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BatchMaster Enterprise 7.25 User Manual Volume IIIb

1. EE EE E 4 Figure 16 1 Intermediate Property Rollup Screen Item Key From This is the Item key that specifies the lower limit of the range of items for the property rollup The lookup here is limited to those items for which at least one item location has a Bill of Materials of the Released status Leaving this field blank has the same effect as entering the first available Item Key Item Key To This is the Item key that specifies the upper limit of the range of items for the property rollup The lookup here is limited to those items for which at least one item location has a Bill of Materials of the Released status Leaving this field blank has the same effect as entering the last available Item Key Search level This field has two options a Top In this case the roll up will be single level b Bottom In this case the roll up will be multi level starting with the lowest level raw materials Status not Allowed This stores the Formula Statuses that will be excluded from the Intermediate Property Rollup This prevents rolling up the intermediates material property specifications Leaving this field blank implies that none of the formula statuses have been excluded Trial Mode Use this option to view the proposed changes without actually making the changes Actual Mode Processing a roll up with this option selected will write the changes to the databases DOCNUMBER 066 April 14 200
2. Costing Reports i 0 Routing Report E Pom fALTERNATE_A Slien For Production level 2 fem Kel a Production To aP y Sien For Production level 3 SL Production Utilit z i Fi Fao Dro E Ge SS Location ae al eeh Le In woe INLOC S O MAP A 4 Run MAP D GE ES Plan Start Date 06 07 04 O DemandFe Plan End Date 20 07 04 gt ID Demand Fe D Demand Fe Change Status C Ti From EXCEPTION v Te FIRM PLANNED gt O Planned MF C Planned MF D Transfer MF D Transfer MF C MRP Reports _ Process Cell Mc _ QC Masters 1 Process Cell Re 1 QC Reports C MSDS _ BOM Utilities I MSNS emt ES EE EE EE Figure 11 6 MRP Order Range Processing Screen Item Key From The lookup at this field displays those MRP items for which there exists at least one Purchase Order or Production Order This specifies the lower limit of the range of MRP items for which the order status needs to be changed Leaving this field blank has the same effect as selecting the first available item via the lookup Item Key To The lookup at this field displays those MRP items for which there exists at least one Purchase Order or Production Order This specifies the upper limit of the range of MRP items for which the order status needs to be changed Leaving this field blank has the same effect as selecting the last available item via the lookup Location From This sp
3. Figure 10 5 4 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold i Multiple Bins Requirement Yes or No 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date sa oQ0T p sao np a DOCNUMBER 066 April 14 2005 Issue 2 Page 87 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Planning Worksheet Clicking this button opens the Planning Worksheet screen with focus on the Planned Production Order tab ER BatchMaster Manufacturing Transfer MPS Production Order a E x EZ File Edit View Help Module Special Functions Windows 2 x Cell alzle wl a gt rif ale 1 Costing Utilities 1 Costing Reports Routing Reports 1 Production Production Utilitie 1 Production Repor C MPS ID Forecast Entr O Run MPS CY MPS Plannine O Transfer MPS DN El m Select MPS Item Location TESTAVERAGE ITE Planning Worksheet _TESTAVERAGE ITE Button From MPS Item To From DS TU To
4. Fire Hazard IT Pure Sudden Release of Pressure Hazard IV Mixture Reactivity Hazard IT Solid Immediate Health Hazard Acute T Liquid Delayed Health Hazard Chronic m SARA Information Delayed Health Hazard Chronic Details ID SARA Process Add Line O MSDS Master Ea O MSDS Sched Delete Line O Print MSDS ID Customer Histe ID Update Custor Di MSDS Setup 1 BOM Utilities C MSDS Reports 1 Laboratory a 1 ahnratnn les al p gt G Figure 14 5 3 CAS Number Master Safety Info Continued Tab SE E EE Fire Hazard Check this box if this material is readily combustible and or presents a potential fire hazard Sudden Release of Pressure Hazard Check this box if this material will react violently when pressure is suddenly released from this material Reactivity Hazard Check this box if this material will react possibly violently when combined with certain other materials Immediate Health Hazard Acute Check this box if this material presents an immediate and or severe health hazard should some one come in contact with it Contact may be interpreted as physical contact on the skin inhalation ingestion etc Delayed Health Hazard Chronic Check this box if this material presents a long term delayed and or recurring health hazard should some one come in contact with it Contact may be interpreted as physical contact on the skin inhalation
5. UE EE E EE Figure 10 3 3 MPS Planning Worksheet Cust Orders Tab Select When this box is checked for a row that row becomes available for deletion via the Delete Line button When this box is un checked for a row that row becomes unavailable for deletion via the Delete Line button Sales No This is the sales order number associated with this row Line No This is the SO line number as stored at the Rownum field of the OELIN table Order Qty During Run MPS the Order Quantity is fetched from the Sales Order Entry screen The Order Quantity can be changed on this screen Changing the Order Quantity and saving it updates the related demand on the planning worksheet on Tab 1 automatically but does not change the actual SO line quantity on the Sales Order Entry screen DOCNUMBER 066 April 14 2005 Issue 2 Page67 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Request Date This is the date on which the Order Qty of this item is requested to be ready During Run MPS the Request date is fetched from the Sales Order Entry screen The Request Date can be changed on this screen Changing the Request Date and saving it updates the related demand on the planning worksheet on Tab 1 automatically but does not change the actual Sales Order line on the Sales Order Entry screen Select All Clicking this button checks the boxes for all the rows in the grid Unsele
6. m Target Values Alphanumeric Value jal 2 Nominal Value 0 0000 r Control Limits Lower Value 0 0000 Upper Value 0 0000 Figure 13 3 QC Item Tests Screen Item This is the Item with which one or more quality control tests are associated This is a mandatory field Test and Measuring Criteria Test ID This is the Test ID associated with the test selected at this row Measuring This is the measurement type of the test results The value of this field can be set to one of the following 1 Pass Fail Value The result value of the test can be either Pass or Fail 2 Numeric Value The result value has to be a numeric value 3 Alphanumeric Value The result value can be alphanumeric Add Line Clicking this button inserts a new line into the Test and Measuring Criteria grid Delete Line Clicking this button deletes the selected line If the grid contains a single line deleting this line deletes the header also Target Values Alphanumeric Value This is the Target value for a test of Alphanumeric measuring type Nominal Value This is the Target value for a test of Numeric measuring type DOCNUMBER 066 April 14 2005 Issue 2 Page174 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Control Limits Lower This is the lower control limit for a test of Numeric measuring type Upper This is the upper control limit f
7. SL QC Masters PLANNED eo 07 04 SL Process Cell Repo PLANNED el He Heras PLANNED 13 07 04 SL MSDS ege Ia oana SL BOM Utilities SL MSDS Reports MBP Order Details Laboratory Process Line OrderNo Batch Type Status Scheduled Start Date Ice ji j i Figure 12 2 1 Process Cell Scheduling Screen Process Cell Schedule Detail tab Batch Details grid Only batches having status New or Allocated will be displayed in the grid If for a specific day the Process Cell is overloaded that is the number of hours specified for the process cell have been exceeded for that day then the overloaded lines in the grid are highlighted with red color Process Line This number specifies the relative sequence on the selected date in which the production of this batch is scheduled to begin It can be modified using the re sequence button on the tool bar DOCNUMBER 066 April 14 2005 Issue 2 Page 163 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Batch Number This field displays the number associated with a batch for a line in the grid Batch Type This field displays the batch type associated with a batch for a line in the grid Batch Status This field displays the status of a batch for a line in the grid Scheduled Start Date This field displays the date on which the production of this batch is scheduled to start It can be modified When a Pr
8. iew Item Location a EZ Item Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Warehouse te Main watebeo 3S SLBCH RES Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order 23 0000 Quantity Commit To Sales 0 0000 Quantity Commit To Production 0 0000 Figure 11 2 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No se mpoapgp 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date oeren lt a Sg DOCNUMBER 066 April 14 2005 Issue 2 Page 125 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 3 Demand Fence 2 MRP Purchase Order The Demand Fence 2 MRP Purchase Order option provides a way to define the order status for a MRP Purchase Order having status as Exception and falling under the period of Demand Fence 2 With Demand Fence 2 MRP Purchase Order one can convert the order status of a selected MRP order a
9. MRP 4 EXCEPTION __ MRP Plan run Dt Order Status Plan Start Dt Plan End Dt Confirm End O Run MRP 0 D 4 50 001 04 04 08 04 5 O Demand Fe E O Demand Fe ID Demand Fe k 4 ER 2 EL UI 13 4 15 Bj E E Ej b MRP Order PC d O Planned MF P C Planned MF fo m D Transfer MF he O Transfer MF iE a HO MRP Reports d 1 _ Process Cell Mc SL QC Masters ps Es GEN men _ QC Reports i SL MSDS Select All UnSelect All Delete Line Exception Firm Planned Confirmed Club Orders SL BOM Utilities E a Des me Pernt Figure 11 5 1 Demand Fence 2 MRP Production Order Screen Item Key This the Item Key associated with the Item Location for which the Demand Fence 2 MRP Production Order is displayed Location This the Location Key associated with the Item for which the Demand Fence 2 MRP Production Order is displayed DOCNUMBER 066 April 14 2005 Issue 2 Page 134 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MRP Order No This is the system generated number for the MRP order Plan Run Dt This is the date when the MRP ord
10. C Demand Fi Select date range for demand consolidation Generate Planned Orders as ee Demand Start Date Ze Planned Demand End Date 19 08 04 be C Firm Planned MPS Run Date 20 07 04 IN Pull MPS II L MPS Orde CJ MAP 1 MPP Reports Process Cell M 1 QC Masters C Process Cell R C QC Reports C MSDS BOM Utilities _ MSDS Report 1 Laboratory 1 ahnratan e z 20 07 04 C Confirmed H EE E E E E E EE EE Figure 10 2 Run MPS Screen Select Item Range for MPS Run From MPS Item This field specifies the lower limit of the range of item keys for use as filter criteria during processing The lookup in this field is restricted to items maintained as MPS items using the Maintain MPS Item screen This MPS Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available MPS item key via the lookup To MPS Item This Item key specifies the upper limit of the range of item keys for use as filter criteria during processing The lookup in this field is restricted to items maintained as MPS items using the Maintain MPS Item screen This MPS Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last avai
11. sssssssssetrerttrtrrrtrrtttrtrttrrtnrtntrnr rnrn rreren reenen 93 14 7 1 Screen Fields Description 93 14 7 2 Working with Demand Fence 1 MPS Production Order 95 14 7 3 Special FUNCIONS E 96 14 8 DEMAND F ENCE 2 MPS PURCHASE ODER 97 14 8 1 Screen Fields Description 97 14 8 2 Working with Demand Fence 2 MPS Purchase Order 99 14 8 3 Special FUNCUONS EE 100 14 9 DEMAND F ENCE 2 MPS PRODUCTION O RDER 0sccceeeeeeeeceeeeeeeeeeeeeeeseeeeeeesaeeeeeeeseeeseeesens 101 14 9 1 Screen Fields Description EE 101 14 9 2 Working with Demand Fence 2 MPS Production Order 103 14 9 3 Spe cial FUNCIONS EE 104 14 10 MAINTAIN MPS IEN 105 14 10 1 Screen Fields Description 105 14 10 2 Maintaining a MPS ltem cccccccc eet e cette eee ene e teen teen tet ee ee eennn a eeeeeennetneeetaa 106 LE E Special tee 107 14 11 COMPANY CALENDAR SETUP 0cccceecececccusecee seecesecceseeseueeseueeseueeseuseeaesenseseseeseaeseseeses 108 DOCNUMBER 066 April 14 2005 Issue 2 Page5 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 11 1 Screen Fields Description 108 14 11 2 Creating a Company Calendar 109 14 12 PLANNING CALENDAR amp ere Ee gege ENEE geed 109 VM eM EE 109 14 122 Screen Fields Descriptio ENER EEN ne EE EEE E ENESTE eee veneered 110 14 12 3 Creating a Planning Calendar 111 14 13 MP S SETUP EE 111 14 13 1 Mandatory Imputs eet eee e tree need t te eeennete
12. 3 Production Utilities Item Location To MFG Al Item Class From P AN Item Class To Ei Al lI R R O O Transfer S0 T ID Batch Range F O Create Batche CY Purge Batches Co Pae D Sales Order Entry Date From oso 04 ba 1 Production Report Sales Order Entry Date To 09 22 04 be JM a GE Sales Order Requested Delivery Date From 09 24 04 x C MPP Reports 1 Process Cell Mode C QC Masters _ Process Cell Repo 1 QC Reports CJ MSDS BOM Utilities 1 MANS Bette z Sales Order Requested Delivery Date To 03 24 04 Default Generated Batch Start Date 09 24 04 Default Generated Batch End Date 09 30 04 bi Schedule Formula Key fi Append Create Schedule Append he Figure 9 1 Generate Schedule Screen E EE III EE EEN DOCNUMBER 066 April 14 2005 Issue 2 Page 13 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Schedule Type This is a filter criterion on the basis of which the lookups at the Item Key From and Item Key To fields display the items The type of a Schedule can be one of the following 1 Both Intermediate and Finished Good If this option is selected a The item lookups display only those items for which an Intermediate or Finished Good types of released BOM exists b Schedules can be
13. 8 Click on the Process button on the toolbar to create a report 26 MPS Reports 26 1 MPS Planning Report The MPS Planning Report provides a broad view of planning for an MPS item The report also depicts the Available to Promise ATP within a single period and on the cumulative basis This report may be seen as an effective way to gather a sense of the scope of planning for a single item across the defined planning horizon The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 26 1 1 Generating an MPS Planning Report 1 Complete the MPS Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields DOCNUMBER 066 April 14 2005 Issue 2 Page 268 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 26 2 MPS Demand Report The MPS Demand Report is taken directly from the Planning Calendar s three demand ranges The MPS Demand Report provides the means to see demand
14. ousnniiinensnninnnnnnrrrnnnnrrrrnnrerrrrrrreerrrreeens 234 22 5 SUPPLEMENTARY FILE HERORT ceeececeeeesaeeeseeeeeeeeeeseeee sa eesaueeeeeesenegeeesaees 234 22 5 1 Generating a Supplementary File Report 222 cccceeeeeeeneeeceeeeeeeeesseeeessaeeeeeeeaeetes es 234 22 6 MSDS HAZARD TYPE REPORT 2 0ssccsseccecscenceetosstonescensuesteenodsecarscsenseesstesceccseessnencesssesenes 235 22 6 1 Generating a MSDS Hazard Type Report Screen 0 cccceeeeeeeennteeee eee e ea neeeeeeeeeenaneees 235 22 7 MSDS PRINT RANGE REPORT 22ccsseccseccceeceeecoeesaeeecescueeeeseecueeseueeseeesesseseseeseseeseresaes 235 22 7 1 Generating a MSDS Print Range Report Zoreen 235 22 8 HAZARD TYPE PRINT CDmTERIA totte ntrr tetro reret tttrt rener trette merrte errre rennene 235 22 8 1 Generating a Hazard Type Print Criteria Screen cceccccctteeeeeeeeeenneeeeeeeenaneteeeeeeenanes 235 22 9 MATERIAL SAFETY INFORMATION REPORT ccseccesccceeeceeeeceeeseeeeeeeecueeeaueeseeeseeeeseeeseneeseneesens 236 22 9 1 Generating a Material Safety Information Heport 236 22 10 PRINT OTT 236 22 10 1 Generating Print Mail Labels cece cece cece enn eee eee e canna eeeeeeeaana ae eeeeeeaaaaaeeeeeeeaaaaaees 236 22 11 SARA TIER UI TRACKING HERORT seseeeeeeseeeeseueeseueeseeesenceeeeeeeeesaneeees 236 22 11 1 Generating a SARA Tier VII Tracking Repott ccccccseeeeee cece nteeeeeeeeenn aa eeeeeeeeennanees 237 22 12 SARA TITLE III TIER REPORT eee eeeee
15. Assembly Type The value in this field is defaulted from the value of the Assembly Type field at the BOM Entry screen The possible values are for intermediate F for finished good and A for assembly type of BOM Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Warehouse Transfers Click this button to create a Warehouse Transfer order for the selected MPS Orders instead of transferring them to a Production Order Orders can be selected by checking the select box for the order lines On the popup window that opens enter the Location and choose Inventory Transfer or Inventory Move to perform warehouse transfer w Warehouse Transfer Detail x Warehouse Transfer Detail Location tests X Inventory Transfer Inventory Move OK Cancel Figure 10 5 2 Warehouse Transfer Detail Window If an item is available at or procured via another location of the company it may be desirable to obtain the item from that location to fulfill demand rather than creating a new production batch Once a Warehouse Transfer has been created for such an order the same order cannot be transferred to a Production batch Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned
16. Boilerplate Maintenance E SS la sl E File Edit View Help Module Special Functions Windows l x BAE Alzlgl lr ale 1 MAP Reports m Header Information Group Name Al Dese arance and Odor i HA Process Cell Mode SL QC Masters Boilerplate ID _ fara _ Process Cell Repo E I ENGLISH C QC Reports Language ENGLISH Su a MSDS Status Active DI D Boilerplate Gro k r Boilerplate Text O Boilerplate Ove OD Supplementary DN CAS Number h O Hazard Type h ID Hazard Print R ID Hazard Print C D Material Safety IN SARA Process O MSDS Master IN MSDS Schedt D Print MSDS ID Customer Histe ID Update Custor IN MSDS Setup s 1 BOM Utilities C MSDS Reports e ahnratan a a i Figure 14 2 Boilerplate Maintenance Screen fruity odor Clear light yellow liquid Group Name This field stores the name of the boilerplate group associated with this boilerplate The group name can be entered by typing or selected via the associated lookup on this screen This is a mandatory field Boilerplate ID This field stores a unique identification for a boilerplate This is a mandatory field Language This is the language that is used for printing on a MSDS the text associated with this boilerplate The language key can be entered by typing or selected via the associated lookup on this screen This is a mandatory field Status This fie
17. MRP OrdNO This is the system generated number for the MRP order This value is defaulted from the Planned Production screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed ItemKey This is the Item Key for which the confirmed MRP production order has been generated Description This is the description of the item Location This the Location Key associated with the Item for which the Confirmed MRP Production Order has been generated UOM This is the Stock UOM for the Item Key Reg Qty This is the Required Quantity in stock UOM recommended by the system to be produced in a batch Weight This is the Order weight arrived at by converting the required quantity from the Production Order to the System Weight Unit Volume This is the Order volume arrived at by converting the required quantity from the Production Order to the System Volume Unit FMKey This is the formula key associated with the BOM of this line item BatchNo If the user has manually entered the Batch Number using the ellipse button adjacent to this field then the Batch Number so entered gets displayed here The line items that have been assigned a common batch number are clubbed in a single batch The line items that have not been assigned any batch number are clubbed with those line items that use the same formula as the one used by these line items BatchType This is the type of the batch It can be one
18. Material Safety Information j f SS si Ge File Edit View Help Module Special Functions Windows lej xj BAE Alz OH al gt ri ale _ Production Report Q MPS C MRAP C MRP Reports 1 Process Cell Mode _ QC Masters 1 Process Cell Repo C GC Reports 3 MSDS O Boilerplate Gro OD Boilerplate Mai L Boilerplate Ove D Supplementary O CAS Number h O Hazard Type h O Hazard Print R O Hazard Print C O D SARA Process O MSDS Master O MSDS Sched CY Print MSDS C Customer Histe C Update Custor T mens wm hd m Material Safety Information Item key Ces Item For Production level 2 1 General Information y 2 Safety Info y 3 Safety Info continued Y 40EL m HMIS Values Health foMinmal z Chronic Factor Cacmogenic 0 UY Flammability Sit d Reactivity esi d Personal Protection D Face Shield Gloves Synthetic Apon d m Material Hazard _ MattazTypelD IL KE fire hazard Add Line Delete Line Figure 14 8 2 Material Safety Information Safety Info tab EE DEE EE E E 4 4 EN DOCNUMBER 066 April 14 2005 Issue 2 Page 203 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing HMIS Values Health This is the HMIS Health rating for this item HMIS stands for Hazardous Material Identification System The valid values are 0 4 or a blank
19. and the Production History Detail Report The sub batches of a super batch cannot be purged via this screen 12 5 1 Screen Field Descriptions ER BatchMaster Manufacturing Purge Batches s b laj x E File Edit View Help Module Special Functions Windows l x Delles alzle wl 4 gt gt lgl r Purge Batches H A Formula Reports SL Bill OF Materials Batch From oo0000000000000 EC Costing To mmm A Si L Costing Utilities SL Costing Reports From baam SSCS q H Routing Reports Start Date SL Production To 09 24 04 M CH Production Utilities C Generate Sch Batch Status fe CLOSED X O Transfer S0 T Dn Batch Range t Cancelled on or before 03 24 04 gt O Create Batche O k Purge Super B SL Production Report C MPS MRP _ MRP Reports SC Process Cell Modu D C OC Masters Si Process Cell Repo E QC Reports CJ MSDS KL BOM Utilities C LI pees L a Figure 9 5 Purge Batches Screen Batch From This is the batch that specifies the lower limit of the selected range of batches that need to be purged Leaving this field blank has the same effect as selecting the first available batch via lookup Batch To This is the batch that specifies the upper limit of the selected range of batches that need to be purged Leaving this field blank has the same effect as selecting the last available batch via lo
20. w Warehouse Transfer Detail x Warehouse Transfer Detail Location fanata X Ze Inventory Transfer Inventory Move OK Cancel Figure 11 10 2 Warehouse Transfer Detail Window If an item is available at or procured via another location of the company it may be desirable to obtain the item from that location to fulfill demand rather than creating a new production batch Once a Warehouse Transfer has been created for such an order the same order cannot be transferred to a Production batch Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 15 10 2Transferring MRP Production Orders 1 Select a MRP Item at the From field using the lookup button at this field 2 Select a MRP Item at the To field using the lookup button at this field 3 Select a location at the From field using the lookup button at this field 4 Select a location at the To field using the lookup button at this field 5 Click on the Fetch Production Orders button on the toolbar to fetch the Production Orders for the specified range Processing the range fetches those MRP Production Orders whose status is Confirmed and have a BOM released 6 If one wishes to create
21. 1 cccsceeeeeeeeeeee ceaeeeeeeeteetaeeestneetees 39 13 6 TRANSFER SALES ORDER TO BATCH HERORT rren reee 40 DOCNUMBER 066 April 14 2005 Issue 2 Page3 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 13 6 1 Generating a Transfer Sales Order To Batch Report 0 cceeeeeeeetnteeeee teen nnn teeeenneeeees 40 13 7 BATCHWISE LOT DETAILS REPORT 2 cceccccsseeseecceeecececeucecececsusesecccseeeceseueensuetsesessusseeseneeses 40 13 7 1 Generating a Batchwise Lot Details Heport en eeeeeeeeennetteeeesnnaaaees 40 13 8 SUPER BATCH TICKET REPORT c ccccscccseceeseeseeccneceeeecusececceeeceuecesecueeearseusseseeseeenseseueeaeeenes 41 13 8 1 Generating a Super Batch Ticket Repott 22 c ccccceeeeeeeee ceeeeeneeeecaeeeeeesaeeeeesaaeee tees 41 13 9 SUPERBATCHWISE LOT DETAILS HEpORT ttrt trrtt rrr rrrnr rt tntr nenene 41 13 9 1 Creating a SuperBatchwise Lot Details Hepnort ce eeeeeteeteeteeeeeeeneesees 42 13 10 SUPER BATCH EXPLOSION REPORT esses sacceseeseuedeidestvdennncenmediedeavesaenauduneudddededdencsmnesedebeneadeds 42 13 10 1 Creating a Super Batch Explosion Heport 42 13 11 MAX P RODUGIBLE BY STOCK EE 42 13 11 1 Creating a Max Producible by Stock Heport ceca nae eeeeeeeaaaaeeeeeeeanaes 42 13 12 MATERIAL W HERE UspoHrpcOnT reeet tttrt ttrt rttr ttrttt rrtt ttn tettr arent r trar nren eneee 43 13 12 1 Generating a Material Where Used Report ccccccccceee cece eet neeet
