
� Update Status Code of Work Order
� Print Report - Shortage List, Shop Paper Work, Shop Packet
Summary
� Issue Inventory automatic through a batch program
(Preflush)
� Generate Purchase Order automatic for Outside Operation
� Calculate Standard Cost for Configured Item
� Substitute Item performed
21
Shop Floor Processes Cycle
Enter WO
WO Process
Invent Issue
Report Hrs &
Quantity
WO Completion
Pick/Issue
� Relieve inventory using
one of the following:
� Manual issue
� Preflush
� Relieve upon work order
completion using:
� Backflush
� SuperBackflush
23
Production Scheduling
� Schedule work center production for work orders
� Compare planned against actual schedules
� Use the scheduling workbench to review and change
schedules real-time
Capacity
Orders
24
Shop Floor Processes Cycle
Enter WO
WO Process
Invent Issue
Report Hrs &
Quantity
WO Completion
Hours and Quantities
� Enter and track time and quantities by
� Work Order
� Employee
� Track resource usage by work center
� Compare standard Vs. actual
� Charge actual hours
25
Post Hours and Quantities
� Run Hours and Quantities Update program
� Interactively through Hours and Quantities entry
Operation Hours Quantity
Hour & Quantity
Shop Floor
Update Routing (F3112)
Hour & Quantity
(P311221)
Shop Floor
Write Time Transaction (F31122)Post
27
Shop Floor Processes Cycle
Enter WO
WO Process
Invent Issue
Report Hrs &
Quantity
WO Completion
Completions to Inventory
� Partial completions as they occur
� Full completion when entire work request is satisfied
Inventory
Item Loctn Qty
Candy Bin-X
2000
Complete2000