22. 1 Complete the MPS Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields DOCNUMBER 066 April 14 2005 Issue 2 Page 269 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 Select Order Types as required 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 26 4 MPS Supply Report The report includes the supply for the various MPS items for which MPS was last run The supply sources listed are 1 Scheduled Receipts from batches in Production 2 Scheduled Receipts from existing Purchase Orders 3 Scheduled Receipts from Warehouse Transfers coming in 4 All MPS orders of planned firm planned and confirmed type generated via the latest processing on the Run MPS screen This excludes any firm planned or confirmed MPS orders that existed before the latest Run MPS was processed The report also lists the On Hand Quantity minus the Safety Stock The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 26 4 1 Generati
23. 2 Enter or specify the values for the various fields as needed 3 Click on the Save button to save the Laboratory Setup 23 5 Physical Property Search Filter The Physical Property Search Filter screen provides a way to create filtering criteria for use while generating the Physical Property Search Report Using Physical Property Search one can establish a numeric search filter key and a description of the filter and then define an equation which sets the filtering criteria Using the filtering criteria it can serve to reduce the number of formulae eligible for inclusion in the report DOCNUMBER 066 April 14 2005 Issue 2 Page261 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 5 1 Screen Fields Descriptions FR BatchMaster Manufacturing Physical Property Search Filter 7 E l x a File Edit Yiew Help Module Special Functions Windows l x osale axel Aa ET BatchMaster Manufacturi 1 Routing Reports lt Search Filter Key fi Description fiter key 1 1 Production Equation IF Weight 5 Or Volume Item For Production level 2 gt 2 wk 1 Production Utilitie 1 Production Repor C MPS 0 MRP _ MRP Reports 1 Process Cell Mod 1 QC Masters 1 Process Cell Rep 1 QC Reports C MSDS BOM Utilities C MSDS Reports Laboratory bh Physical Prop O Physical Prop b Comparative O Labor
24. Delete Line Clicking this button deletes the selected line s from the OEL Details grid DOCNUMBER 066 April 14 2005 Issue 2 Page 206 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 9 3 Creating Material Safety Information for an Item Click the Insert button 2 Select an Item via the lookup presented on the screen for which the Material Safety Information has to be created 3 Select the CAS Number associated with this Item If a CAS Number is selected then data maintained on Tab 1 4 of that CAS Number master record is defaulted on the Material Safety Information screen 4 Enter the data on Tabs 1 4 if the data is not defaulted on Tab 1 4 or modify the data on Tabs 1 4 as needed 5 Click on the Save button to save the Material Safety Information record 21 10 SARA Processing The SARA Processing option provides a way to perform Hazard Communication Standard Superfund Amendment and Reauthorization Act SARA Title III compliance This screen can be used to report the amounts of hazardous materials and the durations for which those hazardous materials were maintained at various locations The SARA processing can be 1 Period End Processing 2 Year End Processing It is recommended to back up the database before the processing This may be useful in case one needs to revert back to the data before Period End or Year End Processing DOCNUMBER 066 April 14 200
25. EI x E File Edit View Help Module Special Functions Windows x fat ta S axla KIKIA lgl E Ee QC Masters FrishedGood sl i Finished Good 0 Process Cal Hepo Schedule Type inished Goo X KL DC Reports r Selection Criterion Fa MSDS Formula Key From fo N ID Boilerplate Gro D Boilerplate Mai Formula Key To TRY Al D Boilerplate Ove ID Supplementary Finished Good Key From Jar ERNATE_A Al SN h K Ge Ce d Finished Good Key To JE O Hazard Print R C Hazard Print C Formula Status All x C Material Safety D SARA Process O MSDS Master B IN Print MSDS ID Customer Histe OD Update Custor O MSDS Setup 1 BOM Utilities C MSDS Reports 1 Laboratory 1 Laboratory Utilities Dsg eet T 2 0 0 0 a Figure 14 11 2 MSDS Schedule Generation Finished Goods Schedule Type Finished Good This setting is used to generate a schedule to print the MSDS of only those Hem Locations that have a Released BOM of any type including Finished Good Intermediate and Assembly The data required to generate a schedule of Finished Good type is fetched from the BOM Entry screen and the Material Safety Information screen Formula Key From This Formula key specifies the lower limit of the range of formula keys for use as filter criteria during processing This Formula key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank
26. Exception If any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 14 9 2 Working with Demand Fence 2 MPS Production Order 1 Select a MPS Production order record on this screen 2 Change the status for the MPS Production order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the confirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MPS Production order as needed 6 For Exception Orders club order lines together by clicking on the Club Orders button if so desired
27. S Dn Demand Fi E 26 07 04 CONFIRMEC 30 07 04 30 07 04 100 0000 30 07 04 30 07 04 100 0000 DN Demand a 98 26 07 04 CONFIRMEL 31 07 04 31 07 04 100 0000 31 07 04 31 07 04 100 0000 O Maintain M B C Company KI _ 26 07 04 FIRM PLANE 03 08 04 100 0000 03 08 04 03 08 04 100 0000 DN Planning C kim 26 07 04 FIRM PLANT 04 08 04 04 08 04 100 0000 04 08 04 04 08 04 100 0000 CY MPS Setup a O Pull MPS I O MPS Order C MRP 1 MRP Reports Process Cell M 1 GC Masters 1 Process Cell A BL es Bereits H al D Figure 10 7 1 Demand Fence 1 MPS Production Order Screen Select All UnSelect Al Delete Line Exception Eim Planned Confirmed Club Orders Multiples of EOQ F 4 4 Item Key This is the Item Key associated with the Item Location for which the Demand Fence 1 MPS Production Order is displayed Location This is the Location Key associated with the Item for which the Demand Fence 1 MPS Production Order is displayed DOCNUMBER 066 April 14 2005 Issue 2 Page93 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MPS O
28. sa oQ00 a DOCNUMBER 066 April 14 2005 Issue 2 Page 146 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 9 Transfer MRP Purchase Orders The Transfer MRP Purchase Orders screen can be used to transfer the confirmed MRP orders to purchase orders 15 9 1 Screen Fields Description ER BatchMaster Manufacturing Transfer MRP Purchase Order E la x EZ File Edit View Help Module Special Functions Windows Jl x Della Al X es vldlrlyl ee giel m Select MRP Item Location _ Costing Reports cay THe eae PAT I From Item For Production level 3 SL Routing Reports MRP Item jAP_AVG_PURCHASE al i i CH Production To AP_AVG_PURCHASE ater For Production level 3 a Cl Production Utilities i S From FGLOC SL Production Reports Location none AN oO MPS To INLOC fe RAR See MRP Max No of Lines in PO 10 000 D Run MRP Q EE MRP OrdNO Item Key ipti Location i Demand Fence 2t i AP_AVG_PURCHASE Item For Produc INLOC 10 0000 30 07 04 ID Demand Fence 1t ees AP _AVG_PURCHASE em For Produc INLOC 10 0000 30 07 04 DN Demand Fence 2 GI AP_AVG_PURCHASE _ Item For Produc FGLOC 600 0000 30 07 moe GEES aP Ap PURCHASE MAAA ee nge 5 AP_AVG PURCHASE lem For Produc FGLOC 200 0000 30 07 04
29. 1 BOM Utilities C MSDS Report Si Laboratory Kit ps E D EE E E E EE E E E E E EE Figure 13 1 QC Test Description Screen Test ID This is the key that uniquely identifies this Test This is a mandatory field Test Description This is the description of this Test 18 1 2 Creating a QC Test Description 1 Click on the Insert button on the toolbar 2 Enter the Test ID at the Test ID field 3 Enter a description at the Test Description field if needed 4 Click on the Save button on the toolbar to save the QC Test Description record 18 2 QC Formula Tests Using the QC Formula Tests screen one can associate one or more QC tests with a formula These QC tests can then be applied to these formulas via the Quality Control Process screen With the QC Formula Tests screen the Measuring type the target values and the control limits for each of the tests associated with a formula can also be specified DOCNUMBER 066 April 14 2005 Issue 2 Page171 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 18 2 1 Screen Fields Descriptions ER BatchMaster Manufacturing QC Formula Tests 3 A File Edit View Help Module Special Functions Windows lj x Ca coe ta alzlel wl a gt ri lel _ Formula Repor 1 Bill Of Material
30. 23 1 6 Screen Fields Description Tab 4 Line jemsl 247 23 1 7 Screen Fields Description Tab 5 Grvproduct eee eee ee enneeeeeeeenateteeennanenes 250 23 1 8 Modifying a Formula to obtain a desired Physical Property 251 23 1 9 Creating anew Formula at the Physical Property Analysis screen 251 23 1 10 lt Sp Clal FUNCHONS sssaaa idee eves Ahead ee esa a ieee Ses 252 23 2 PHYSICAL PROPERTY FORMULA 0scccssccceccceeeecee seeceeeeneusecsusessesecusensus seaeseneeteueeseeessesenes 257 23 2 1 Screen Fields DeSCriDlONS arser iii ase ee ne 258 23 2 2 Creating a Physical Property Formule 259 23 3 COMPARATIVE PROPERTIES ANALYSIS cc00ccceecceeeeeeecceeeeceeceeeeeeeeseeeeeseeeeueesueseeeeseeegeeeeaees 259 23 3 1 Screen Fields Descriptions 202 aeded cesses eis eateiie oi es 259 23 3 2 Performing a Comparative Properties Analysis cccccccccteceeeee tees nnneeeeeeeeanaaeeeeeeeeanes 260 23 4 LABORATORY S ETU P riean anana o EE E Gutadetedededodtmeuautuancdeededaleadiachbedeeudws 260 23 4 1 Screen Fields Descriptions ANE 260 23 4 2 Creating a Laboratory Zen 261 23 5 PHYSICAL PROPERTY SEARCH FILTER 0cccceecececceeeeeeeeceeeeeaeeseueeseceseeeesaeeseeeseesaeeeeaeeseeeges 261 23 5 1 Screen Fields Descriptions ANE 262 23 5 2 Creating a Physical Property Search Eiter 263 24 LABORATORY UTILITIES wescecsesccassaiic cicecassaserpewcuevecees ege RSSSNEN E ESKEENNE GES deEeEE REES EES dias 263 24 1 INTERMEDIATE P ROPERTY BRO
31. 7 Save the Demand 2 MPS Production Order record DOCNUMBER 066 April 14 2005 Issue 2 Page 103 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 9 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Oty On Hand _ ty On Order E Warehouse 4 1249 9899 0 0000 0 0000 2 JMaN Main Wareho A 356 0000 0 0000 0 0000 3 _ SLECH BIEN AJ 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 10 9 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No sea EHGEE 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status sao ong DOCNUMBER 066 April 14 2005 Issue 2 Page 10
32. CONFIRMEL 27 07 04 20204 50 0000 27 07 04 27 07 04 50 0000 Ut L Pull MPS II Em inca s 27 07 04 50 0000 27 07 04_ 27 07 04 50 0000 MPS Ord Ger een REES H MRP Reports 9 O QC Masters Select All UnSelect AII Delete Line Exception Firm Planned Confirmed Club Orders Multiples of EOO s C Process Cell R 1 1 OP Renne gt Figure 10 6 1 Demand Fence 1 MPS Purchase Order Screen Item Key This is the Item Key associated with the Item Location for which the Demand Fence 1 MPS Purchase Order is displayed Location This is the Location Key associated with the Item for which the Demand Fence 1 MPS Purchase Order is displayed Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MPS Order No This is the system generated number for the MPS order Plan Run Dt This is the date when the MPS order was generated Order Status The Order Status on this screen can be one of the following 1 Exception These orders before being transferred to Purchase Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MPS Exception MPS Orders get erased when Run MPS is processed or when the Replan MPS button is clicked DOCNUMBER 066 April 14 2005 Issue 2 Page 89 of274 BatchMaster Software BatchMas
33. DOCNUMBER 066 April 14 2005 Issue 2 Page 12 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 Production Utilities 12 1 Generate Schedule Using the Generate Schedule one can create production schedules for a range of Item Locations The production schedules are created here on the basis of any scheduling formula defined via Scheduling Formula screen While generating a schedule one can choose to create a new schedule or append to an existing one Batches can be created for the schedule via the Create Batches from Schedule screen 12 1 1 Mandatory Inputs The following data should have been maintained before a schedule can be generated 1 A Bill of Materials for the Item Location for which a schedule has to be generated should have been created and released 2 A Scheduling Formula should have been created via the Schedule Formula screen 12 1 2 Screen Fields Description ER BatchMaster Manufacturing Generate Schedule K EI x Ge File Edit Yiew Help Module Special Functions Windows lej x MAE alzlel al gt rif lgl BatchMaster Manufacturing Schedule Type Both Intermediate and Finished Good D 1 1 Formula Reports lt Item Key From fi 03011 A 1 Bill Of Materials Iso Glucose 1 Costing Item Key To 202021 A 1 Costing Utilities Solvent M C Tape 50mm x 990mm 1 Costing Reports ee Item Location From oss A A
34. Demand Forecast If this option is selected the Gross Demand will be calculated by adding up the following i Sales Orders ii Warehouse Transfers Transfer out from this Location iii MPS type raw materials remaining to be issued to production batches that are not on hold iv The quantity by which On Hand Quantity is less than the Safety Stock as defined at the Item Location V Forecast entries of Active status d Greater of Demand or Forecast If this option is selected the Gross Demand will be equal to the greater of Demand and Forecast This option is generally used for the intermediate range planning Demand Range 2 The value in this field decides how gross demand for a range will be calculated Demand Range 3 The value in this field decides how gross demand for a range will be calculated Display Color Demand Range 1 The value in this field decides the color that will be used for displaying Demand Range 1 on the MPS Planning Worksheet Different colors should be selected for different demand ranges to differentiate between them in the worksheet Demand Range 2 The value in this field decides the color that will be used for displaying Demand Range 2 on the MPS Planning Worksheet Demand Range 3 The value in this field decides the color that will be used for displaying Demand Range 3 on the MPS Planning Worksheet Top Level Finished Good batch to be created as The value in this field can be one of Mix When a Batch i
35. Loss Constant 0 2800 1 Production Report CI MPS CJ MAP _ MRP Reports 1 Process Cell Modu C QC Masters 1 Process Cell Repo C GC Reports C MSDS 1 BOM Utilities MSDS Reports Laboratory m Fixed Costs Hours _ LaborKey Amount__ Overhead Key AP_LABOR_ 10 000000 AP_MAX_ m Setup Costs Labor Key 3 0000 L1 8 000000 EIE 02 15 0000 Add Line Delete Line m Variable Costs ee tt Factor Toso sone 2 500 0000 AP_LABO Gm 15 OO00 10 000000 AP MA ONE DE E EE EE EE E E E E EE EE EE EE b Physical Prope b Comparative P Ai tani Get An SE Figure 15 1 3 Physical Property Analysis Screen Cost Tab Markup Factor x 100 The Markup Factor is used for cost analysis Multiplying this number gives the markup factor as a percentage A value of zero means that there is no markup at all Loss Factor x 100 The Loss Factor is used to determine the variable loss of the product being produced by the formula This number is entered as a fraction not as a percentage Loss Constant This is the fixed loss in the System Weight Unit independent of the quantity of the product being produced by this formula Hours Fixed Costs This is the value of hours of the fixed costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as t
36. MPs Boltz lanke ee ee ee i HU a 31 0000 23 07 7 04 8 07 04 4 Select All Unselect All Warehouse Transfers Club Orders Figure 10 4 1 Transfer MPS Purchase Orders Screen Select MPS Item Location MPS Item From The lookup at this field displays only those MPS items for which there exists at least one Confirmed Purchase Order This specifies the lower limit of the range of MPS items for which the Purchase Orders need to be transferred Leaving this field blank has the same effect as selecting the first available item via the lookup MPS Item To The lookup at this field displays only those MPS items for which there exists at least one Confirmed Purchase Order This specifies the upper limit of the range of MPS items for which the Purchase Orders need to be transferred Leaving this field blank has the same effect as selecting the last available item via the lookup Location From This specifies the lower limit of the range of locations Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations Leaving this field blank has the same effect as selecting the last available location via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page 76 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Max
37. No of Lines in PO The value in this field defines the maximum number of lines that can be added to one Purchase Order Grid Fields Select When this box is checked for a row that row becomes available for transfer to purchase order MPS OrdNO This is the system generated number for the MPS order This value is defaulted from the Planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed ItemKey This is the Item Key for which the planned MPS purchase order has been generated Description This is the description of the item Location This the Location Key associated with the Item for which the planned MPS purchase order has been generated UOM This is the Stock UOM for the Item Key Reg Qty This is the Required Quantity recommended by the system Conf Dt This is the date on which the status of the planned purchase order was set to Confirmed Actual Dt This is the date on which the purchase order was generated by running MPS Vendor This is the Vendor for the purchase order The value in this field is defaulted from the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed The vendor can be changed here using the lookup button in the field Plan Run Dt This is the date when the MPS order was generated The value in this
38. OD D Physical Prope b Comparative F Be Se A S 7 ormula Totals Sa D Physical Prope _AddLine Delete Line FFs Weight GAM 27 0000 __ Laboratory Utilities A S Total Yolume CC 10 5035 a Laboratory Report Create Line Dr Insert Line Line GRM CC 2 5706 I MPS Reports Color if Physical Cost GRM 16 051383 ig PROE Property Value not Cost CC 41 261251 1 General Table Vie between Min and Total RM Cost 433 39 i i SS Maximum Value 4 b Figure 15 1 7 Toggle Units Button DOCNUMBER 066 April 14 2005 Issue 2 Page 252 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Toggle Costs This button is enabled when the focus is on Tab 4 or Tab 5 Clicking on this button toggles the costs as follows 1 If the focus is on a Material line item on Tab 4 the values of the Cost Unit Ext Cost Cost LB Cost GAL and Total RM Cost field get toggled 2 If the focus is on a byproduct line item on Tab 5 the values of the Cost Unit Ext Cost Cost LB Cost GAL and Total Byproduct Cost field get toggled ER BatchMaster Manufacturing Physical Property Analysis Ga File Edit Yiew Help Module Special Functions Windows la x pelala axe alal Ell 2 Batchaster EUT EOT Formula Routing Reports lt Formula Key Q 00 Quality Control Enlarge View C1 Production Description Cost Metho
39. Production Utilities H C Production Reports MES Item Type ege D Forecast Entry CY Run MPS Economic Order Quantity 50 0000 4 MPS Planning Works Default Vendor DC A fendor For ANMOL D Transfer MPS Purcha D Transfer MPS Produc Low Level Code O Demand Fence 1 MP Lot Sizing Method Je E00 x ID Demand Fence 1 MP se CY Demand Fence 2 MP Last MPS Run Date 26 07 04 D Demand Fence 2 MP O OD Company Calendar Se TD Planning Calendar ID MPS Setup DN Pull MPS Items ID MPS Order Range Pr 1 MRP H MRP Reports be FIRED Drocess Call Mech de Ga gt Figure 10 10 1 Maintain MPS Item Screen DOCNUMBER 066 April 14 2005 Issue 2 Page 105 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing BatchMaster MPS ltem MPS Item Select a MPS Item from the lookup at this field The lookup here displays only those items whose Order Method has been defined as MPS on the Item Master screen This is a mandatory field Location This is the location key associated with the item This is a mandatory field Unit This is the stock UOM for the Item Location This is a read only field Item Type The value in this field decides the type of the item The type can be either Purchase or Manufacture depending on which Run MPS will generate Purchase Orders or Production Orders respectively The Item Type can be selected as Manufacture only if a Released BOM exists for the selected Item Locat
40. Select Apply Date From using the drop down arrow When the process button is clicked the critical report will be generated as of this apply date 5 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 6 Click on the Process button on the toolbar to create a report DOCNUMBER 066 April 14 2005 Issue 2 Page 37 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 13 3 2 Transferring Materials to a Purchase Requisition using Critical Material Report To transfer the critical items to a purchase requisition perform the following steps 1 Click the Transfer to Purchase Requisition button on the tool bar of the critical report 2 If the Vendor field is blank on this grid then specify a Vendor by typing or selecting it from the lookup at this field This Vendor Key is defaulted from the Item Location screen A Branch Key of the BatchMaster Enterprise Company should have been associated with this Vendor on the Vendor Master screen 3 Check the box adjacent to the items for which Purchase Requisition needs to be generated 4 Enter values at the Max number of lines in PR to specify the maximum lines that can be added to a single purchase requisition any additional lines will be carried to additional pu
41. This is the Plan End Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to purchase order Vendor This is the Vendor for the purchase order If a vendor is associated with this Item Location via the Item Location screen then via Run MPS the vendor key is defaulted here from the Primary Vendor Key field of the Item Location screen This value can be modified here Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows hav
42. a H one wishes that the assignment of bts be done automatically check the Auto Lot Assignment box If this box is not checked then the lots will not be assigned only the quantity will be allocated If one wishes that purchase requisitions be created for the raw materials to be used for he batches check the Create Purchase Req box If one wishes to assign batch number manually for each of the line items do so using the ellipse button adjacent to the BatchNo field If the user wishes to assign batch number to one or more line items manually in one go then Select the lines by clicking on them while holding the Ctrl or Shift button down Click on the Select In Range button Select Manual Entry option Enter the batch number Click OK moo Cp If one wishes to create a Warehouse Transfer order for the selected line items instead of transferring them to a Batch a Select the lines by clicking on them while holding the Ctrl or Shift button down b Click on the Warehouse Transfers button c On the popup window that opens enter the Location and choose Inventory Transfer or Inventory Move Click OK Note If an item is available at or procured via another location of the company it may be desirable to obtain the item from that location to fulfill demand rather than creating a new batch Once a Warehouse Transfer has been created for such an order the same line item cannot be transferred to a batch
43. gt APF x KL Costing Utilities Select from LotMaster Where ItemKey gt AP_F Add Criteria KL Costing Reports FL Routing Reports Production w Table Data d Production Utities e EE EE EE M VendorLotNo a E AEE i ASSEMBLY_1 6 1 2004 o jofi wi OtyOnOrder L MPs 0000000000000070 ASSEMBLY _1 6 1 2004 001 M RecUserld i 0000000000000070 ASSEMBLY _1 6 1 2004 001 wi Recdate MRP i DOC ASSEMBLY _1 6 1 2004 ohh M BinNo C MAP Reports 0000000000000070 ASSEMBLY 1 6 1 2004 001 si LotStatus Process Cell Module 0000000000000070 ASSEMBLY_1 6 1 2004 oo i ve _ GC Masters 0000000000000070 ASSEMBLY_1 6 1 2004 o 01 ee zl Process Cell Reports 0000000000000070 ASSEMBLY_1 6 1 2004 001 S i V User4 C OC Reports 0000000000000070 ASSEMBLY _1 6 1 2004 0 01 Geet C MSDS DOE ASSEMBLY_1 6 1 2004 001 ra Users t m BOM tities EE ASSEMBLY_ 2 0 User Cj MSDS Reports 0000000000000070 ASSEMBLY_1 GG User8 i DOE ASSEMBLY_1 6 1 2004 ni wl User C Laboratory 0000000000000070 ASSEMBLY 1 6 1 2004 001 J User _ Laboratory Utilities 0000000000000070 ASSEMBLY_1 6 1 2004 ni wi User 1 Laboratory Reports DOC ASSEMBLY _1 6 1 2004 oh z i SL MPS Reports L H General Table View E Crim Select Al Unselect All Select Al Unselect Table Name flomaster x Process Maximum Records 5000 Figure 17 1 1
44. ingestion etc Pure Check this box if this material is Pure Mixture Check this box if this material is a Mixture Solid Check this box ifthis material is a Solid Liquid Check this box if this material is a Liquid Gas Check this box if this material is a Gas DOCNUMBER 066 April 14 2005 Issue 2 Page 195 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing SARA Information grid Type This field stores the storage type represented by a letter of this item for a line in the grid Pressure This field stores the pressure represented by a number associated with a storage type for a line in the grid Temperature This field stores the temperature represented by a number associated with a storage type for a line in the grid Add Line Clicking this button inserts a line in the SARA Information grid Delete Line Clicking this button deletes the selected line s from the SARA Information grid Tab 4 OEL ER BatchMaster Manufacturing CAS Number Master d R aj a xj Ga File Edit View Help Module Special Functions Windows lej sl Dell Alle vl4dlrlnl ale gt CAS Number Master H A Process Cell Modu lt CAS Number QC Masters 1 General Information 1 2 Safetyinfo 3 Safety Info continued j _ Process Cell Repo m OEL Details SL QC Reports p Occupational Exposure Limits H 2 MSDS O Boilerplate Gro O Boilerplate Mai D B
45. x ER BatchMaster Manufacturing Material Safety Information Ga File Edit View Help Module Special Functions Windows Cy cas ta Al x es lt gt pi e m Material Safety Information D Boilerplate Gro L Boilerplate Mai L Boilerplate Ove D Supplementary IN CAS Number h O Hazard Type h O Hazard Print R In Hazard Print C k D SARA Process C MSDS Master 4 MSDS Schedt O Print MSDS ID Customer Histe D Update Custor TA MANS Sehin dl al D SL Production Report tember Qes o Item For Production level 2 MPS eC MRP T General information IT 2S fetyInfo 3 Safety Info continued 40EL Po Mar Repote M General Information SL Process Cell Mod Sees 2 OC Masters CAS Number f e3 252 A rade Secre SL Process Cell Repo Chemical Name eaba SL QC Reports CH MSDS Other Information NMethylCabamate rm Properties Wap Pressure mm Hg Wap Pressure Temp Lower Explosive Limit Upper Explosive Limit Boiling Point Flash Point Flash Pt Method Used Figure 14 8 1 Material Safety Information General Information Tab CAS Number This is the Chemical Abstracts Service CAS number for this item This can be entered by typing or selected via the available lookup on the screen Chemical Name This is the name by which this item is known Other Information This field stores
46. 066 April 14 2005 Issue 2 Page 80 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 5 Transfer MPS Production Order The Transfer MPS Production Order screen can be used to transfer Confirmed MPS Production Orders to Batches or Super Batches The procedure for using Transfer MPS Production Order is substantially similar to the procedure for Transfer MPS Purchase Order 14 5 1 Screen Fields Description ER BatchMaster Manufacturing Transfer MPS Production Order g 8 x File Edit view Help Module Special Functions Windows lej x HAE alzle vl4lrlnl Sleel m Select MPS Item Location _ Routing Repor l From JAP_FINISHED_GOOD Item For Production level 1 0 EIGN MPS Item AP_FINISHED_GOOD A m For Production SL Production Util To JAP_FINISHED_GOOD Ejen For Production level 1 a 1 Production Re m MPS Location From rte gjeo E D Forecast E To rte Sr O Run MPS IN MPS Planr hy esis I Transfer to Super Batch T Fill From Invento Allocate E Auto Lot Assignment SELECT IN RANGE D J MPS Oi eng em en eg Er O Demand Fi sai FINISHED_GOl i For Produc SC PY Demand Fi AP_FINISHED_GOI Item For Produc FGLOC SS 50 0000 BY Demand F SG a FINISHED_ GOI Item For Produc FGLOC CC 50 00 1 L Demand Fi L Maintain M O Company C b Planning C C MPS Setu O Pull MPS
47. 1 Costing 1 Costing Utilities CI Costing Repor Leg Measuring o e Routing Repor Nume BS EE Production Add Line Delete Line 1 Production Util m Target Values _ Production Re C MPS C MRP 1 MRP Reports 1 Process Cell M Alphanumeric Value Nominal Value 1 5000 r Control Limits Lower Value 1 0000 Upper Value l 2 0000 E E EE EE EE E E E 4 4 EE EE EH C3 GC Masters O oC test Ba OC Formul D oC Item Te C Quality Cor SL Process Cell R H 0 DC Reports SL MSDS SCH BOM Utilities MSDS Report SL Laboratory e Kgl pee I qaa Figure 13 2 QC Formula Tests Screen Formula This is the Formula with which one or more quality control tests are associated This is a mandatory field Test and Measuring Criteria Test ID This is the Test ID associated with the test selected at this row Measuring This is the measurement type of the test results The value of this field can be set to one of the following 1 Pass Fail Value The result value of the test can be either Pass or Fail 2 Numeric Value The result value has to be a numeric value 3 Alphanumeric Value The result value can be alphanumeric Add Line Clicking this button inserts a new line into the Test and Measuring Criteria grid Delete Line Clicking this
48. 104 22 10 200 25 27 10 400 31 12 59 100 10 51 so 50 192 250 12 300 5 138 taken as 0 Cumulative ATP Exception 120 59 Orders On 16 09 04 Demand Customer Orders Forecast Warehouse Transfer Out Dependent Demand 100 10 10 0 120 Supply Purchase Orders Production Orders Warehouse Transfer In 59 0 0 59 Requirement Demand Supply 120 59 61 One needs 61 stock units on 16 09 04 but that order needs to be completed at least one day earlier that is by 15 09 04 so an order is created on 15 09 04 amp since 15 09 04 is less than server date it is an EXCEPTION order Again orders in back date are not considered for EOQ sizing so a consolidated order of 61 stock units is created PAB Orders Generated Requirement 61 61 0 ATP Supply MPS Prod Ord Purch Ord WT In Demand Cust Ord WT Out Dep Dmd 59 100 10 51 which is taken as 0 Cumulative ATP 0 17 09 04 Demand Customer Orders Forecast Warehouse Transfer Out Dependent Demand 50 25 0 0 75 Supply Purchase Orders Production Orders Warehouse Transfer In Previous PAB 22 10 10 0 42 Requirement Demand Supply 75 42 33 This order will be placed on 16 09 04 As order type is EOQ sized order will be of 200 stock units PAB Orders Generated Requirement 200 33 167 ATP Supply MPS Prod Ord Purch Ord WT In Demand Cust Ord
49. 2 Inserting QC Test Information for Items and Formule 177 18 4 3 Updating QC Test Information for Items and Formulas cceeeceeeee tee e eee e eee nnnneeee eee enee 178 18 4 4 Deleting QC Test Information from Items and Formulas 2 11 ccccceeeeeeeeeeeneeeeeeeneeees 178 19 PROCESS CELL REPORTS weicicccecececicesccescteceseceees cccccdececetucciaiseseesseseceseeeees cccccccccceanauannanaees 179 19 1 CAPACITY UTILIZATION HERORT ceaeeecaecesaeeeceeeeeeeeeseeeee sa eesaneeeeeseneaeeesaaes 179 19 1 1 Generating a Capacity Utilization Report ccceeeee cece eect cnneeee tree cana teeeeeeeeeennnae ae 179 19 2 PROCESS CELL SCHEDULE REPORT 0sccccseccseeceseseeeesceecueeecseecueescueesaeeseusesseeseeeseesesaes 179 19 2 1 Generating a Process Cell Schedule Repott cccccccceeeeeeeetnneeeeeeeee naa eeeeeeeeeeeaaees 180 19 3 PROCESS CELL MASTER REPORT essscdscemestnciehiciaastincansecaamededenedsepuciicwutdwalessudanentameneensoyensesebiins 180 19 3 1 Generating a Process Cell Master Henort ee neeeeteee ean eeeeeeeeaaaaaeeeeeeeaaa 180 20 QC REPORU EE 180 20 1 QG TEST MASTER REPORT Geteste e d et Eet g Uadadanbwomnncnstbanersaats 180 20 1 1 Generating a QC Test Master Reno 180 20 2 FORMULA TEST REPORT waiiescccisananceccinciuccstecaine gue NEES EE lee Eege eege 181 20 2 1 Generating a Formula Test Henort 181 20 3 PRODUCTION QG REPORT WE 181 20 3 1 Generating a Production QC Heport cent eee eeeee cnet eeeee aaa
50. 2 MRP Purchase Order Screen KR RK 8 9 m UI 4 We E i Item Key This the Item Key associated with the Item Location for which the Demand Fence 2 MRP Purchase Order is displayed Location This the Location Key associated with the Item for which the Demand Fence 2 MRP Purchase Order is displayed Unit This is the Stock UOM for the Item Key shown on this screen DOCNUMBER 066 April 14 2005 Issue 2 Page 126 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MRP Order No This is the system generated number for the MRP order Plan Run Dt This is the date when the MRP order was generated Order Status The Order Status on this screen can be one of the following 1 Exception These orders before being transferred to Purchase Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MRP Exception MRP Orders get erased when Run MRP is processed 2 Firm Planned These orders before being transferred to the Purchase Order need to be Confirmed The Orders that are FIRM PLANNED will not be erased when Run MRP is processed 3 Confirmed The Orders that are Corfirmed are ready to be transferred to a purchase order and w
51. 2005 Issue 2 Page 25 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Maintain Serial Lot Clicking this button opens the Serial Lot Maintenance screen where the user can conveniently maintain serial lots for several items for a batch ER BatchMaster Manufacturing Batch Range Processing EZ File Edit Yiew Help Module Special Functions Windows oeae AL X25 Lal rir algl a BatchMaster Manufacturing _ Formula Reports a Bill Of Materials Costing Costing Utilities C Costing Reports 1 Routing Reports 1 Production Select Batch Maintain Serial Lot Button Fro To oo0000000000005 V Auto Lot Assign Batch No 3 Production Utilities O Generate Sche O Transfer S0 T O E re EH ee Iesel EE rn for 2 ates F85650 Formula for 0000000000001 MRPFORMULE Formula to te O Create Batche RRE MRPFORMULE Formula to te O Purge Batches 0000000000001 MRPFORMUL Formula to te k Purge Super B s 1 Production Report MPS C MRP Reports C Process Cell Mode 1 QC Masters _ Process Cell Repo 1 QC Reports C MSDS C BOM Utilities ES KM MSNS Renare d a gt Figure 9 3 4 Maintain Serial Lot Button 12 4 Create Batches From Schedule The Create Batches From Schedule option provides a way to create a production
52. 3 If needed modify the path of the MS Word Template file This field cannot be left blank 4 Enter a file name to save the MSDS being generated Specifying a file name is mandatory 5 Enter the output path where the MSDS will be generated This path can be entered by typing or selecting it via the associated button on the screen Specifying the output path is mandatory 6 To view on screen the MSDS when it gets generated check the View Document box 7 To generate the MSDS in Debug mode check the box for Debug Mode 8 Enter the Schedule ID From by typing or selecting it via the available lookup on the screen Leaving this field blank has the same effect as entering the first available Schedule ID 9 Enter the Schedule ID To by typing or selecting it via the available lookup on the screen Leaving this field blank has the same effect as entering the last available Schedule ID 10 To print a MSDS for the second or subsequent time re using a schedule check on the Re Use Schedule ID box Leave the Re Use Schedule ID box un checked to use only the pending schedules 11 Click on Refresh Schedules button to display the schedules as per the setting on the Re Use Schedule ID box 12 Un select or select specific schedules by clicking on the Sel field for that schedule ID 13 Click on the Process button The MSDS is generated The MSDS is displayed on the screen if the field View Docu
53. 4 D Figure 15 1 13 View Mode Button 23 2 Physical Property Formula The Physical Property Formula screen provides a way to create equations and use them in calculations of Physical Properties of the Formula Using Physical Property Formula one can create a physical property assign it characteristics that were defined using the Material Property Master screen in the Inventory module and write an equation which defines how the physical property s value is to be calculated with the formula ingredients One can also write an equation which defines how the physical property is to be adjusted when BatchMaster Enterprise adjusts a marked material on the Line Items tab of the Physical Property Analysis screen The Physical Property Formula also provides a way to define the minimum and maximum values for a physical property The Physical Property Adjust Equation is used when raw material quantities are changed to meet a physical property target value that has been specified The other property values are then recalculated using the Physical Property Equation DOCNUMBER 066 April 14 2005 Issue 2 Page 257 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 2 1 Screen Fields Descriptions ER BatchMaster Manufacturing Physical Property Formula E Je x E F
54. 7 25 User s Guide Volume III Manufacturing 5 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 6 Click on the Process button on the toolbar to create a report 13 18 Formula Production Report The Formula Production Report screen provides a way to generate a report showing the total quantity of end items produced via selected formulas Using the Formula Production Report screen provides a way to generate overall material cost and quantity weight or volume for the selected date range for each of the selected formulas In addition the report displays the average of cost and yield for the selected duration These numbers are also converted to monthly and annualized averages One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 18 1 Generating a Formula Production Report 1 Select Measure In as By Weight or By Volume 2 Select the Report Type as Formula Production Report or Formula Production Report History 3 Select the Formula From and To range using the lookup buttons next to the fields 4 Select the Formula Class From and To range using the lookup buttons next to the fields 5 Select the Status From and To range
55. 7 Batchwise Lot Details Report The Batchwise Lot Details Report shows the lot details for several items that are lot tracked from a batch The report contains the following information Lot Number Item Key Location Quantity in Stock Unit Stock Unit Quantity in Display Unit Display Unit PNO OI GO RO 13 7 1 Generating a Batchwise Lot Details Report 1 Complete the Batch From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters DOCNUMBER 066 April 14 2005 Issue 2 Page 40 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 Click on the Process button on the toolbar to create a report 13 8 Super Batch Ticket Report The Super Batch Ticket Report provides the means to create a report detailing the batch ticket information for a super batch and its components sub batches With it one can examine when each component super batch or sub batch began and finished production its formula and status its order in the execution sequence and the low level code One can also create a unique name for a report that is used on a regular basis save that report s defined parameters and then run that defined report on a regular basis Super Batch Ticket Report ca
56. Cell is scheduled to be used for this MRP Order Hours From This field displays the start time of the process cell for this MRP Order on the grid Hours To This field automatically determined by adding the Batch Time Hr to the Hours From Formula ID This field displays the formula key associated with an MRP Order if the Batch Type for that MRP Order on the Planned MRP Production Order is Mix Formula Desc This field displays the formula description associated with the formula for a line in the grid Item Key Depending on the Batch Type for an MRP Order as shown on the Planned MRP Production Order this field displays the Assembly key associated with an Assembly type batch or the Intermediate key associated with a Fill type batch Item Description This field displays the description associated with the Item Key for a line in the grid Location This field displays the location associated with an Item for a line in the grid Location Description This field displays the description associated with a Location for a line in the grid Tab 2 Chart Display The schedule for a particular Process Cell on a given day is displayed in the form of a graph IR BatchMaster Manufacturing Process Cell Scheduling a p d la x File Edit View Help Module Special Functions Windows l x BAE alx zal gt vif lgl el al F Downtime a Process Cell ff JAP_MAX_PROCESS_CELL_ For Mix
57. Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold i Multiple Bins Requirement Yes or No 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date om cm a0 7p om om np E DOCNUMBER 066 April 14 2005 Issue 2 Page75 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 4 Transfer MPS Purchase Order The Transfer MPS Purchase Order screen can be used to transfer Confirmed MPS purchased orders to Purchase Orders 14 4 1 Screen Fields Description ER BatchMaster Manufacturing Transfer MPS Purchase Order 8 5 la x E File Edit View Help Module Special Functions Windows l x KAE KIXI niall lel Slel 1 Routing Repor 1 Production 1 Production Util 1 Production Re CH MPS L Forecast E O Run MPS DN MPS Planr k O Transfer M O Demand Fi D Demand Fi L Demand Fi L Demand Fi ID Maintain M IN Company t IN Planning C Dn MPS Setu O Pull MPS L MPS Order C MRP _ MAP Reports Process Cell M C QC Masters 1 Praorese a rm Select MPS Item Location From f MPS Item f A To fi q A Location From Fa LOC A FGLOC To Jaar BS FGLOC Max No of Lines in PO 10 000 D EE
58. Customer Key To JHOMECURRENCY O Customer Histe D Update Custor Batch Status All lt O MSDS Setup SL BOM Utilities SL MSDS Reports H Laboratory O Laboratory Utilities m 1 1 ahoratan Rennt al T D Figure 14 11 5 MSDS Schedule Generation Production Finished Good Schedule Type Production Finished Good This setting is used to generate a schedule to print the MSDS of a Production Finished Good a finished good made by a Batch The data required to generate a schedule of production finished good type is fetched from the Production batches that have not yet been purged and the Material Safety Information screen Batch No From This Batch number specifies the lower limit of the range of batch numbers for use as filter criteria during processing This Batch number may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available batch number via the lookup Batch No To This Batch number specifies the lower limit of the range of batch numbers for use as filter criteria during processing This Batch number may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available batch number via the lookup Item Key From This Item key specifies the lower limit of the range of item keys for use as filter criteria during processing This Item key may be ente
59. DOCNUMBER 066 April 14 2005 Issue 2 Page 19 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 9 Click on the Transfer to Batch button to transfer the selected line items of the sales orders to batch 12 2 4 Special Functions Transfer To Batch Clicking on this button transfers the selected sales orders to production batches ER BatchMaster Manufacturing Transfer SO To Batches Ga File Edit View Help Module Special Functions Wimdo Az A cob Ge alzlel wl Al gt gt From Nooo0067 A CPI AT EG Ee EET Select Sales Order onge A 218 x H Formula Reports C Bill OF Materials Costing Costing Utilities aoe Transfer to A Routing Reports Batch Button C Production Production Utilities DO Generate Sch k L Batch Range F O Create Batche D Purge Batches O Purge Super B H0 Production Report H 0 MPS CJ MRP s MRP Reports SL Process Cell Mod zl QC Masters H 0 Process Cell Repo SL QC Reports CJ MSDS H BOM Utilities i F MSNS nmz D IV Transfer to Super Batch SuperBatch IV Create Purchase Reg SELECT IN RANGE IT Allocate Auto Lot Assignment J Fill From Inventory ITEM_FOR_ROUTI df WME 09 22 04 IKG 444 00 Select All Deselect All Warehouse Transfers Figure 9 2 2 Transfer to Batch Button DOCNUMBER 0
60. Data View Screen DOCNUMBER 066 April 14 2005 Issue 2 Page 271 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Table Name This is the name of the table on which SQL queries can be run Filter Data A SQL query can be entered or edited in the text field When there are records displayed in the View Table data grid one can use the various drop down list fields to modify the query View Table Data This grid displays the records fetched as per the SQL query entered in the Filter Data text field that was last processed The window adjacent to this grid displays all the headers of the grid The user can hide any of the columns on the grid by un checking the corresponding boxes on the right side of the grid Process On clicking the Process button the grid is populated with data fetched from the BatchMaster Enterprise company database according to the SQL query entered in the Filter criteria field Maximum Records Enter the maximum number of records to be fetched on this screen This number can be between 1 and 999 999 Add Criteria When the Add Criteria button is clicked the selections made on the various drop down lists get suffixed to the text in the Filter Criteria text field Select All View Table Data grid Clicking this button checks all the boxes on the grid above this button Unselect All View Table Data grid Clicking this button un checks all boxes on the
61. Demand Fi IN Maintain M In Camnann LL gt Item For Production level 1 D E E 4 4 4 4 4 4 4 D lealealeaiea es olojojlojo Select All Un Select ll Delete Line Figure 10 3 2 MPS Planning Worksheet Forecast Tab Select When this box is checked for a row that row becomes available for deletion via the Delete Line button When this box is un checked for a row that row is unavailable for deletion via the Delete Line button Forecast Key This is the Forecast Key associated with the row Line No This is the line number associated with the forecast key that is shown on the same row This is a system generated field Forecast Qty This is the quantity that is requested via this forecast line During Run MPS the Forecast Qty is fetched from the Forecast Entry screen The Forecast Qty can be changed on this screen Changing the Forecast Quantity and saving it updates the related demand on the planning worksheet on Tab 1 automatically but does not change the actual forecast on the Forecast Entry screen Request date This is the date on which Forecast Qty of the item is requested to be ready During Run MPS the Request date is fetched from the Forecast Entry screen The Request date can be changed on DOCNUMBER 066 April 14 2005 Issue 2 Page 66 of274 Ba
62. Enter the Location Key From Leaving this field blank has the same effect as entering the first available location 7 Enter the Location Key To Leaving this field blank has the same effect as entering the last available location 8 Enter the Customer Key From Leaving this field blank has the same effect as entering the first available customer 9 Enter the Customer Key To Leaving this field blank has the same effect as entering the last available customer 10 Select the Batch Status DOCNUMBER 066 April 14 2005 Issue 2 Page 220 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 11 Click on the Process button Depending upon the filter criteria the schedules are generated for the production finished goods A report displays all those production finished goods for which schedules were generated 12 Save the record by assigning some parameter name to the record in the input box on the toolbar 21 12 11 Screen Fields Descriptions for MSDS Customer History ER BatchMaster Manufacturing MSDS Schedule Generation E E laj x E File Edit View Help Module Special Functions Windows l x 7 ba alzle KIKALI lgl DI m Schedule Basis EEN Ta salary er Schedule Type MSDS Customer History e I SL QC Reports r Selection Criterion Fy MSDS Item Key From cc ec ee ee D Boilerplate Gro DY Boilerplate Mai ltem Key To AP_FIFO_P
63. Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 1 1 Generating a Batches in Process Report 1 Complete the Formula From and To range using the lookup buttons next to the fields 2 Complete the Batch From and To range using the lookup buttons on the toolbar next to the fields 3 Select the Batch Status as required 4 Select Schedule start date and Schedule completion date using the drop down arrows range respectively 5 Complete the Customer From and To range using the lookup buttons on the toolbar next to the fields 6 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 7 Click on the Process button on the toolbar to create a report DOCNUMBER 066 April 14 2005 Issue 2 Page 36 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 13 2Batch Ticket Report The Batch Ticket Report screen provides a way to generate a report showing batch tickets created using the Batch Ticket screen One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 2 1 Generating a Batch Ticket Report 1 Complete the Batch Fro
64. Formula Supplementary File of Formula Classes type attached to the relevant Formula Class at the Supplementary File screen If there are any reportable components in the formula the boilerplates for the reportable components are also applicable Supplementary File of Template type attached to the item at the Item Master screen Supplementary File of Materials type attached to the Material at the Supplementary File screen Supplementary File of Materials Classes type attached to the relevant Item Class at the Finished Good Supplementary File screen Supplementary File of Material Hazard type attached to the Material Hazard Type ID at the Supplementary File screen This Hazard Type ID is connected to this Finished Good at the Material Safety Information screen If there are any reportable components in the formula the boilerplates for the reportable components are also applicable Supplementary File of Template type attached Raw Material to the item at the Item Master screen Supplementary File of Materials type attached DOCNUMBER 066 April 14 2005 Issue 2 Page 188 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing to the Material at the Supplementary File screen Supplementary File of Materials Classes type attached to the relevant Item Class at the Supplementary File screen Supplementary File of Material Hazard type attached to the Material Hazard Ty
65. IN MPS Order C MRP 1 SL MRP Reports WI Process Cell M SL OC Masters DI Prnrace E Select Al Unselect All Warehouse Transfers Club Orders Figure 10 5 1 Transfer MPS Production Orders Select MPS Item Location MPS Item From The lookup at this field displays only those MPS items for which there exists at least one Confirmed Production Order This specifies the lower limit of the ange of MPS items for which the Production Orders need to be transferred Leaving this field blank has the same effect as selecting the first available item via the lookup MPS Item To The lookup at this field displays only those MPS items for which there exists at least one Confirmed Production Order This specifies the upper limit of the range of MPS items for which the Production Orders need to be transferred Leaving this field blank has the same effect as selecting the last available item via the lookup Location From This specifies the lower limit of the range of locations Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations Leaving this field blank has the same effect as selecting the last available location via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page81 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Grid Fields Transfer to Super Batch C
66. Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available Item key via the lookup The lookup displays only those items excluding finished goods for which the Item Type optionally with Sub Type has been maintained at Tab 2 of MSDS Setup screen 21 12 6Generating a Schedule of Raw Material type 1 Select the Schedule Type as Raw Material 2 Enter the Item Key From Leaving this field blank has the same effect as entering the first available item raw material DOCNUMBER 066 April 14 2005 Issue 2 Page 216 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 Enter the Item Key To Leaving this field blank has the same effect as entering the last available item raw material 4 Click on the Process button Depending upon the filter criteria the schedules are generated for the raw materials A report displays all those raw materials for which schedules were generated 5 Save the record by assigning some parameter name to the record in the input box on the toolbar 21 12 7Screen Fields Descriptions for Production Formula 18 x 16 x ER BatchMaster Manufacturing MSDS Schedule Generation File Edit View Help Module Special Functions Windows fat ad axle n T ln lgl Di Schedu
67. MPS Planning v D Transfer MPS P Forecast Start Date joaz ooo M D Transfer MPS P O Demand Fence O Demand Fence O Demand Fence O Demand Fence O Maintain MPS It O Company Caen D Planning Calenc ___ ForecastKkey Location Status 9717 2004 971872004 91972004 E T 322 0000 334 0000 342 342 0000 JEN 2 fl Add Line O MPs Setup Delete Line O Pull MPS Items D MPS Order Ran MRP j H MRP Reports M Prorgse Fall mnz D Figure 10 1 5 Toggle Units Button DOCNUMBER 066 April 14 2005 Issue 2 Page 56 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Change Forecast This button is used to change the forecast start date This button should be used when the user wants to view the forecast starting from a date different from the date that has been saved Changing the forecast start date and clicking on this button modifies the forecast entry grid with the new forecast start date ER BatchMaster Manufacturing Forecast Entry E E lej x E File Edit View Help Module Special Functions Windows l x BAE al x gs KRILA LI ole PAKJES zl Costing Utilities Costing Reports 1 Routing Reports 1 Production 1 Production Utilities Production Reports EJ MPS O D Run MPS ID MPS Planning v O Transfer MPS P O Transfer MPS P ID Demand Fence ID Demand Fence ID Demand Fence ID Demand Fence Dn Maintain MPS It ID Company Caen
68. Pu rging S per Ee TEE 36 13 PRODUCTION REPORTS geegeeeeeseergseegeeeesee anacan naea sasaaa aaacasa EES 36 13 1 BATCHES IN PROCESS REPORT 2 cscccccecsecceeccusneeecaeceueccseecetesececescateeesesensescusesseeseseseees 36 13 1 1 Generating a Batches in Process Report cceeeeeeeee cece eee cnnteeee eee enna aeeeeeeeeeeennae anes 36 13 2 BATCH TICKET REPORT 0cccccceceececececeeceeeeseeeeeaeeceeeeeeeeeeeeeseneeeeeeseeseeeesseeseeeeseeeseeeesenegeeeees 37 13 2 1 Generating a Batch Ticket Report ccceeeeeeeetneeeee eee e nna eeeeeeeea naa eeeeeeaanteeeeeeeeanatneeees 37 13 3 CRITICAL MATERIAL REPORT a naneneneennnttrtttttttttt rttr ttt rtrt EEEE EErEE EErEE E EEE EEEE EEEE EEEE EEEE EEEE 37 13 3 1 Generating a Critical Material R DOSt 0 ccccccccccccteeee eee e een tneee ee eeea naan eeeeeenaateeeeeenannnes 37 13 3 2 Transferring Materials to a Purchase Requisition using Critical Material Report 38 13 3 3 Screen Field Description in Transfer Critical Items To Purchase Requisition grid 38 13 4 PRODUCTION HISTORY SUMMARY HERORT ennen eeene tett rerttt rttr ttrt ert ttertntter rttr rn nnne eent 39 13 4 1 Generating a Production History Summary Report ssssiieessiennnnnnenrrneeerrrrreeeenrnreeens 39 13 5 PRODUCTION HISTORY DETAIL REPORT 0cccseeeceeeeeeeeeeceeeeeeeeeeseeeeeeeeseeeeeeesseeeseeeseeeeeeeeseegs 39 13 5 1 Generating a Production History Detail Report
69. RE 227 21 14 CUSTOMER HISTORY EE 227 21 14 1 Screen Fields Descriptions 112 1 ccceeeeee cee eeeeneeeeneeeeecaeeesauaeeeaatesssaeessaaeteeteaeeeees 228 21 14 2 Creating a Customer Histon eect eee e ene ee tees canna eee eee e anna eeeeeeanaaeeeeeeaanaaaees 228 21 15 UPDATE CUSTOMER HISTORY EE 229 21 15 1 Screen Fields D SCIIDLONS AA 229 21 15 2 Updating Customer History 229 21 16 MSDS SETUP eieiei EE saudaduebetedeesenebebebencements 230 DOCNUMBER 066 April 14 2005 Issue 2 Page9 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 16 1 Screen Fields Descriptions 112 1ccccecceeeeceeeee anette ceeeeescaeeeeaneeeeaaetesssneessaneneessaeesees 230 22 MSDS REPORTS 3 22scscccccccevecttrteccecsccccedsdeeedscccesadeasdcedededacceccceccdvedyevdeausesesevesascesicecececaa lt ecudes 232 22 1 ME EREROET eege gees dee EES 232 22 1 1 Generating a MSDS Setup Hepnort nnne nnrennnnnnernnennenrnenrnenrnnnnnnnnrnnnrnnnne 233 22 2 BOILERPLATE GROUP HERORT ttt ttr ttrt rEt rA EEE EEA EEEE E EEEE EEEE Enr E nren 233 22 2 1 Generating a Boilerplate Group Heport 233 22 3 BOILERPLATE MAINTENANCE HERPORT ceeeseeeeeeeeeseeeeseeeeseeeeseeceeeeesaeeeneeenes 233 22 3 1 Generating a Boilerplate Maintenance Report Screen 233 22 4 BOILERPLATE OVERRIDE REPORT sssssseieenseitertttttttttt tet tttttt ttrt trr tnter Errr EEEn EEEE EEren renren 234 22 4 1 Generating a Boilerplate Override Report
70. Replan MPS button is clicked Plan Qty This is the Plan Quantity that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked For a Planned Order this date can be modified by the user Confirm End Dt This cate is defaulted with the Plan End Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked For a Planned Order this date can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked For a Planned Order this quantity can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to a production batch Batch Type This can be one of Mix Fill or Assembly depending on the assembly type of the associated BOM Process Cell This is the Process Cell associated with the formula being used by the BOM of this item Hours Required This value is assigned by the system during Run MPS This value can be changed at the Process Cell Formula Capacity screen The value can also get modified when orders get clubbed Select All Clicking this button checks the boxes for all the rows in the g
71. Sale A DI 1 249 9899 0 0000 0 0000 2 JIMAIM Main Wareho 356 0000 KR good D good 3 SLECH RIES 12 101 0000 Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order P Quantity Commit To Sales Quantity Commit To Production Figure 11 7 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No EEGEN DOCNUMBER 066 April 14 2005 Issue 2 Page 142 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date 15 8 Planned MRP Production Order The Planned MRP Production Order option provides a way to update and edit the planned Production orders generated by MRP Run With Planned MRP Production Order one can make specific changes to a planned Production order modifying the order s defining details The user can also delete the Planned Production Order entirely emp pb ed ae 15 8 1 Screen Fields Description ER BatchMaster Manufacturing Pla
72. Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 8 1 Mandatory Inputs Data should be setup at the following screens before creating a Hazard Print Criteria 1 Hazard Type Maintenance 2 Hazard Print Range Maintenance if Range is selected at the List Qty As field 21 8 2 Screen Fields Descriptions ER BatchMaster Manufacturing Hazard Print Criteria Maintenance EI x aa File Edit View Help Module Special Functions Windows 8 x Cy cos ta al x eal ia a gt gt Aka A r Hazard Print Criteria Maintenance 1 LA Production Report Hazard Section ID d NEWSEC C MPS SL MRP Material Hazard Type ID Ur Kje hazard SL MRP Reports fC Process Cell Modu Include by Wt gt 3 0000 QC Masters i Include by Vol gt 7 0000 SL Process Cell Repo Reese H 0 QC Reports Include Top n Ingredients E MSDS TD Boilerplate Gro List Oty As Range D ID Boilerplate Mai F IT y E oe Ost Round to Nearest Range n 0 0001 D Supplementa EE bn ae table 1 C CAS Number h azard Type emical Name Prefix O Hazard Type h Chemical Name Prefi f D Hazard Print R k C Material Safety O SARA Process O MSDS Master DN MSDS Schedt D Print MSDS O Customer Histe D Update Custor In msns gn Figure 14 7 Hazard Print Criteria Maintenance Hazard Section ID This is the key to identify this Hazard Section Thi
73. User s Guide Volume III Manufacturing 23 1 1 Mandatory Inputs The data should be maintained at the following screens 1 Item Locations 2 Unit Conversions For an Hem Location that is to be used as a formula line item or a formula byproduct e If the Stock Unit of the item is different from the System Weight unit then a conversion should be defined from the Stock Unit to the System Weight Unit e If the Stock Unit of the item is different from the System Volume unit then a conversion should be defined from the Stock Unit to the System Volume Unit Formula Class Formula Status Physical Property Formulas with valid equations and adjust equations Physical Properties by weight volume or constant for the materials in Material Property Master Screen of Inventory module of Distribution Application 7 The values of the Material Properties for Items used in a formula Oo Ro 23 1 2 Screen Fields Descriptions Header ER BatchMaster Manufacturing Physical Property Analysis WE la x E File Edit View Help Module Special Functions Windows lej x ouelas a xlel 1 Routing Formula Key g FORMULA A Quality Control Enlarge View Formula Reports E CTANDAR i Bil OFM p i Description Formula A for Melnvalid record can be saved 2 Cost Method STANDARD aterials on the Maintain Downtime master zl e View Mode By Quantity i L Costing Recalculate Property Hide Physical Property I Hide Formula Summa 1 Costing Ut
74. WT Out Dep Dmd 200 10 22 10 50 0 0 192 Cumulative ATP 0 192 192 18 09 04 Demand Customer Orders Forecast Warehouse Transfer Out Dependent Demand 250 150 0 0 400 Supply Purchase Orders Production Orders Warehouse Transfer In Previous PAB 25 27 10 167 229 Requirement Demand Supply 400 229 171 DOCNUMBER 066 April 14 2005 Issue 2 Page61 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing This order will be placed on 17 09 04 As order type is EOQ sized order will be of 200 stock units PAB Orders Generated Requirement 200 171 29 ATP Supply MPS Prod Ord Purch Ord WT In Demand Cust Ord WT Out Dep Dmd 200 25 27 10 250 12 Cumulative ATP 192 12 204 19 09 04 Demand Customer Orders Forecast Warehouse Transfer Out Dependent Demand 300 50 5 0 355 Supply Purchase Orders Production Orders Warehouse Transfer In Previous PAB 12 31 0 2 2 Requirement Demand Supply 355 72 283 This order will be placed on 18 09 04 As order type is EOQ sized order will be of 400 stock units PAB Orders Generated Requirement 400 283 117 ATP Supply MPS Prod Ord Purch Ord WT In Demand Cust Ord WT Out Dep Dmd 400 12 31 300 5 138 Cumulative ATP 204 138 342 14 2 4 Processing a Run MPS 1 Se
75. a Date 3 Select a Graph type The capacity utilization details of the selected Process Cell are displayed as a graph and are also displayed under the Capacity Utilization Details grid 17 2 Process Cell Scheduling This screen provides users with a way to schedule the process cells for the production of the associated batches The user can 1 Adjust the schedule of a process cell for a specific batch by changing a The scheduled start date b The scheduled end date 2 Change the relative sequence of the assigned batches by moving the different assignments up or down 3 Assign a different process cell to any of the batches The schedule can also be modified for process cells that are associated with 1 Planned Firm Planned and Confirmed MPS Production Orders 2 Planned Firm Planned and Confirmed MRP Production Orders The schedule can be viewed in the form of a graph for a particular Process Cell on a given day DOCNUMBER 066 April 14 2005 Issue 2 Page 162 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 17 2 1 Screen Fields Descriptions Process Cell This field displays the Process Cell that has been selected via the lookup button on the toolbar Selecting a process is mandatory before viewing or changing its utilization Date This is the date that is applicable to all the batches associated with the selected Process Cell The date can be selected from the calendar displayed on the
76. a Warehouse Transfer order for the selected MRP Orders instead of transferring them to a Batch click on the Warehouse Transfers button 7 To club order lines together click on the Club Orders button 8 Click on the Transfer to Batch button to transfer the selected production orders to batch DOCNUMBER 066 April 14 2005 Issue 2 Page 155 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 10 3Special Functions Transfer to Batch Clicking this button transfers the planned production orders to Production Batches BatchMaster Enterprise generates a crystal report giving details of the production batch generated iej ER BatchMaster Manufacturing Transfer MRP Production Order EZ File Edit Yiew Help Module Special Functions Window Ke Costing SC Costing Utilities To i a Routing Reports SH Production Ip Production Utilities _ Production Reports J MPS From Location _ SELECT IN RANGE IN RANGE 3 MRP D Run MRP O Demand Fence 1t Ge A i For rae ALTERNATE_A Item For Produc FGLOC GEM 50 0000 111161 5 epee ALTERNATE_A ien For Produc FGLOC GEM 50 0000 11 11 61 Demand Fence 1t ALTERNATE_A Item For Produc FGLOC GEM 50 0000 11 11 61 O Demand Fence 2t ALTERNATE_A Item For Produc FGLOC GEM 50 0000 11 1161 Item For Produc FGLOC GRM 50 0000 11 11 61 ALTERNATE A Item For Prod
77. a value at the field Round to Nearest Range n if Number is selected at the field List Qty As 9 Select a Range Table if Range is selected at the field List Qty As 10 Click on the Save button to save this Hazard Section record 21 9 Material Safety Information This screen can be used to define the safety information associated with a specific inventory item The user can specify the general information such as CAS number Trade Secret status and specific item properties These properties may include vapor pressures explosive limits flash point boiling point and flash point method being used The SARA information delayed health hazards and occupational exposure limits may also be specified here DOCNUMBER 066 April 14 2005 Issue 2 Page201 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing The user may also set the HMIS values for Health Chronic factor Flammability Reactivity Personal protection Specific material hazards Oonrwn gt If a CAS Number is selected on this screen then the data maintained on Tab 1 4 of that CAS Number master record is defaulted on the Material Safety Information screen 21 9 1 Mandatory Inputs Data should be maintained at the Item Master screen 21 9 2 Screen Fields Descriptions Item key This is the Item key for which the safety information is defined Tab 1 General Information 18 x 18
78. and volume for each premix can ke printed utilizing a customized report rpt file for printing Batch Tickets A specialized setup is available for such a customized report DOCNUMBER 066 April 14 2005 Issue 2 Page 248 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Add Line Clicking this button adds a line at the bottom of the formula line items grid Delete Line Clicking this button deletes the selected line from the formula Create Line Clicking this button copies the selected line and copies it at the bottom of the formula line items grid Insert Line Clicking this button inserts a new line above the selected line in Formula Line Items Total Weight This field displays the sum total of the weights of all the Material lines in the System Weight UOM Total Volume This field displays the sum total of the volumes of all the Material lines in the System Volume UOM Weight Volume This field displays the density of the item produced using this formula The density is calculated by dividing the Total Weight by Total volume Cost Weight This field displays the cost per unit weight of the item being produced using the formula This value is calculated by dividing the Total RM Cost by the Total Weight Cost Volume This field displays the cost per unit volume of the item being produced using the formula This value is calculated by dividing the Total RM Cost by the Total Volume Total
79. any other related information for this item DOCNUMBER 066 Issue 2 April 14 2005 Page 202 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Trade Secret This field indicates whether the Company regards this item as a trade secret This field is for reference purpose only Vap Pressure mm Hg This field stores the pressure of a saturated vapor of De item in terms of millimeters of mercury Vap Pressure Temp This field stores the temperature in degrees Fahrenheit F or degrees Celsius C at which this item was subjected to when the Vapor Pressure mm Hg was measured Lower Explosive Limit This is the value of the lowest concentration by volume in air at which this item will burn or explode if an ignition source is available Upper Explosive Limit This is the value of the highest concentration by volume in air at which this item will burn or explode if an ignition source is available Boiling Point This is the temperature in degrees Fahrenheit F or degrees Celsius C at which this item will boil at an atmospheric pressure of 760 mmHg Flash Point This is the temperature in degrees Fahrenheit F or degrees Celsius C at which this item gives off sufficient vapor to form a flammable or ignitable mixture with air Flash Pt Method Used This is the method that is used to determine the flash point of this item Tab 2 Safety Info ER BatchMaster Manufacturing
80. as needed 5 For Exception Orders modify the confirmed quantity of the MPS purchase order as needed 6 For Exception Orders club order lines together by clicking on the Club Orders button if so desired 7 Save the Demand 2 MPS Purchase Order record DOCNUMBER 066 April 14 2005 Issue 2 Page99 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 8 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location j xj Item Key BUTANOL Stock UOM LES Description N Butyl Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Qty On Hand T On Order 01 warehouse 1 249 9899 H RH Main areho 356 0000 3 SLECH SIE A 12 101 0000 Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 10 8 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No sae oQ00D 2 Lot Bin Number Details Bin Number Lot Number Received Date
81. associated with a line item DOCNUMBER 066 April 14 2005 Issue 2 Page 16 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Fill From Inventory This box is enabled only when the Transfer to Super Batch box is checked If this box is checked the intermediates related to the Super Batch are taken from the available inventory If the Available Quantity of an intermediate suffices the required quantity then a Sub batch is not created for this intermediate If the Available Quantity of an intermediate is less than the required quantity then a Sub batch is created for the remaining quantity For this purpose the Available Quantity is equal to On Hand Quantity plus On Order Quantity in Production minus Committed to Production If this box is not checked the Fill From Inventory option is turned off In such a case the available quantities of any related intermediates are ignored when the super batch is created Number of runs This option is present when the value in the Super Batch type is selected as BatchWithRuns The value in this field decides the number of batches of the end item that will be made The order quantity of the end item is equally distributed in these batches Allocate If this box is checked the raw materials for the line items of the Sales Orders get allocated when the Sales orders are transferred to batches Auto Lot Assignment This box is enabled o
82. associated with a Fill type batch Item Description This field displays the description associated with the Item Key for a line in the grid Location This field displays the location associated with an Item for a line in the grid Location Description This field displays the description associated with a Location for a line in the grid MRP Order Details grid If for a specific day the Process Cell is overloaded the number of hours specified for the process cell have been exceeded for that day then the overloaded lines in the grid are highlighted with red color Process Line This is the relative sequence on the selected date in which the production for this MRP Order is scheduled using this process cell It can be modified Order No This field displays the MRP Order number for a line in the grid Batch Type This field displays the batch type associated with a MRP Order for a line in the grid Status This field displays the status of a MRP Order for a line in the grid This can be one of Planned Firm Planned or Confirmed Scheduled Start Date This field displays the date on which the production of this MRP Order is scheduled to start It can be modified When a Process Cell Schedule is saved after changes the Confirm Start date of the MRP Order as seen on the Planned MRP Production Order is changed to the Schedule Start Date saved in this field Scheduled End Date This field displays the date on which this MRP Order is schedul
83. batch directly from a schedule The batches created here can be viewed and modified at the Batch Entry screen 12 4 1 Mandatory Inputs A schedule should have been created before a batch can be created from it Select All Unselect All Smile DOCNUMBER 066 Issue 2 April 14 2005 Page 26 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 4 2 Screen Field Descriptions ER BatchMaster Manufacturing Create Batches From Schedule p EI x A File Edit View Help Module Special Functions Windows l x MARE AIXE Miall ll Slel E E 1 Select Item Location From Schedule 1 Formula Reports a Don fiTEM_FOR_ROUTING Fe t item for routing 0 Buor Materials To ITEM_FOR_ROUTING ay t item for routing 1 Costing Costing Utilities Location From MFG Be facturing Location _ Costing Reports T nb perabrset paren o MFG Manufacturing Location Routing Reports A Production 1 Production Utilities IV Transfer to Super Batch SuperBatch D IV Create Purchase Req SELECT IN RANGE O Generate Sch IEN IT Allocate Auto Lot Assignment I Fill From Inventory O Transfer 0 T K iler RE EC EE EE Ba Create Batchel ao D EM_FOR_ROUT ff m 200 00 200 00 TEST C Purge Batches L Purge Super B l Production Report i P MPS H Q MRP K
84. boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines Multiples of EOQ For the rows that have their boxes checked clicking on this button converts the value in the Plan Quantity field to an integral multiple of the Economic Order Quantity of that item The value of EOQ defined at item location is overridden by the value established at the Maintain MPS Item or Pull MPS Item screens 14 7 2 Working with Demand Fence 1 MPS Production Order 1 Select a MPS Production order record on this screen 2 Change the status for the MPS Production order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start
85. button deletes the selected line If the grid contains a single line deleting this line deletes the header also Target Values Alphanumeric Value This is the Target value for a test of alphanumeric measuring type Nominal Value This is the Target value for a test of Numeric measuring type DOCNUMBER 066 April 14 2005 Issue 2 Page172 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Control Limits Lower This is the lower control limit for a test of Numeric measuring type Upper This is the upper control limit for a test of Numeric measuring type 18 2 2 Creating a QC Formula Test 1 Click on the Insert button Clicking this button opens a lookup that displays all the formulas 2 Select a formula from the lookup 3 Maintain various rows on the grid as needed using the following steps 1 Click on the Add Line button to insert a line into the grid 2 Select a QC Test at the Test ID field 3 Select an option at the Measuring field 4 For each row on the grid enter the target test values as follows 1 If the test highlighted on the grid is numeric type enter the target test value at the Numeric Value field 2 If the test highlighted at the upper grid is alphanumeric type enter the target test value at the Alphanumeric Value field 3 If the test highlighted at the upper grid is numeric type enter control limits at the Lower and the Uppe
86. button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 15 5 2 Working with Demand Fence 2 MRP Production Order 1 Select a MRP Production order record on this screen 2 Change the status for the MRP Production order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the confirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MRP Production order as needed 6 For Exception Orders club order lines together by clicking on the Club Orders button 7 Save the Demand Fence 2 MRP Production Order record DOCNUMBER 066 April 14 2005 Issue 2 Page 136 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 5 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location a EZ Item Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol
87. can be one of the following 1 Exception These orders before being transferred to Purchase Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MRP Exception MRP Orders get erased when Run MRP is processed 2 Firm Planned These orders before being transferred to the Purchase Order need to be Confirmed The Orders that are FIRM PLANNED will not be erased when Run MRP is processed 3 Confirmed The Orders that are Confirmed are ready to be transferred to a purchase order and will not be erased when Run MRP is processed Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is processed Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is
88. cell It can be modified MPS Order No This field displays the MPS Order number for a line in the grid Batch Type This field displays the batch type associated with a MPS Order for a line in the grid Status This field displays the status of a MPS Order for a line in the grid This can be one of Planned Firm Planned or Confirmed Scheduled Start Date This field displays the date on which the production of the MPS Order is scheduled to start It can be modified When a Process Cell Schedule is saved after changes the Confirm Start date of the MPS Order as seen on the MPS Planning worksheet is changed to the Schedule Start Date saved in this field Scheduled End Date This field displays the date on which this MPS Order is scheduled to be closed It can be modified When a Process Cell Schedule is saved after changes the Confirm End date of the MPS Order as seen on the MPS Planning worksheet is changed to the Schedule End Date saved in this field Process Cell This field displays the Process Cell associated with an MPS Order for a line in the grid It can be modified When a Process Cell Scheduling is saved after changes the Process Cell of the MPS Order on the MPS Planning Worksheet screen is set to the Process Cell saved in this field Allocated Date This is the date on which this process cell is scheduled to be used for this MPS Order Batch Volume This field has the same value as does the Order Volume field on this screen B
89. checked If this box is checked the intermediates related to the Super Batch are taken from the available inventory If the Available Quantity of an intermediate suffices the required quantity then a Sub batch is not created for this intermediate If the Available Quantity of an intermediate is less than the required quantity then a Sub batch is created for the remaining quantity For this purpose the Available Quantity is equal to On Hand Quantity plus On Order Quantity in Production minus Committed to Production If this DOCNUMBER 066 April 14 2005 Issue 2 Page27 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing box is not checked the Fill From Inventory option is turned off In such a case the available quantities of any related intermediates are ignored when the super batch is created Allocate If this box is checked the raw materials for the production of the selected item locations get allocated when these item locations are transferred to batches Auto Lot Assignment This box is enabled only when the Allocate box is checked If this box is checked then the assignment of lots is done automatically If this box is not checked then the lots will not be assigned only the quantity will be allocated Create Purchase Req If this box is checked a purchase requisition is created for those raw materials whose quantity falls short of the quantity required for
90. date as needed 4 For Exception Orders modify the confirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MPS Production order as needed 6 For Exception Orders club order lines together to create a single line if so desired 7 For Exception Orders club certain lines together and convert the added quantity of these lines to an integral multiple of EOQ if so desired 8 Save the Demand Fence 1 MPS Production Order record DOCNUMBER 066 April 14 2005 Issue 2 Page95 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 7 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Oty On Hand _ ty On Order E Warehouse 4 1249 9899 0 0000 0 0000 2 JMaN Main Wareho A 356 0000 0 0000 0 0000 3 _ SLECH BIEN AJ 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 10 7 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed
91. demand ranges The choices a user makes in the planning calendar definitions govern the overall time constraints throughout the MPS and MRP options 14 12 1 DOCNUMBER 066 April 14 2005 Issue 2 Page 109 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 12 2Screen Fields Description ER BatchMaster Manufacturing Planning Calendar J lj x E File Edit Yiew Help Module Special Functions Windows la x pelele axel vlalrlvl ele Planning Calendar 1 _ Production a S l Planning Calendar K w 1 Production Utiities anning Calendar Key Ca SL Production Reports Planning Calendar Description this is the calendar for MPS MPS D Forecast Entry Demand Range 1 O Run MPS Days Per Period ID MPS Planning Works O Transfer MPS Purcha D Transfer MPS Produc ID Demand Fence 1 MP D Demand Fence 1 MP 1 30 1 O Demand Fence 2 MP Number of Periods 30 1 30 Number of Periods Demand Range 2 Days Per Period C Demand Fence 2 MP D Maintain MPS Item Demand Range 3 L Company Calendar Se Days Per Period L MPS Setup Number of Periods IN Pull MPS Items Totals MPS Order Range Pr Number of Days in Calendar 30 SL MRP JU _ MAP Reports Number of Periods in Calendar 90 SL Process Cell Module BL QC Masters SL Process Cell Reports F a AP Renars Figure 10 12 Planning Calendar S
92. during which this Process Cell is scheduled to be used for this batch Hours From This field displays the start time of the process cell for a batch of a line in the grid Hours To This field is automatically determined by adding the Batch Time Hr to the Hours From Formula ID This field displays the formula key associated with a Mix type Batch for a line in the grid Formula Desc This field displays the formula description associated with a formula for a line in the grid Item Key This field displays the Assembly key associated with an Assembly type Batch or the Intermediate key associated with a Fill type Batch Item Description This field displays the description associated with the Item Key for a line in the grid Location This field displays the location associated with an Item for a line in the grid Location Description This field displays the description associated with a Location for a line in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page 164 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing MPS Orders Details grid If for a specific day the Process Cell is overloaded the number of hours specified for the process cell have been exceeded for that day then the overloaded lines in the grid are highlighted with red color Process Line This is the relative sequence on the selected date in which the production for this MPS Order is scheduled using this process
93. field is defaulted from the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed Item Type This is the type of the item maintained at the Maintain MPS Item or Pull MPS Item screen Order_Status The value in this field is defaulted from the planned Purchase Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed The status of all the orders is Confirmed for this screen Plan Start Dt This is the Plan Start Date that is recommended by the system The value in this field is defaulted from the value of the plan start date field in the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed Plan End Dt This is the Plan End Date that is recommended by the system The value in this field is defaulted from the value of the plan end date field in the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed Plan Qty This is the Plan Quantity recommended by the system The value in this field is defaulted from the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was con
94. for each MPS item In addition to showing the location and the type of demand each report details the order rumber line number order quantity and order date The sources of demand shown on this report are 1 Forecast 2 Sales Orders 3 Warehouse Transfers Out 4 Dependent Demand from Planned Firm Planned and Confirmed orders of higher level MPS Items The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 26 2 1 Generating an MPS Demand Report 1 Complete the MPS Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 26 3 MPS Order Report The report includes MPS orders of the following statuses Exception Planned Firm Planned Confirmed Transferred IRN The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 26 3 1 Generating a MPS Order Report
95. for which the Production Orders need to be transferred Leaving this field blank has the same effect as selecting the first available item via the lookup MRP Item To The lookup at this field displays only those MRP items for which there exists at least one Confirmed Production Order This specifies the upper limit of the range of MRP items for which the Production Orders need to be transferred Leaving this field blank has the same effect as selecting the last available item via the lookup Location From This specifies the lower limit of the range of locations Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations Leaving this field blank has the same effect as selecting the last available location via the lookup DOCNUMBER 066 Issue 2 April 14 2005 Page 152 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Grid Fields Select in Range Using this button the user may select an option for manual or automatic generation of batch number for the highlighted line items For transferring these highlighted line items into one batch the following must be true a A released BOM must exist for each of these line items b All these line items must use the same formula Select When this box is checked for a row that row becomes available for transfer to production order
96. generated for only those items for which Intermediate or Finished Good types of released BOM exists 2 Intermediate If this option is selected a The item lookups display only those items for which Intermediate type of released BOM exists b Schedules can be generated for only those items for which Intermediate type of released BOM exists 3 Finished Good If this option is selected a The lookups display all those items for which a Finished Good type of released BOM exists b Schedules can be generated for only those items for which Finished Good type of released BOM exists 4 Assembly If this option is selected a The lookups display all those items for which an Assembly type of released BOM exists b Schedules can be generated for only those items for which Finished Good type of released BOM exists Item Key From This is the Item key that specifies the lower limit of the range of items for which a schedule has to be generated Leaving this field blank has the same effect as entering the first available Item The lookup here is limited by the Schedule Type field Item Key To This is the Item key that specifies the upper limit of the range of items for which a schedule has to be generated Leaving this field blank has the same effect as entering the last available Item The lookup here is limited by the Schedule Type field Item Location From This is the location that specifies the lower limit of the range of locations wit
97. grid above this button Select All Clicking this button checks all the boxes above this button Unselect All Clicking this button un checks all boxes above this button 27 1 2 Running a SQL query 1 Select a Table Name from the dropdown list The space below the Filter Data field displays the SQL query accordingly 2 Change or modify the SQL query as needed To apply a filter criteria to the SQL query do one of the following i Make selections on the drop down lists of the columns under the Filter Data field or type and click on the Add Criteria button ii Modify by typing the SQL query displayed in the text field 3 Enter maximum number of records to be displayed on this screen 4 Click on the Process button The SQL gets executed if written properly The grid displays the results of the SQL query as appropriate DOCNUMBER 066 April 14 2005 Issue 2 Page 272 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 27 1 3 Special Functions Transfer to MS Word When this button is clicked the information in the grid is displayed in a MS Word file The user can save this file if so desired ER BatchMaster Manufacturing Data iew l Ga File Edit Yiew Help Module Special Functions Windows la x Ci cot tS axel a p lable Name a 1 Bill Of Materials GH Costing m Filter Data Le Costing Utilities Where z
98. gt mJ ale r Material Hazard Type SL Process Cell Modu SC QC Masters Mat Haz Type ID I _ Process Cell Repo Gei Geen E SL QC Reports EEN MSDS ID Boilerplate Gro OD Boilerplate Mai OD Boilerplate Ove O Supplementary C CAS Number A k O Hazard Print R O Hazard Print C C Material Safety O SARA Process Dn MSDS Master O MSDS Schedi O Print MSDS L Customer Histe O Update Custor C MSDS Setup _ BOM Utilities _ MSDS Reports _ Laboratory R 1 aharatan en he Figure 14 5 Hazard Type Maintenance Screen Mat Haz Type ID This field stores a unique identification of a Material Hazard type This is a mandatory field Description This is the description associated with this type of Material Hazard DOCNUMBER 066 April 14 2005 Issue 2 Page 197 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 6 2 Creating a Material Hazard Type 1 Click the Insert button 2 Enter a unique identification and the description for a Material Hazard type 3 Click on the Save button on the toolbar to save the record 21 7 Hazard Print Range Maintenance This screen provides the users with a way to define the ranges of numbers that can be printed instead of the actual percentage of hazardous materials on a MSDS 21 7 1 Screen Fields Descriptions ER BatchMaster Manufacturing Hazard P
99. has the same effect as selecting the first available formula key via the lookup Formula Key To This Formula key specifies the upper limit of the range of formula keys for use as filter criteria during processing This Formula key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available formula key via the lookup Finished Good Key From This Finished Good key specifies the lower limit of the range of finished good keys for use as filter criteria during processing This Finished Good key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available finished good key via the lookup Finished Good Key To This Finished Good key specifies the upper limit of the range of finished good keys for use as filter criteria during processing This Finished Good key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available finished good key via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page214 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Formula Status This is the status of a Formula Any formula statuses other than the selected status get excluded 21 12 4 Generating a Schedule of Finished Good type 1
100. information produced by BatchMaster Enterprise s MRP group makes it possible for the user to schedule both purchases and production Demand can be broadly defined as the commitments that have to be met because there are open production batches warehouse transfers or dependent demands Forecast on the dher hand represents an estimate of future demand and can represent a number of things ranging from a prediction based upon production history or an analysis of future market conditions that one believes one should be prepared for in the future 15 1 RunMRP With Run MRP one can define MRP scheduling needs and generate a MRP schedule for those items whose order method is marked as MRP at the Item Master screen This screen is used to Run MRP for a range of items in regenerative mode Run MRP generates MRP production orders or MRP purchase orders depending whether the item is Make type or Buy type respectively as defined at the item location screen This is different from Run MPS Run MPS can generate production orders only if the item location is Manufacture type on the Maintain MPS Item screen and a released BOM exists for it For all other item locations Run MPS can generate purchase orders only DOCNUMBER 066 April 14 2005 Issue 2 Page 118 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing The sources of demand for Run MRP are 1 Forecast depending on the setting for the D
101. is the description of the Formula 21 12 2Generating a Schedule of Master Formula type 1 Select the Schedule Type as Master Formula 2 Enter the Formula Key From Leaving this field blank has the same effect as entering the first available formula 3 Enter the Formula Key To Leaving this field blank has the same effect as entering the last available formula 4 Enter the Formula Class From Leaving this field blank has the same effect as entering the first available formula class 5 Enter the Formula Class To Leaving this field blank has the same effect as entering the last available formula class 6 Enter the Formula Status From Leaving this field blank has the same effect as entering the first available formula status 7 Enter the Formula Status To Leaving this field blank has the same effect as entering the last available formula status 8 Enter the Formula Description 9 Click on the Process button Depending upon the filter criteria the schedules are generated for the formulas A report displays all those formulas for which schedules were generated 10 Save the record by assigning some parameter name to the record in the input box on the toolbar DOCNUMBER 066 April 14 2005 Issue 2 Page213 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 12 3 Screen Fields Descriptions for Finished Good ER BatchMaster Manufacturing MSDS Schedule Generation KE
102. it with other orders MRP Order No This is the system generated number for the MRP order Plan Run Dt This is the date when the MRP order was generated Order Status The Order Status on this screen can be one of the following 1 Exception These orders before being transferred to Production Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MRP Exception MRP Orders get erased when Run MRP is processed 2 Firm Planned These orders before being transferred to Production Orders need to be Confirmed The Orders that are Firm Planned will not be erased when Run MRP is processed 3 Confirmed The Orders that are Confirmed are ready to be transferred to a production order and will not be erased when Run MRP is processed Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is processed Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the
103. level 3 SL Routing Reports Location aer oo FGLOC SL Production Unt _ Production Utiities E _ Production Reports C MPS Sy MRP ee i Joe Sia Pen Si Pi Coren Dn Run MAP 44 29 07 04 F N 10 08 04 ER D4 EE 04 e 04 C Demand Fence SG d ID Demand Fence cn CA FIRM PLANT 13 08 04 13 08 04 200 0000 13 08 04 13 08 04 200 000 ID Demand Fence DN Demand Fence E 49 290704 CONFIRMEL 17 08 04 200 0000 17 08 04 200 000C KH D MRP OrderRar fa m O a 52 29 07 04 CONFIRMEL 20 08 04 20 08 04 20 08 04 20 08 04 200 000C O Planned MRP F G m O Transfer MAP F zir D Transfer MRP F SL MRP Reports SL Process Cell Moduh SL DC Masters SL Process Cell Repor 4 OC Reports e Select Al UnSelect All Delete Line Planned Firm Planned Confirmed Club Orders H MSDS _Sonfimed Ciub Orders SL BOM Utilities ai LI p Bette al D Figure 11 7 1 Planned MRP Purchase Order Screen Item Key This the Item Key associated with the Item Location for which the Planned MRP Purchase Order is displayed Location This the Location Key associated with the Item for which the Planned MRP Purchase Order is displayed Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MRP Order No This is the system generated number for the M
104. low level coding to the items in the BOM hierarchy so if no change has been made to the hierarchy then skipping reassignment of low level codes speeds up processing Generate Planned Orders as Planned This button should be clicked if it is required that the status of planned orders generated using Run MRP be set to Planned Firm Planned This button should be clicked if it is required that the status of planned orders generated using Run MRP be set to Firm planned Confirmed This button should be clicked if it is required that the status of planned orders generated using Run MRP be set to Confirmed 15 1 3 Processing a Run MRP 1 Select a MRP Item at the From MRP Item field using the lookup button at this field 2 Select a MRP Item at the To MRP Item field using the lookup button at this field 3 Select a location at the From Location field using the lookup button at this field 4 Select a location at the To Location field using the lookup button at this field 5 Enter the Demand End Date The Server Date is automatically taken as Demand Start Date 6 If one wishes to skip the low level coding the box for Skip low level coding should be checked The user should be very sure before skipping low level coding If the low level codes are wrong then the MRP planning could be incorrect 7 Select a Generate Planned Orders as option from the following Any planned orders when they are genera
105. ma zl Process Cell Repo 1 HO QC Reports Group Name g fao Abrres ance and Odor y MSDS 2 AOI Boilerplate ID Gei b Boilerplate Gro Sala a D Boilerplate Mai b r Replace with Boilerplate O Supplementary Group Name lag Bl zseaace and Odor CAS Number h Boilerplate ID PO O Hazard T ypeh O Hazard Pit Reason foonfictineolor o O Hazard Print C C Material Safety Status Active x A SARA Process ID MSDS Master O MSDS Sched O Print MSDS ID Customer Histe IN Update Custor Di MSDS Setup BOM Utilities C MSDS Reports LI el Figure 14 3 Boilerplate Override Screen EE Conflicting Boilerplates Group Name This is the boilerplate group key that is associated with the adjacent boilerplate key The group name can be entered by typing or selected via the associated lookup on this screen This is a mandatory field DOCNUMBER 066 April 14 2005 Issue 2 Page 186 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Boilerplate ID This field displays the boilerplate key Group Name This is the boilerplate group key that is associated with the adjacent boilerplate key The group name can be entered by typing or selected via the associated lookup on this screen This is a mandatory field Boilerplate ID This field displays the boilerplate key Replace with Boilerplate Group Name This is the name of the group t
106. mandatory field Description This is the description of the boilerplate group Status This field displays the status of a boilerplate group The status of a group can be one of Active Inactive Marked for Deletion or Deleted A boilerplate will be printed on a MSDS only if its status is Active 21 1 2 Creating a Boilerplate Group 1 Click the Insert button 2 Enter the Group Name and the description 3 Select the status 4 Click on Save button to save the boilerplate group 21 2 Boilerplate Maintenance This screen can be used to create blocks of text for use on a MSDS when the user wants to print significant information on the MSDS DOCNUMBER 066 April 14 2005 Issue 2 Page 183 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing BatchMaster Enterprise uses a combination of a group name and boilerplate identification to place the text associated with the boilerplate on the MSDS A Boilerplate cannot be added by itself to a MSDS Instead a Boilerplate Group should be added to the template file for the MSDS this in turn will fetch the associated boilerplates on the MSDS April 14 2005 DOCNUMBER 066 Page 184 of 274 Issue 2 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 2 1 Mandatory Inputs At least one Boilerplate Group and one language should be created 21 2 2 Screen Fields Descriptions ER BatchMaster Manufacturing
107. numeric value at the field Time Fence 2 3 Select a Planning Calendar created via the Planning Calendar screen from the lookup at this field 4 Define the Gross Demand for each of the Demand Ranges at the Demand Range 1 Demand Range 2 and Demand Range 3 fields 5 Select a display color for Demand Range 1 Demand Range 2 and Demand Range 3 at their respective fields 6 Select a value for the Top Level Finished Good Batch to be created as field 7 Select a value for the Allow transfer of intermediates of Super Batch field 8 Check the box for Use multiple economic order quantities if so desired 9 Click the Save button to save the MPS Setup 14 14 Pull MPS Items The Pull MPS Items screen adds MPS Items to the Maintain MPS Items screen It picks up those items whose Order Method has been marked as MPS at the Item Master screen At the Pull MPS Items screen one can establish the following values that may differ from the corresponding values at the Item Location 1 Item type Purchase or Manufacture 2 Lot sizing Method The Lot Sizing Method specified at this screen overrides the Lot Sizing Method specified at the Item Master screen 3 Economic Order Quantity The EOQ defined here overrides the EOQ defined at the Item Location screen 4 Default Vendor The Vendor specified at this screen overrides the Vendor associated with this item via the Item Location screen The above
108. of Active Inactive Marked for Deletion or Deleted The default value of this field is set to Active when a new supplementary file is inserted If a supplementary file is not Active it is ignored when a MSDS is printed Boilerplates grid BPGroup This is the key of the boilerplate group that is associated with the boilerplate on this line After clicking the ellipsis button on this field the user can select the group name from the displayed lookup The identification associated with the selected group name is displayed at the field BPID This is a mandatory field BPID This field displays the boilerplate key for this line Add Line Clicking this button inserts a line in the Boilerplates grid Delete Line Clicking this button deletes the selected line s from the Boilerplates grid 21 4 3 Creating a Supplementary File 1 Click the Insert button 2 Select the type of Supplementary File 3 Enter or select a value for Supplementary File ID or Item Key or Item Class or Formula Key or Formula Class or Material Hazard Type ID 4 Select a Status for the supplementary file 5 Click on Add Line button 6 On the added line click on the ellipsis button under the field BPGroup 7 Select a row on the look up form and click OK 8 Click on the Save button to save the supplementary file 21 5 CAS Number Master This screen can be used to maintain the material safety information for a CAS number CAS Number stands for Chemical
109. option s filtering parameters to define the report One can also specify 1 Quantity by weight or volume 2 Search level 3 Printing or non printing of formula properties Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 25 1 1 Generating a Formula Material Analysis Report 1 Complete the Formula Key From and To range using the lookup buttons next to the field 2 Complete the Formula Class From and To range using the lookup buttons next to the fields DOCNUMBER 066 April 14 2005 Issue 2 Page 265 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 Complete the Formula Status From and To range using the lookup buttons next to the fields 4 Complete the Property 1 6 range using the lookup buttons next to the fields 5 Complete the Quantity by Weight or Volume 6 Sect the Search Level to top or bottom 7 Complete the Print All Formula Properties 8 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 9 Click on the Process button on the toolbar to create a report 25 2Formula Physical Property Report The Formula Physical Property Report screen provides a way to generate a report showing up to four formula physical properties
110. parameters DOCNUMBER 066 April 14 2005 Issue 2 Page 158 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 4 Click on the Process button on the toolbar to create a report 16 3 MRP Demand Report The MRP Demand Report provides the means to see demand for each MRP item In addition to showing the location and the type of demand each report details the order number and line number order quantity and order date The sources of demand shown on this report are 1 Forecast 2 Sales Orders 3 Warehouse Transfers Out 4 Dependent Demand from Planned Firm Planned and Confirmed orders of higher level MPS Items and higher level MRP Items The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 16 3 1 Generating a MRP Demand Report 1 Complete the MRP Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 16 4 MRP Planning Report The MRP Planning Report pro
111. parameters it displays the results as a Crystal Report that one can print or export 19 1 1 Generating a Capacity Utilization Report 1 Complete the Process Cell From and To range using the lookup buttons next to the fields 2 Complete the From Date and To Date range 3 Check the Print Chart box to enable this feature 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to generate a report 19 2 Process Cell Schedule Report The Process Cell Schedule Report screen generates schedule information for all the process cells that are associated with one or more batches Sorted by process cells falling within the report s defined parameters each report contains batch numbers beginning date ranges ending date ranges batch DOCNUMBER 066 April 14 2005 Issue 2 Page179 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing times and time ranges In addition to this the report displays the batch s characteristics including volume weight cell capacity the batch quantity sizing setting and the processing time The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Rep
112. procured via another location of the company it may be desirable to obtain the item from that location to fulfill demand rather than creating a new purchase order Once a Warehouse Transfer has been created for such an order the same order cannot be transferred to a Purchase Order Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 15 9 2 Transferring MRP Purchase Orders 1 Select a MRP Item at the From field using the lookup button at this field 2 Select a MRP Item at the To field using the lookup button at this field 3 Select a location at the From field using the lookup button at this field 4 Select a location at the To field using the lookup button at this field 5 Click on the Process button to fetch the Purchase Orders for the specified range Processing the range fetches those MRP Purchase Orders whose status is Confirmed 6 At the Max No of Lines in PO field enter the maximum number of lines that can be added to one Purchase Order 7 If one wishes to create a Warehouse Transfer order for the selected MRP Orders instead of transferring them to a Purchase Order then click on the Warehouse Transfers button 8 Club order line
113. production batches ER BatchMaster Manufacturing Create Batches From Schedule BB File Edit view Help Module Special Functions Windows Delale alel all gt se eb Se Sh Select Item Location From Schedule El Formula Reports 0 Bill Of Materials ltem Key H Costing C Costing Utilities Costing Reports Location Transfer to Batch Button location location 0 Routing Reports SL Production m Production Utilities JW Transfer to Super Batch SupeBatch IV Create Purchase Req SELECT IN RANGE O Generate Sch D Transfer SO T IT Allocate AutoLotAssianment J Fill From Inventory pees Reqd wags a Re OI P TE FOR ROUT il EKG Pe F_TEST O Purge Batches O Purge Super B B C Production Report C MPS H C MRP wO MRP Reports 1 1 Process Cell Modu CH QC Masters _ Process Cell Repo C GC Reports C MSDS wO BOM Utilities A Ma pee M Figure 9 4 2 Transfer To Batch Button SelectAll DeselectAll DOCNUMBER 066 Issue 2 April 14 2005 Page31 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing View Item Location The user may click this button to view the inventory details for all the item locations of the selected line iew Item Location E xi ItemKey ALTERNATE_A Stock UOM GRM Description ltem For Production level 2 Display Unit GRM 1 Location Detail DC Ge 65 245 0
114. properties of the current composition The option s filtering parameters can be used to define the intermediate update range One can also specify the 1 Search level for intermediates either from Top or Bottom 2 Formula Statuses to exclude from the roll up DOCNUMBER 066 April 14 2005 Issue 2 Page 263 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 24 1 1 Screen Fields Description E BatchMaster Manufacturing Intermediate Property Rollup E E laj x E File Edit View Help Module Special Functions Windows 8 x Glelslcl alles Kl lolol algl Item Key From PPA 23 Manufacturing C Formula Item For Production level 2 Formula Utilities ltem Key T Iw x L Compare Prio Se Gas Ett A k EE ile Pri em For Froduction level 3 IN Intermediate Search Level bd IN Material Subs SC To D Purge Prior V1 Status not Allowed ju A D View Prior Ve IN Intermediate l 0 Kl Routing SL Formula Reports Mode i d Trial _ Bill Of Materials oo Costing C Actual IV Roll up density IN Costing Setup CY Product Cost Formula Key Range y Costing Utilities From PAULA E L Formula Loss A IN Intermediate To FORMULA_F a C Update Finist 1 Costing Reports 1 Routing Reports 1 Production Production Utilitie I DL j ition Renny
115. save these parameters enter the name to be assigned to the report parameters in the dop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 9 Click on the Process button on the toolbar to create a report 14 MPS Master Production Schedule MPS provides a means to plan production based upon forecasts and anticipated demand The information produced by BatchMaster Enterprise s MPS group makes it possible for the user to schedule both purchases and production and to produce the gross requirements for use by BatchMaster Enterprise s MRP group The BatchMaster Enterprise MPS option generates production and purchase orders by making calculations based upon forecasts and demands Demand can be broadly defined as the commitments that have to be met because sales orders need to be fulfilled or internal commitment has been made to manufacture intermediates Forecast on the other hand represents an estimate of future demand and can represent a number of things ranging from a prediction based upon sales history for the items or an analysis of future market conditions that the user should be prepared for in the present MPS uses a mixture of demands and forecasts within the defined time frame and tells the user how to make and when to make the finished goods to meet deadlines The following figure depicts the logical process flow of the MPS module DOCNUMBER 066 April 14 20
116. specifies the lower end of the Plan Dates Leaving ths field blank has the same effect as entering January 01 1900 DOCNUMBER 066 April 14 2005 Issue 2 Page117 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Plan End Date This specifies the upper end of the Plan Dates Leaving this field blank has the same effect as entering the current Server date Change Status From The Orders having this selected status will qualify for the change of status The value in this field can be one of Exception Planned Firm Planned or Confirmed Change Status To The status of the selected Orders will change to this status upon processing The value in this field can be either Firm Planned or Confirmed 14 15 2 Processing a Range of MPS Orders 1 Select a MPS Item at the From field using the lookup at this field 2 Select a MPS Item at the To field using the lookup at this field 3 Select a Location at the From field using the lookup at this field 4 Select a Location at the To field using the lookup at this field 5 Enter a Plan Start Date 6 Enter a Plan End Date 7 Select a status at the Change Status From field 8 Select a status at the Change Status To field 9 Click on the Process button on the toolbar to change the status 15 MRP Material Requirements Planning MRP provides a means to plan purchases based upon forecasts and anticipated demand The
117. the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User d k Record Date SCENE Sege e DOCNUMBER 066 April 14 2005 Issue 2 Page 100 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 9 Demand Fence 2 MPS Production Order The Demand Fence 2 MPS Production Order option provides a way to define the order status for a MPS Production Order having status as Exception and falling under Demand Fence 2 With Demand Fence 2 MPS Production Order one can convert the order status of a selected MPS order and MPS item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MPS Production Order option The confirmation dates can be established as well If a user has access to the Demand Fence 2 MPS Production Order option that user may not access the Demand Fence 1 MPS Production Order option which typically has more order confirmation authority This screen does not display those orders that are displayed on the Demand Fence 1 MPS Production Order 14 9 1 Screen Fields Description ER BatchMaster Manufacturing Demand Fence 2 MPS Production Order B J a x E File Edit View Help Module Special Functions Windows lej x oleae axel vlalrlrl ele el 1 Production ASSEMBLY_1 L Production Uti Location Fao raoc 1 P
118. the date when this order was transferred to purchase order Vendor This is the Vendor for the purchase order If a vendor is associated with this Item Location via the Item Location screen then via Run MRP the vendor key is defaulted here from the Primary Vendor Key field of the Item Location screen This value can be modified here Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Exception H any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked DOCNUMBER 066 April 14 2005 Issue 2 Page 123 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest p
119. the same effect as selecting the last available location via the lookup Max No of Lines in PO The value in this field defines the maximum number of lines that can be added to one Purchase Order DOCNUMBER 066 April 14 2005 Issue 2 Page 147 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Grid Fields Select When this box is checked for a row that row becomes available for transfer to purchase order MRP OrdNO This is the system generated number for the MRP order This value is defaulted from the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed ItemKey This is the Item Key for which the confirmed MRP purchase order has been generated Description This is the description of the item Location This the Location Key associated with the Item for which the confirmed MRP purchase order has been generated UOM This is the Stock UOM for the Item Key Req Qty This is the Required Quantity recommended by the system Conf Dt This is the date on which the status of the planned purchase order was set to Confirmed Actual Dt This is the date on which the purchase order was generated by running MRP Vendor This is the Vendor for the purchase order The value in this field is defaulted from the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens de
120. using the lookup buttons next to the fields 6 Select Completion Date From and To range using the drop down arrows respectively 7 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 8 Click on the Process button on the toolbar to create a report 13 19 Super Batch Critical Material Report The Super Batch Critical Material Report screen provides a way to generate a report showing quantities of materials that are lacking in the inventory and so are unable to meet production obligations for the selected Super Batches The critical materials are determined for the entire Super Batch as a whole and not for the individual sub batches of the Super Batch One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report paramders it displays the results as a Crystal Report that one can print or export 13 19 1Generating a Super Batch Critical Material Report 1 Select the Formula From and To range using the lookup buttons next to the fields DOCNUMBER 066 April 14 2005 Issue 2 Page 46 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 2 Select the Super Batch From and To range using the lookup buttons next to the fields 3 Set the Item Type as needed 4 Set the Apply Date
121. values defined here will supersede during Run MPS any conflicting values that may be stored at the Item Location DOCNUMBER 066 April 14 2005 Issue 2 Page 114 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 14 1 Screen Fields Description ER BatchMaster Manufacturing Pull MPS Items E la x a File Edit Yiew Help Module Special Functions Windows la x olema alle KIKA gt ole A Routing Reports Production _ Production Utilities 1 _ Production Reports MPS L Forecast Entry O Run MPS Dn MPS Planning ID Transfer MPS F O Transfer MPS F C Demand Fence C Demand Fence ID Demand Fence ID Demand Fence m Select MPS Items to save ep Demo feegen entes Lot Sizing Mthd Econ SE GE L Lot for Lot HH A iE F uction level 1 Purchase L Lot for Lot ttt ID Maintain MPS II D Company Calen Select All UnSelect ll TD Planning Caen LY MPS Setup ID MPS Order Rar C MRP 1 MPP Reports 1 Process Cell Modul C QC Masters 1 Prarase Cell em z t Figure 10 14 Pull MPS Item Screen Select MPS Items to Save Select When this box is checked for a row that row becomes available for pulling for MPS MPS Item The value in this field contains those items whose Order Method has been defined as MPS on the Item Master screen Descript
122. 000 344 0000 Toggle UOM Quantity on Hand 65 0000 Quantity on Order 245 0000 Quantity Commit To Sales 344 0000 Quantity Commit To Production 0 0000 Figure 9 4 3 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold i Multiple Bins Requirement Yes or No 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date oe 2050p sea 9a00p a ae DOCNUMBER 066 April 14 2005 Issue 2 Page 32 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 5 Purge Batches The Purge Batches option provides a way to purge batches from production history With Purge Batches one can specify which batches are to be removed permanently from production history One can use the option s filtering parameters to define the purge Once BatchMaster Enterprise processes the purge parameters it displays the results as a report one can print or save Only those batches can be purged that have been closed The purged batches can be viewed at the Production History Summary Report
123. 004 Friday M 9 18 2004 Saturday M 9 19 2004 Sunday Cl Tuesday C 9 20 2004 Merde L Demand Fence 2 MP Wednesday 7 9 21 2004 Tuesday O Demand Fence 2 MP I Thursday 8 z os Se Wednesday E E Frid ursday D Maintain MPS Item mE C 9 24 2004 Friday Bi Company Calendar S4 ri E 9 25 2004 Saturday D Planning Calendar iz 9 26 2004 Sunday 3 27 2004 Monday MPS Setup I 9 28 2004 Tuesday DN Pull MPS Items T 3 29 2004 Wednesday a ID MPS Order Range Pr H 9 30 2004 Thursday 10 1 2004 Friday MAP a Vv LU 10 2 2004 Saturday MAP Reports 10 3 2004 Sunday BL Process Cell Module I 10 4 2004 Monday H O QC Masters C 10 5 2004 Tuesday H Process Cell Reports 107872004 __ Wednesday Z m ar emer Z Figure 10 11 Company Calendar Setup Screen Year The value in this field decides the year for which the company calendar is to be setup Select Weekly Holidays Select Checking these boxes sets the corresponding day of the week as a holiday on processing Day The value in this field defines the day of the week Checking the box next to the respective days sets them as company holidays on processing This is a read only field List of Holidays Select Checking these boxes sets the corresponding day of the week as a holiday This option can be used to define public holidays DOCNUMBER 066 April 14 2005 Issue 2 Page 108 of 274 BatchMaster Software BatchMast
124. 05 Issue 2 Page49 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Company Calendar Setup Planning Calendar Definition Establishing MPS Setup Maintaining Pulling MPS Items Defining Forecast Entry Running MPS Viewing Planning Worksheet Transferring Orders 14 1 Forecast Entry The Forecast Entry screen provides a way to create a forecast for any item location With Forecast Entry a forecast based on either quantity of the item or amount of money can be established This screen also has provision for setting a cost method and defining a forecast quantity 14 1 1 Mandatory Inputs Data at the following screens should be maintained before a forecast entry is made 1 Item Location 2 Planning Calendar DOCNUMBER 066 April 14 2005 Issue 2 Page 50 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 1 2 Screen Fields Description ER BatchMaster Manufacturing Forecast Entry E laj x E File Edit Yiew Help Module Special Functions Windows la x BAE alx n T gt ri ole Sleiglzlel 1 Routing Repor a Gm Foe Proch actinwn Leen i ltem Key AP FINISHED GOOD 3 Item For Production level 1 1 Production ia Eelen A i S C Production Uti Unit of Measure ere a Production Re Es Planning Calendar GH MPS E A b E Forecast Type D Run MPS Qu
125. 0704 Sun 10 0000 0 0000 0 0000 10 0000 0 0000 I ei UU ahoratan ig d 4 gt Figure 12 1 Capacity Utilization Screen Process Cell This is a work center for mix lines fill lines or assembly lines where batches are manufactured The process cell can either be entered or selected via the available lookup on the screen This is a mandatory field Select Date This date decides the week for which the capacity utilization of the selected process cell is to be viewed The date can be selected from the calendar displayed on the screen Graph Type This is the type of the graph that is used to represent the capacity utilization of the selected process cell The user can either select Bar type or Line type of graph to view the capacity utilization of the selected process cell The following colors are used to display the capacity utilization details of a process cell Capacity Utilization details Availability of the selected Process Cell per day for production Red C2 Batches associated with the selected Process Cell having Light Green status as New or Allocated C3 Planned MPS or MRP orders that are associated with the Blue selected Process Cell for a specific day DOCNUMBER 066 April 14 2005 Issue 2 Page 161 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Remaining capacity of the selected Process Cell Batches associated with the selected Pr
126. 2005 Issue 2 Page 237 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 22 13 1Generating a SARA Title Ill Tier II Report Screen 1 Complete the Item From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to ke assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 22 14 MSDS Master Format Report The MSDS Master Format Report is established from the MSDS Master Format record On clicking the MSDS Master Format Report icon BatchMaster Enterprise uses the data from the MSDS Master Format record and displays the Crystal Report for viewing on the screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 14 1Generating a MSDS Master Format Report Screen 1 Complete the From and To range using the lookup buttons next to the fields 2 Select the Status as required 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process but
127. 4 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing j User Id k Record Date 14 10 Maintain MPS Item The Maintain MPS Item screen provides a way to select an item for MPS processing With Maintain MPS Item one can establish a selected Item Location s 1 Item type Manufacture or Purchase The setting here overrides the setting at the Item Location screen 2 Economic Order Quantity The EOQ defined here overrides the EOQ defined at the Item Location screen 3 Default Vendor The Vendor specified at this screen overrides the Vendor associated with this item via the Item Location screen 4 Lot sizing Method The Lot Sizing Method specified at this screen overrides the Lot Sizing Method specified at the Item Master screen Only those items can be maintained for MPS processing whose Order Method has been set to MPS at the Item Master screen MPS can be run only for those Item Locations that have been maintained at this screen This screen also gets populated by the Pull MPS Items screen 14 10 1Screen Fields Description ER BatchMaster Manufacturing Maintain MPS Items i EI x EZ File Edit View Help Module Special Functions Windows l x pela axel l lgl e m BatchMaster MPS Item 1 0 Costing Utiities zl MPS Item ffi A 1 1 Costing Reports a Routing Reports Lemie a oe AP e g 1 Production Unit GAL SL
128. 5 Issue 2 Page 262 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Type Key The lookup in this field is determined by the value established in the Type field Type Desc This is the description on the Type Key Operator This field determines the operator that will be used to compare or equate the Type Key value with the number defined in the Value field Value This field holds a numeric value which is used during comparison with the Type Key value field Using this field the number of closing parentheses used in the search filter criteria can be maintained One can choose up to three parentheses 23 5 2 Creating a Physical Property Search Filter 1 Open the Physical Property Search Filter screen 2 Enter a unique Search Filter Key and the Description 3 Add Line to Enter the Equation in the grid 4 Enter values on the various columns on the grid as needed to create the desired equation 5 Click Save button on tool bar to save the Physical Property Search Filter 24 Laboratory Utilities 24 1 Intermediate Property Rollup The Intermediate Property Rollup Utility provides a way to update the in house intermediates material property specifications based on the material properties of the intermediate s lower level ingredients Using Intermediate Property Rollup adjustments can be made to the intermediates on a regular basis to ensure that the intermediates reflect the
129. 5 Issue 2 Page 207 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 10 1Screen Fields Descriptions ER BatchMaster Manufacturing SARA Processing 2 x EZ File Edit Yiew Help Module Special Functions Windows l x r Select Processing Criteria 1 Production Report H 0 MPS A s ir MRP Ze Period End SARA Processing Year End SARA Processing Le MRP Reports Item Key From AP_B alte i For Production level 2 SL Process Cell Modu Item Key To ber Mis 1 For Production level 3 H DC Masters O Bee Location Key From anc tt apace C MSDS Location Key To Fme W MLOC O Boilerplate Gro O Boilerplate Mai Period End Date Le o gt O Boilerplate Ove IN Supplementary DN CAS Number h CY Hazard Type h D Hazard Print A a O Hazard Print C D Material Safety B O MSDS Master DN MSDS Sched O Print MSDS O Customer Histe O Update Custor TS MANG Gehin M al I gt Figure 14 9 SARA Processing Screen Period End SARA Processing This option updates the Inventory with SARA information based upon the Inventory transactions This processing examines every reportable material including intermediates and determines how long a material has been on a particular location and in how much quantity Year End SARA Processing This option resets all the reportable materials SARA values to zero Item Key From Thi
130. 5 Issue 2 Page 264 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Roll Up Density The Intermediate Property Roll Up is performed irrespective of the choice made here regarding the density roll up a If one does not wish to roll up the density leave the Roll up Density box un checked b If one wishes to roll up the density check the Roll up Density box This displays the fields for entering the Formula Key Range i Enter the Formula Key From Leaving this field blank has the same effect as entering the first available formula ii Enter the Formula Key To Leaving this field blank has the same effect as entering the last available formula 24 1 2 Rolling up Intermediate Property The Intermediate Property Rollup can be processed using the following steps 1 Select Item Key From for which intermediate rollup has to be processed 2 Select Item Key To for which intermediate rollup has to be processed 3 Select a Search Level 4 Select the Formula Status to be excluded from the rollup 5 Select Trial or Final mode 6 Check or uncheck the Roll up Density box as needed 7 Click Process button on the tool bar 25 Laboratory Reports 25 1 Formula Material Analysis Report The Formula Material Analysis Report screen provides a way to generate a report showing an analysis of up to six physical properties of the raw materials contained in a formula One can use the
131. 5 6 MRP ORDER RANGE P DOCESoING ttrt tttrt attert r trr ErE Erenn rn rrn rreren Eneee 138 15 6 1 Screen Fields DescriptiOr rsirasinecnreniia Maile lla ar TEE EEE hide ey lassie 138 15 6 2 Processing a Range of MRP Orders ccccceeeeeceeenneeeeeee enn neeeeeeaana eee eeeeeaaaaeeeeeeeanaes 139 15 7 PLANNED MRP PURCHASE ODER 139 15 7 1 Screen Fields Description iiss sii tii ee eae 140 15 7 2 Working with Planned MRP Purchase Order 141 15 7 3 Special FUNCTIONS eserse ea e aaa er E eaaa E yer ea aa Posysleascurens canta Toades 142 DOCNUMBER 066 April 14 2005 Issue 2 Page 6 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 8 PLANNED MRP PRODUCTION ORDER seeeeeeeeseeeeseeeseeeeseeeesenseeeeesaeesseeenes 143 15 8 1 Screen Fields Description 143 15 8 2 Working with Planned MRP Production Order 145 15 8 3 Special FUNCIONS x eeneg Eed EE ee 146 15 9 TRANSFER MRP PURCHASE ORDERS coeeeeeeeeeaeeeeseeeeseeesseeeessueeaeeeeeeesenegs 147 15 9 1 Screen Fields Description rirerire a raa EEE EEE Gi eee 147 15 9 2 Transferring MRP Purchase Orders cccccccteeeeee eer nttee teen cena nee eeeeea naa teeeeeeaanneeeeea 149 15 9 3 Special FUNCTIONS 00 10 cccccccceeeceeeeeceeecneeeeceeeee cence cee caaeeeaaaeseeeeesaeeecseeeeaaeeesaeeesaaeessees 150 15 10 TRANSFER MRP PRODUCTION ORDERS nnennnneeeeeiee ertt ttirrrtrttr rrtt rtra tert trentnreren remenen 152 15 10 1 Screen Field
132. 6 April 14 2005 Issue 2 Page 209 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 11 1Screen Fields Descriptions ER BatchMaster Manufacturing MSDS Master Format J EI x E File Edit View Help Module Special Functions Windows l x Cy coe ta lag lt gt rif ale r MSDS Master Format Description HO QC Masters Master Format Key Jfrest Status Active DI KE Process Cell Repo SL QC Reports Description master format for testing E J MSDS O Boilerplate Gro Report Template Filename C Program Files B atchM asterEnterprise USA dot E Boilerplate Mai Revision Date 29 05 04 Mi O Boilerplate Ove D Supplementar Reason for Revision O CAS Number h O Hazard Type h O Hazard Print R O Hazard Print C O Material Safety D SARA Process O O MSDS Sched D Print MSDS ID Customer Histe ID Update Custor Dn MSDS Setup BOM Utilities C MSDS Reports Laboratory 1 Laboratory Utilities 1 aharatani eme z ES EE EE Figure 14 10 MSDS Master Format Screen Master Format Key This field stores a unique Master Format key for a MS Word template file that is used to print a MSDS Status This is the status of this Master Format The status of a Master Format can be one of Active Inactive Marked for Deletion or Deleted Only Active master formats are fetched in the lookup for Print MSDS Des
133. 66 April 14 2005 Issue 2 Page 20 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing View Item Location The user may click this button to view the inventory details for all the item locations of the selected Disassembly Item iew Item Location E E x OG TERNATE_A Stock UOM GRM Description ltem For Production level 2 Display Unit GRM 1 Location Detail l oe eee Qty On Hand T On Order Commit to Sale FGLOC gois 245 0000 344 0000 Toggle UOM Quantity on Hand 65 0000 Quantity on Order H Quantity Commit To Sales 344 0000 Quantity Commit To Production 0 0000 Figure 9 2 3 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold i Multiple Bins Requirement Yes or No 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date oo om On oe mn pp eg dee DOCNUMBER 066 April 14 2005 Issue 2 Page21 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 3 Batch Range Processing The Batch Range Processi
134. Abstracts Service Number which is an assigned number used to identify a chemical CAS stands for Chemical Abstracts Service an organization that indexes information published in Chemical Abstracts by the American Chemical Society and that provides index guides by which information about particular substances may be located in the abstracts The numbers have no chemical significance DOCNUMBER 066 April 14 2005 Issue 2 Page191 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing When a CAS Master is inserted on the Material Safety Information screen the information contained in the CAS Master is defaulted on the Material Safety Information screen 21 5 1 Screen Fields Descriptions CAS Number This stores the Chemical Abstracts Service CAS number for this material Tab 1 General Information ER BatchMaster Manufacturing CAS Number Master i 7 la x E File Edit Yiew Help Module Special Functions Windows l x BAE Alle Miall ole BatchMaster Manufacturing CAS Number Master CJ Process D i Me cas Number J 63 252 SL QC Masters a GE lat 1 General Information 2 Safety Info 3 Safety Info continued 40EL eports 1E S MSDS p m General Information O Boilerplate Gro K ee He Chemical Name carbaryl oilerplate Ove O Supplementary Other Information B 7 ID Hazard Type h FREE Un Hazard Print R
135. Al I Figure 10 1 3 Fill Forecast Button and Window DOCNUMBER 066 April 14 2005 Issue 2 Page 54 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Zero Forecast This button is used to set the forecast value to zero for the selected lines DE BatchMaster Manufacturing Forecast Entry 18 x ajx Osale alx all ll NT a CTESTAVEBOGAITEM Al Average COST ITEM to test PO fy Zero Forecast Button e Ober ae e ra Figure 10 1 4 Zero Forecast Button DOCNUMBER 066 April 14 2005 Issue 2 Page55 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Toggle Units This button is enabled when the forecast type is set to Quantity Clicking on this button toggles the unit of measure field which in turn toggles the values in the Forecast entry grid ER BatchMaster Manufacturing Forecast Entry E Eile Edit View Help Module Special Functions Windows ouelel axel lal rol zlgl alone BatchMaster Manufacturing t _ Costing Utilities SL Costing Reports S ltem Key g _TESTAVERAGE ITEM Average COST ITEM to test PO Routing Reports Unit of Measure S H Toggle Units Button C Production Planning Caen g Planning Calendar DAY1 Production Utilities 1 Production Reports Forecast Type lt MPS Quantity C Amount D D Run MPS Cost Method IR O
136. All Button Uncheck All Clicking this button un marks all the material lines on Tab 4 EE BatchMaster Manufacturing Physical Property Analysis x Ga File Edit View Help Module Special Functions Windows l x elal axel al algl ale Gem Z Routing Reports Formula Key Quality Contra Enlarge View f Production Description Cost Method STANDARD Production Utilities _ Production Report Recalculate Property ide Formula Summary coe Quaniiy H MPS ale e C MRP Reports Pier rooms a eaer pe ea ES T Material AP AVG PURCHASE lem Fo 33 3333 C QC Masters Material AP_FIFO_PURCHASE Il Process Cell Repe Material AP_STD_PURCHASE lem Fo AC QC Reports Labor AP_LABOR_10 _ WI Nothing C Msps BOM Utilities MSDS Reports Laboratory B UN Physical Prope O Comparative F tere Name Formula Totals i z 3 Formula Totals Physical Prope _AddLine Delete Line FS Weight GRM J Laboratory Utilities 7 S Total Volume CC 18 5607 cS EES Create Line Insert Line GAM CC 1 3396 C MPS R Color if Physical Cost GAM 22 038537 i bead Property Value not Cost CC 42 745446 C General Table Vie between Minand Total RM Cost 793 39 v Maximum Value al I Figure 15 1 12 Uncheck All Button DOCNUMBER 066 April 14 2005 Issue 2 Page 256 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Ma
137. BatchMaster Enterprise 7 25 User s Guide Volume IIIb Manufacturing DOCNUMBER 066 Issue 2 Date of Document Release April 14 2005 BatchMaster Enterprise version 7 25 63 02 000 BATCHMASTER PROCESS MANUFACTURING BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Copyright and Legal Information Copyright BatchMaster Enterprise 7 25 User s Guide Volume IIIb Manufacturing 2005 by BatchMaster Software Inc All rights reserved Your right to copy this document is limited by copyright law and the terms of the license agree ment As a software licensee you may make a reasonable number of copies or printouts for your own use Making copies for any other purposes constitutes a violation of copyright law Trademarks The names of actual companies and products mentioned herein may be trademarks or registered marks of in the United States and or other countries of their respective owners The names of companies products persons and or data used in the examples are fictitious and are n no way intended to represent any real individual company product or event unless otherwise noted Warranty Disclaimer BatchMaster Software disclaims any warranty regarding the example data in this documentation including the warranties of merchantability and fitness for a specific business use Limitation of Liability The content of this document provided for informational use only is subject
138. CNUMBER 066 April 14 2005 Issue 2 Page 64 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing purchase order or to a batch The firm planned orders do NOT get regenerated that is the firm planned orders are NOT deleted and then re written via Run MPS and Replan MPS Confirmed Orders This represents the quantity for which confirmed orders have been created The related details can be seen on Tab 5 or Tab 6 depending on whether the item is purchase type or manufacture type at the Maintain MPS Item screen The confirmed orders can be transferred to a purchase order or to a batch The confirmed orders do NOT get regenerated that is the confirmed orders are NOT deleted and then re written via Run MPS and Replan MPS Total Order Release This is the sum of the quantities of Planned Orders Firm Planned Orders and Confirmed Orders on the same column MPS This is the quantity expected to be received in a given period from Total Order Release of this or prior periods Production Orders This is the quantity that is scheduled to be received from existing production batches that have not yet been closed Purchase Orders This is the quantity that is scheduled to be received from existing purchase orders of New or Open statuses Warehouse Transfers In This represents the supply arising from 1 Warehouse Transfers In that exist but have not been processed yet 2 Inventory Moves that have been
139. Click on the Save button to save the schedule 8 To see the schedule in the form of a graph click on Tab 2 Chart Display 17 2 3 Scheduling a Process Cell associated with MPS Orders 1 Select a Process Cell via the lookup available on the tool bar 2 Select a Date 3 Click on the Fetch Data button 4 To adjust the schedule of a process cell for a specific MPS Order change the Scheduled Start Date field and the Scheduled End Date field of that line in the grid 5 If needed change the Process Cell This can be done by typing the value in this field or by selecting a process cell using the associated lookup button on the grid 6 To change the relative sequence for a MPS Order modify the sequence at the Process Line field and click on Re sequence Process Line button The reseouenced process lines will get displayed in the grid 7 Click on the Save button to save the schedule 8 To see the schedule in the form of a graph click on Tab 2 Chart Display 17 2 4 Scheduling a Process Cell associated with MRP Orders 1 Select a Process Cell via the lookup available on the tool bar 2 Select a Date 3 Click on the Fetch Data button DOCNUMBER 066 April 14 2005 Issue 2 Page 168 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 4 To adjust the schedule of a process cell for a specific MRP Order change the Scheduled Start Date field and the Schedule
140. Customer Key To Leaving this field blank has the same effect as entering the last available customer 8 Select the Batch Status 9 Click on the Process button Depending upon the filter criteria the schedules are generated for the production formulas A report displays all those production formulas for which schedules were generated 10 Save the record by assigning some parameter name to the record in the input box on the toolbar DOCNUMBER 066 April 14 2005 Issue 2 Page218 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 12 9Screen Fields Descriptions for Production Finished Good ER BatchMaster Manufacturing MSDS Schedule Generation K E EI x File Edit View Help Module Special Functions Windows l x oeae axel aaa ll z m Schedule Basis 1 QC Masters I Schedule T Production Finished Good S H Process Cell Repo chedule Type troduction Finished Goo dl H 0 QC Reports r Selection Criterion bm ae GE atch No From foooooooo0000000 A oilerplate Gro BY Boilerplate Mai Batch No To oo0000000001 nae Al L Boilerplate Ove D Supplementary ltem Key From ALTERNAT EA A D CAS Number h Item Key T Jop ID Hazard Type h ed al O Hazard Print R O Hazard Print C Location Key From FG LOC Al O Material Safety Een Eet Jg CLO Al O SARA Process R TET haus Customer Key From BARMART Al Dn Print MSDS
141. D Planned MAP Pur e AP_AVG_PURCHASE _ Item For Produc FGLOC 200 0000 30 07 04 TD Planned MRP Proc AP_AVG_PURCHASE lem For Produc FGLOC 600 0000 30 07 04 IBY Transfer MAP Purg O Transfer MRP Proc SL MRP Reports SL Process Cell Module SL QC Masters SL Process Cell Reports _ QC Reports i SCH MSDS SL BOM Utilities Select al All Unselect All Warehouse Transfers Club Orders m a MSNS i cl 4 D Figure 11 9 1 Transfer MRP Purchase Orders Screen Select MRP Item Location MRP Item From The lookup at this field displays only those MRP items for which there exists at least one Confirmed Purchase Order This specifies the lower limit of the range of MRP items for which the Purchase Orders need to be transferred Leaving this field blank has the same effect as selecting the first available item via the lookup MRP Item To The lookup at this field displays only those MRP items for which there exists at least one Confirmed Purchase Order This specifies the upper limit of the range of MRP items for which the Purchase Orders need to be transferred Leaving this field blank has the same effect as selecting the last available item via the lookup Location From This specifies the lower limit of the range of locations Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations Leaving this field blank has
142. Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status sa o9aoo D DOCNUMBER 066 April 14 2005 Issue 2 Page 107 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing j User Id k Record Date 14 11 Company Calendar Setup The Company Calendar Setup screen provides a way to define for a calendar year the working days and holidays that affect the company s production facilities When one sets the company calendar for the current year BatchMaster Enterprise treats all days earlier than the current date as non working days The Company Calendar created here serves as the base calendar for running MPS for an item 14 11 1 Screen Fields Description ER BatchMaster Manufacturing Company Calendar EI sl E File Edit View Help Module Special Functions Windows lej sl HAEE Ixl KKALI lgl BatchMaster Manufacturing r List of Holidays dates are shown in format defined in regional setting r 1 Production Production Utities Se SE z al GG R ursday Fs PG laee enlai TC 9 10 2004 Friday H MPS ER 9 11 2004 Saturday D Forecast Entry Yea 2004 d KR 3 12 2004 Sunday D Gun MPS TC 9 13 2004 Monday CY MPS Planning Work 9 14 2004 Tuesday de deng 9 15 2004 Wednesday O Transfer MPS Purcha m Select Weekly Holidays O Transfer MPS Produc ID Demand Fence 1 MP O Demand Fence 1 MP TI 9 16 2004 Thursday TI 9 17 2
143. Display Unit LBS 1 Location Detail Warehouse te Main watebeo 3S SLBCH RES Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order 23 0000 Quantity Commit To Sales 0 0000 Quantity Commit To Production 0 0000 Figure 11 5 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No oer pnp 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date se EE ed DOCNUMBER 066 April 14 2005 Issue 2 Page 137 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 6 MRP Order Range Processing The MRP Order Range Processing screen enables the user to change the status of the MRP Purchase Production Orders for the entire selected range of MRP Items in one go 15 6 1 Screen Fields Description ER BatchMaster Manufacturing Range Processing E EI x E File Edit View Help Module Special Functions Windows l x D Slll alzle wl 4l gt ri lgl p Range Processing
144. E MRP Reports SL Process Cell Modt SL QC Masters H Process Cell Repo QC Reports SL MSDS BOM Utilities p ey SelectAll Deselectall Figure 9 4 1 Create Batches from Schedule Screen Item Key From This specifies the lower limit of the range of items for which batches have to be created from schedules Leaving this field blank has the same effect as selecting the first available item via lookup Item Key To This specifies the upper limit of the range of items for which batches have to be created from schedules Leaving this field blank has the same effect as selecting the last available item via lookup Location From This specifies the lower limit of the range of locations for which batches have to be created Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations for which batches have to be created Leaving this field blank has the same effect as selecting the last available location via the lookup Transfer to Super Batch Checking this box creates batches not only for the intermediates of he selected item locations but for the item locations as well If this box is not checked then the batches will not be created for the intermediates associated with the selected item locations Fill From Inventory This box is enabled only when the Transfer to Super Batch box is
145. EEEE 162 17 2 1 Screen Fields Description 163 17 2 2 Scheduling a Process Cell associated with DBatchesl 168 17 2 3 Scheduling a Process Cell associated with MPS Order 168 17 2 4 Scheduling a Process Cell associated with MRP Orders sssnnnnnnnnnnnnnsnnnnnnnnnnnne 168 17 2 5 Special FUNCTIONS 22 1cccccceccccneeeeeeeceeeeeaeeseceeeeseeeeseeeecaeeeseeeessaeesaaeessaeeeesaeeesaaeessees 169 18 QC MASTERS eege deed EEN EES Ee 170 18 1 QC TEST DESCRIPTION wiccsiccssetecsittnes EE EE dE eege 170 18 1 1 Screen Fields Descriptions 0nnnnnnnnnnnnnnenennrnnnnnrnnnrnnnennnnrnrnnrnnrrrnrnrnenrrnnerrrnn nenne 171 18 1 2 Creating a QC Test Description seseeeeiiiieeeeeriieeesrrrrreesrrrrreenrrrrreenrrnrrennrnrrrren nnna 171 18 2 QC ler EE 171 18 2 1 Screen Fields Descriptions 2 1 ccccceecneeeeeeeeeeee cnet eeaeeeeeeceeeesaaeeseaaeeeesseeeessaneeeesanees 172 18 2 2 Creating a QC Formula Test 173 18 3 OChrEMTEemg EErEE AEE EEEE EEEE EEEE EEEEEESEEEEEEEEEEEEEEEEE EEE EEE EEEE 173 DOCNUMBER 066 April 14 2005 Issue 2 Page7 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 18 3 1 Screen Fields Descriptions 122 1cccccceeeecceneeecaeetesceeeeeeaeeeseanenesseetestaaaessaaeteeseneeesen 174 18 3 2 Creating a QC liom Test iiin Satie edie lL Seeded EEN EENNN 175 18 4 QUALITY GONTROL PROCESS EE 175 18 4 1 Screen Fields Descriptor 58 ed ieee edie ees 176 18 4
146. Entry Planning Calendar a CAL Lina Gross Demand Calculati 5 gt D MPS Planning Works ross Demand Calculation O Transfer MPS Purcha Demand Range 1 Demand Forecast b D Transfer MPS Produc Demand Range 2 Demand Forecast ba ID Demand Fence 1 MP O Demand Fence 1 MP Demand Range 3 Demand Forecast e O Demand Fence 2 MP f C Demand Fence 2 MP Ba CA Maintain MPS Item Demand Range 1 Red e OD Company Calendar Se D dR 2 b Planning Calendar cmene irange Black EI O MPS Setup Demand Range 3 Blue bs D Pull MPS Items MPS Order Range Pr Top Level Finished Good batch to be Mix X SL MRP created as SL MRP Reports Allow transfer of intermediates of super Y Yes v z Jl Process Cell Module batch 0 QC Masters Use multiple economic order quantities E SL Process Cell Reports I 11 AP Renars D Figure 10 13 MPS Setup Screen Defaults Time Fence 1 The value in this field is the number of days in the first Time Fence The user may define two Time Fences An Exception order is generated for all the MPS orders whose delivery date falls within this Time Fence If the Time Fence enters into the bucket period of planning zone then the Time Fence stretches to the end of that period Suppose the Time Fence is of 4 days and the number of days ina period is 3 then this means that the Time Fence not only covers the first period but also enters into the second period and hence the Time Fence stretches up to the entire second peri
147. Fi Warehouse Transfers In ID Demand Fi 50 00 350 00 0 00 CN Maintain M Cumulative ATP 3 33 00 1183 00 1 183 00 F D A Cammann LZ D Figure 10 3 1 Planning Worksheet Tab 1 Item Key This the Item Key associated with the Item Location for which the MPS planning worksheet is displayed Curr On Hand Safety Stock The value in this field is the difference between the current on hand quantity of the item and the safety stock level defined for the item at the item location Location This the Location Key associated with the Item for which the MPS planning worksheet is displayed Unit This is the Stock UOM for the Item Key shown on this screen Included in last MPS Run If this box is checked it indicates that this Item Location was included in the latest MPS Run This is a read only field Replan MPS Replan MPS takes the demand from Forecasts Warehouse Transfer demand and Sales Order demand from Tabs 2 3 and 4 of this screen The Tabs 2 3 and 4 remain unaffected by Replan MPS Replan MPS does not affect the low level code of MPS Items Replan MPS affects only the item location shown on the MPS planning worksheet when the Replan MPS button is clicked When Replan MPS is clicked for one item location all the planned orders of all the remaining MPS item locations get deleted DOCNUMBER 066 April 14 2005 Issue 2 Page 63 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User
148. Fields Descriptions ER BatchMaster Manufacturing Capacity Utilization i f E la x E File Edit View Help Module Special Functions Windows l x aeae AE A a Process Cell JfaP_Mex_PROCESS_CELL ar or Mix Routing I ke GE hg r Select Date m Graph zi Bil aterial i Costing July gt 2004 a _ Costing Utilities Mon TueWedThu Fri Sat Sun SL Costing Reports 8 SL Routing Reports 10 11 H C Production ee Bc 1 Production Utilities u mc L i _ r 4 H C Production Reports a Hc H O MPS Seam wa SL MRP Mics KL MRP Reports Line Type 0 A es Seed Commited New And Allocated Planned MPS And MAP Orders D Process Cell Sched Utilized Closed Issue PClosed Ee Se SE Report r Capacity Utilization Details Unit in Hours I EE Dau otal Capacity C1 Committed C2 Planned Order C3 Remaining C4 Utilized C5 QC Report i So 05 07 04 Men 10 0000 0 0007 0 0000 3 3993 0 0000 7 MSDS 06 07 04 Tue 10 0000 0 0000 0 0000 10 0000 0 0000 C BOM Utilities 07 07 04 Wed 10 0000 0 0000 0 0000 10 0000 0 0000 08 0704 Thu 10 0000 0 0002 0 0000 3 9998 0 0000 b P E MSDS Reports 090704 Fii 10 0000 0 0000 0 0000 10 0000 0 0000 H Laboratory 10 0704 Seat 10 0000 0 0000 0 0000 10 0000 0 0000 C Laboratory Utities 11
149. Formula The Default Formula Class for the formula is inserted in this field when a new formula is created This is a mandatory field The Formula Class provides a Work in Progress Account for use in the production of items that can be made via this formula DOCNUMBER 066 April 14 2005 Issue 2 Page 241 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Formula Status This is the Status of the Formula This is a mandatory field The Formula Status is used in 1 Production Setup to specify whether or not the Formulas of that status should be allowed in Production 2 Costing Setup to specify whether or not the Formulas of that status should be allowed in Product Cost Analysis 3 Laboratory Setup to specify whether or not the Formulas of that status should be allowed in Physical Property Analysis Date Revised This is the Last Date when the Formula was saved Time Revised This is the Last Time when the Formula was saved Reason Revised This is the default Reason Revised for the formula Date Last Made This is the Last Date when the Formula was used in production Time Last Made This is the Last Time when the Formula was used in production Default Process Cell This is the default process cell associated with this formula Density Override The Density d a formula is calculated by dividing Total Weight of the ingredients by Total Volume of its ingredients This is also called the theoreti
150. Guide Volume III Manufacturing 14 3 2 Screen Field Descriptions Header and _Tab 1 Summary E BatchMaster Manufacturing Planning Worksheet E E la sl E File Edit View Help Module Special Functions Windows l j sl Olelas axel Wal ml pl ele el 2 Manufacturing Item ken JAP FINISHED_GOOD Curr On Hand Safety Stk 227 0000 SL Formula Item For Production level 1 SL Formula Utilitie i e VC Routing Location FGLOC Unit Cc _ Formula Repor i e a Bill Of Material J Included in last MPS run Replan MPS B C Costing SL Costing Utilities 1 Summary 3 Cust Orders A WH Transfers 5 Planned Prod Ord 6 Planned Purch Ord SL Costing Reporl zi Routing Repor Planning Zone SL ez 19 07 04 20 07 04 21 07 04 22 07 04 23 07 04 24 07 04 25 07 04 SL Production Util 12 00 225 00 45 00 555 00 55 00 341 00 C Production Re d CJ MPS Warehouse Transfers Out 225 00 45 00 555 00 55 00 341 00 D Forecast E Dependent Demand 0 00 0 00 0 00 0 00 0 00 ID Run MPS Proj Available Balance 77 00 32 00 27 00 22 00 31 00 Planned Orders 50 00 350 00 50 00 K HPS Plan irm Planned Orders p i Transfer M Confirmed Orders 50 00 50 00 O Transfer M Total Order Release 50 00 350 00 50 00 100 00 O Demand Fi HSH 50 00 350 00 Production Orders DN Demand Fi Purchase Orders D Demand
151. Issue 2 Page 267 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 25 5 1 Generating a Physical Property Equation Report 1 Click on the Physical Property Equation Report icon 2 Click on the Print or Export button on the toolbar 25 6Raw Material Physical Property Report The Raw Material Physical Property Report screen provides a way to generate a report showing an analysis of up to six physical properties of the raw materials contained in a formula One can also specify Quantity by weight or volume One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 25 6 1 Generating a Raw Material Physical Property Report 1 Complete the Item Key From and To range using the lookup buttons next to the field 2 Complete the Item Class From and To range using the lookup buttons next to the fields 3 Complete the Item Type From and To range using the lookup buttons next to the fields 4 Select the Item Status 5 Complete the Property 1 6 range using the lookup buttons next to the fields 6 Complete the Quantity by Weight or Volume 7 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters
152. KE E E E E E EE EE E E C General Table View Hours Per Day 10 00 HH MM 1 Process gaichdetaied Fetch Data Button Process Lind power Batch Status Scheduled Start Date Sche NEW eter ntntine en 1 ul Mix 19 07 04 19 07 19 07 04 19 07 04 MRP Order Details Batch Type Status Scheduled Stat Date Sche Figure 12 2 3 Fetch Data Button DOCNUMBER 066 Issue 2 April 14 2005 Page 169 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Re sequence Process Line When this button is clicked the rows on the grids are resequenced according to their Process Line numbers ER BatchMaster Manufacturing Process Cell Scheduling a xi E Eile Edit View Help Module Special Functions Windows lj x leo alles vldrlgl ee ei BL Costing a Costing Utilities TI Hours Per Day fioo HH MM C Costing Reports Re sequence Process SL Routing Reports 1 Process Cell Sche i 0 Production Batch Details Line Button C Proton ities Process Line Ja GEES Ga Production Report D 000000000000017 NEw 19 07 04 19 07 SCH MPS 7 MAP 0 MRP Reports E 423 Process Cell Modu fo Capacity Utilize MPS Orders Details D MPS Order No Batch Type Status Scheduled Start Date 23 i PLANNED 19 07 04 2 3 PLANNED 19 07 04 C QC Reports e de gt H H O MSDS P SL BOM Utili
153. LLUp rttr tttr rttr tter rr trrrr eneren rennene 263 24 1 1 Screen Fields Description 264 24 1 2 Rolling up Intermediate PDroperty atte eeeeeee anne teeesnaaneeeeeeenaaaaes 265 25 LABORATORY REPORTS ssscsssessesstaiis cocedassaceeeiec cevedecscsaassaieaucecevadeveuseusasacecuceccdsaseaeuauadsdeeee 265 25 1 FORMULA MATERIAL ANALYSIS HERORT rttr ttnttrttrttn rererere ereere 265 25 1 1 Generating a Formula Material Analysis Repott 0 ccccsseeeeee eee nnneeeeeeeennaaeeeeeeennees 265 25 2 FORMULA PHYSICAL PROPERTY HERORT rttr ttertnrrrnrenn rennene een 266 25 2 1 Generating a Formula Physical Property Report ccccssseeeeeeeeenneeeeeeeeeaneeeeeeeeennnes 266 25 3 PHYSICAL PROPERTY ANALYSIS HERORT errre rtnn renren reen 266 25 3 1 Generating a Physical Property Analysis Report ccccseseeeeeeeeenneeeeeeeeenateteeeeeenenes 267 25 4 PHYSICAL PROPERTY SEARCH REPORT a aennnenoaenerooeeoe1otroettorerrrortrtterttonerrrortrrn e tronneenne ennn 267 25 4 1 Generating a Physical Property Search Repott sssessssiieessnnnnneesrrrrreeerrrrreeerrrrreeens 267 25 5 PHYSICAL PROPERTY EQUATION HERORT nar trtrn ernn rn rren neen 267 25 5 1 Generating a Physical Property Equation Report s nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnne 268 25 6 RAW MATERIAL PHYSICAL PROPERTY HEpORT rentrent 268 25 6 1 Generating a Raw Material Physical Property Report 1 0 1 cccceeccsnseeeeeeeeennneteeeeeeenees 268 26 MPS REPORUS
154. Lot Number c Received Date the date on which the lot was received d Expiry Date e Quantity On hand f Quantity Committed g Vendor Lot Number h Vendor Key DOCNUMBER 066 April 14 2005 Issue 2 Page 129 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing i Lot Status j User Id k Record Date 15 4 Demand Fence 1 MRP Production Order The Demand Fence 1 MRP Production Order option provides a way to define the order status for a MRP Production Order having status as Exception and falling under any of the periods of Demand Fence 1 and Demand Fence 2 With Demand Fence 1 MRP Production Order one can convert the order status of a selected MRP order and MRP item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MRP Production Order option The user can also establish the confirmation dates If a user has access to the Demand Fence 1 MRP Production Order option that user should also have access to the Demand Fence 2 MRP Production Order option which typically has more restricted order confirmation authority This screen automatically includes all those orders that are displayed on the Demand Fence 2 MRP Production Order 15 4 1 Screen Fields Description ER BatchMaster Manufacturing Demand Fence 1 MRP Production Order E l x E Eile Edit Yiew Help Module Special Functions Windows l xj le
155. MPS Purchase Order is displayed DOCNUMBER 066 April 14 2005 Issue 2 Page97 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MPS Order No This is the system generated number for the MPS order Plan Run Dt This is the date when the MPS order was generated Order Status The Order Status on this screen can be one of the following a Exception These orders before being transferred to Purchase Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MPS Exception MPS Orders get erased when Run MPS is processed or when the Replan MPS button is clicked b Firm Planned These orders before being transferred to the Purchase Order need to be Confirmed The Orders that are Firm Planned will not be erased when Run MPS is processed or when the Replan MPS button is clicked c Confirmed The Orders that are Confirmed are ready to be transferred to a purchase order and will not be erased when Run MPS is processed or when the Replan MPS button is clicked Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan End Dt
156. Melnvalid record can be saved Cost Method STANDARD 1 L Bi aterials on the Maintain Downtime master a eee Quant a A ia 3y Luantity L Costing Recalculate Property J Hide Physical Property J Hide Formula Summary SE SL Costing Utilities B C Costing Reports 1 Formula Master 3 Safety 4 Line Items 5 Byproducts _ Routing Reports 1 Production Text hoc fO Required Tue O H Property vaus GC Production Utilities Item For Prod INLOC 0 5000 CC ORG SOL 00000 i Item For Prod SL Production Report SL MPS z MRP I SL MRP Reports SL Process Cell Mod SL QC Masters SL Process Cell Repo s QC Reports B A MSDS C BOM Utiities gt t _ MSDS Reports Name Formula Totals p 3 7 CLC Laboratory Add Line Delete Line Total Weight LB 16513 F F Total Volume GAL 0 1678 Create Line Insert Line LB GAL 10 0180 Color if Physical Cost LB 17 842879 D Physical Prope O Comparative P i Property Value not Cost GAL 178 750000 between Min and Total RM Cost 30 00 Maximum Value v aratan Gel Figure 15 1 5 Physical Property Analysis Screen Line Items Tab Sequence Num This displays the serial number of the formula lines The number is generated by the system when a new line is entered This is a read only field Type This field has the following options DOCNUMBER 066 April 14 2005 Issue 2 Page 247 of 274 BatchMaster Software BatchMaster Enterprise 7 25 U
157. O Boilerplate Mai ltem Key To A L Boilerplate Ove ID Supplementary C CAS Number h L Hazard Type h O Hazard Print R O Hazard Print C L Material Safety ID SARA Process O MSDS Master k O Print MSDS O Customer Histe D Update Custor Di MSDS Setup 1 BOM Utilities C MSDS Reports C Laboratory Laboratory Utilities 1 Penna I D ES EE EE al Figure 14 11 3 MSDS Schedule Generation Raw Material Schedule Type Raw Material This setting is used to generate a schedule to print the MSDS of a Raw Material An item is a valid MSDS Raw Material if its Item Type optionally with its Sub Type is maintained at Tab 2 of MSDS Setup screen The data required to generate a schedule of raw material type is fetched from the Item Master screen and the Material Safety Information screen Item Key From This Item key specifies the lower limit of the range of item keys for use as filter criteria during processing This Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available Item key via the lookup The lookup displays only those items excluding finished goods for which the Item Type optionally with Sub Type has been maintained at Tab 2 of MSDS Setup screen Item Key To This Item key specifies the upper limit of the range of item keys for use as filter criteria during processing This
158. OD Planning Calenc Unit of Measure Planning Calendar f Davi 1 a 0 0 0 A Ze Quantity Amount Forecast Type Cost Method Forecast Start Date 09 17 04 M a 9 18 2004 9 19 2004 a Active 322 0000 _ 334 0000 _ 342 342 0000 HURN Add Line ID MPS Setup Delete Line O Pull MPS Items O MPS Order Ran C1 MRP MRP Reports Hl 1 Prneaes Cell hadila gt Figure 10 1 6 Change Forecast Button 14 2 Run MPS The Run MPS option provides a way to perform MPS planning calculations This screen is used to run the MPS for a range of items in regenerative mode From Run MPS MPS scheduling needs can be defined and the MPS Planning Worksheet needed to see the schedule can be generated Processing a Run MPS takes the various values and settings from the Maintain MPS Item screen these values will supersede any conflicting values on the Item Location screen MPS cannot be run for an item that is not present on the Maintain MPS Item screen Run MPS can generate production orders only if the item location is of type Manufacture on the Maintain MPS Item screen and a released BOM exists for it For all other item locations Run MPS can generate purchase orders only This is different from Run MRP In Run MRP production or purchase orders are created depending whether the item is Make type or Buy type respectively
159. Order E Quantity Commit To Sales Quantity Commit To Production Figure 11 10 4 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No se rp pop 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date oe emp op et e BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 16 MRP Reports 16 1 MRP Order Report The report includes MRP orders of the following statuses Exception Planned Firm Planned Confirmed Transferred new N gt The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 16 1 1 Generating a MRP Order Report 1 Complete the MRP Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 Check Order Types as required 4 To save these parameters enter the name t
160. Period End SARA processing is being done This is a mandatory field if the Period End SARA Processing option is selected Year End Date This is the date on which Year End SARA processing is being done This is a mandatory field if the Year End SARA Processing option is selected 21 10 2 Performing Period End SARA Processing 1 Select the Period End SARA Processing option 2 Enter the Item Key From 3 Enter the Item Key To 4 Enter the Location From 5 Enter the Location To 6 Enter the Period End Date 7 Click on the Process button Depending upon the filter criteria the Inventory will be updated with SARA information of the reportable materials 21 10 3 Performing Year End SARA Processing 1 Select the Year End SARA Processing option 2 Enter the Item Key From 3 Enter the Item Key To 4 Enter the Location From 5 Enter the Location To 6 Enter the Year End Date 7 Click on the Process button Depending upon the filter criteria the SARA information in the Inventory will be re initialized 21 11 MSDS Master Format This screen provides users with a way to specify the MS Word templates that can be used to print a MSDS Note During installation of BatchMaster Enterprise a MS Word template file named USA dot is generated in the BatchMaster Enterprise folder This is a sample template file for printing a MSDS and provides examples of using various types of bookmarks DOCNUMBER 06
161. Plan Qty when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to production batch Batch Type This can be one of Mix Fill or Assembly depending on the assembly type of the associated BOM Process Cell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this item Hours Required This value is assigned by the system during Run MRP This value can be changed at the Process Cell Formula Capacity screen The value can also get modified when orders get clubbed Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page131 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Delete Line If any of the rows have their boxes checked such tows get deleted when this button is clicked Exception If any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows h
162. Process Cell Repo _ QC Reports _ MSDS 1 BOM Utilities C MSDS Reports Laboratory D Physical Prope L Physical Prope GB D Laboratory Set D Physical Prope l Laboratory Utilities Laboratory Report H MPS Reports General Table View h i EE E E E E E E E E E E E EE al D Figure 15 3 Comparative Properties Analysis Screen DOCNUMBER 066 April 14 2005 Issue 2 Page 259 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Formula Key The look up on this row displays the formulas for which at least one physical property has been defined When a formula is selected here remaining cells on that column are automatically filled A separate Formula Key can be entered on each of the three columns on this screen Description The value in this field is defaulted when a Formula is selected in the Formula Key field This description of the Formula comes from the Formula Entry screen 23 3 2 Performing a Comparative Properties Analysis 1 Enter by typing or select via lookup a value for the Formula Key A separate Formula key can be entered on each of the three columns 2 If one wishes to print the property comparison click the Print button on the tool bar 23 4 Laboratory Setup The Laboratory Setup screen provides a way to 1 Establish the layout for p
163. Production Util Date hann Process Cell Type Mx Hours Per Day 70 00 HH MM _ Production Re ies 2 Chast Display Forecast E O Run MPS C MPS Plane D Transfer M D Transfer M ID Demand Fi C Demand Fi D Demand Fi i D Demand Fi PS Hours From D Maintain M I Hours To O Company x lale I Hours Per Day C Planning C S S S L MFS Setup S g S DN Pull MPS II 828 DN MPS Order S SZ 8 SCH MRP ray n re SL MRP Reports Process Cell M SS Capacity U B ral m a F Masters or Figure 12 2 2 Process Cell Scheduling Chart Display Tab Data Point Value DOCNUMBER 066 April 14 2005 Issue 2 Page 167 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 17 2 2 Scheduling a Process Cell associated with Batches 1 Select a Process Cell via the lookup available on the tool bar 2 Select a Date 3 Click on the Fetch Data button 4 To adjust the schedule of a process cell for a specific batch change the Scheduled Start Date field and the Scheduled End Date field of that line in the grid 5 If needed change the Process Cell This can be done by typing the value in this field or by selecting a process cell using the associated lookup button on the grid 6 To change the relative sequence for a batch modify the sequence at the Process Line field and click on Re sequence Process Line button The re sequenced process lines will get displayed in the grid 7
164. R 066 April 14 2005 Issue 2 Page 198 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing percentage is taken as greater than the value of this field in the previous row The upper limit extends to the value of this field on this row List as this Range This field displays a range format for the selected line of the grid This is a read only field For example 11 could be printed as 0 20 Add Line Clicking this button inserts a line in the Range Details grid Delete Line Clicking this button deletes the selected line s from the Range Details grid 21 7 2 Creating a Hazard Print Range Table 1 Click the Insert button 2 Enter the identification and the description of the Hazard Print Range Table 3 Click on Add Line button to insert a line into the grid 4 Enter a percentage at the field For Percentage Through The corresponding range is displayed at the field List as this Range 5 Add more lines and their percentages if needed 6 Click on the Save button to save the Hazard Print Range Table record 21 8 Hazard Print Criteria Maintenance This screen provides users with a way to establish how the information about material hazards is to appear on a MSDS The following conditions must be fulfilled for a hazardous material to be listed in the Hazard Section of the MSDS a The Material Hazard Type ID of this screen should be attached to an ingredient of th
165. RM Cost This field displays the sum of the Ext Cost of the Material lines Property This displays the Property Name stored at Physical Property Formula screen An asterisk is suffixed to the Property Name when the Value of that property is outside the minimum or maximum values as specified at the Physical Property screen the associated row is marked with the color blue when this happens Value This is the value of the property on a given row on this grid This field is editable Before a new value is entered mark one or more material line items using the Check Uncheck button or the Check All button on the tool bar Then change the value for the property and click outside this field This will update the quantities of the marked formula ingredients accordingly The values of all the properties then get recalculated as per their respective equations defined at the Physical Property Formula screen DOCNUMBER 066 April 14 2005 Issue 2 Page 249 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 1 7 Screen Fields Description Tab 5 Byproduct ER BatchMaster Manufacturing Physical Property Analysis 7 E la x E File Edit View Help Module Special Functions Windows lej xj pelma axe aaa l 2 D SE E ETE T Formula C Routing Foma ke g FORMULA A Quality Control Enlarge View 1 Formula Reports 1 Bill Of Materials 1 Costing Descri
166. RP order Plan Run Dt This is the date when the MRP order was generated Order Status The Order Status on this screen can be one of the following 1 Planned These orders before being transferred to Purchase Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MRP Planned MRP Orders get erased when Run MRP is processed 2 Firm Planned These orders before being transferred to the Purchase Order need to be Confirmed The Orders that are Firm Planned will not be erased when Run MRP is processed 3 Confirmed The Orders that are Confirmed are ready to be transferred to a purchase order and will not be erased when Run MRP is processed DOCNUMBER 066 April 14 2005 Issue 2 Page 140 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 4 Transferred These orders have already been transferred to a purchase order Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is processed Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or mo
167. Range n field on the Hazard Print Criteria Maintenance screen 2 Range In this case the weight or volume percentage is listed depending on the setting made at the Sort MSDS Components by Weight or Volume field of MSDS Setup screen This percentage is listed as a range according to the value of the Range Table ID to Use field on the Hazard Print Criteria Maintenance screen 3 Do Not List In this case the material itself gets listed on the MSDS but the material s quantity is not shown on the MSDS Round to Nearest Range n This field stores a rounding criterion in percentage if the List Qty as field is set to Number Range Table ID to use This field stores a Range Table ID if the List Qty as field is set to Range Chemical Name Prefix This field stores a prefix that is used to print the Chemical Name as specified on tab 1 of the Material Safety Information or the CAS Number Master screen of the materials associated with the selected material hazard type on a MSDS For example one can store an asterisk to flag a certain material 21 8 3 Creating a Hazard Section 1 Click the Insert button 2 Enter a Hazard Section ID 3 Enter a Material Hazard Type ID 4 Enter the weight in percentage as needed 5 Enter the volume in percentage as needed 6 Enter value for the Include Top n Ingredients as needed 7 Make a selection for the List Qty As field 8 Enter
168. Safety Administration OSHA is a federal government agency in the U S Department of Labor The primary goals of OSHA are to save lives prevent injuries and protect the health of workers OSHA s Hazard Communication Standard 1910 1200 requires employers to establish hazard communication programs to transmit information on the hazards of chemicals to their employees by means of labels on containers material safety data sheets or MSDS and training programs Implementation of these hazard communication programs will ensure all employees have the right to know the hazards and identities of the chemicals they work with and will reduce the incidence of chemically related occupational illnesses and injuries The OSHA HazCom standard specifies the required elements that must be on an MSDS among other important data The MSDS has sections relating to chemical identity manufacturer s name and contact hazardous ingredients identity information physical chemical characteristics fire and explosion hazard data reactivity data health hazard data precautions for safe handling and use and control measures 21 1 Boilerplate Group This screen provide users with a way to create a boilerplate group ID that can be used on the MSDS template to mark where on a MSDS the boilerplate is to be printed For a Boilerplate Group to be added to a MSDS the Boilerplate Group Key preceded with the characters BP_ should be inserted as a bookmark on the cor
169. Select the Schedule Type as Finished Good 2 Enter the Formula Key From Leaving this field blank has the same effect as entering the first available formula 3 Enter the Formula Key To Leaving this field blank has the same effect as entering the last available formula 4 Enter the Finished Good Key From Leaving this field blank has the same effect as entering the first available finished good 5 Enter the Finished Good Key To Leaving this field blank has the same effect as entering the last available finished good 6 Select the Formula Status 7 Click on the Process button Depending upon the filter criteria the schedules are generated for the finished goods A report displays all those finished goods for which schedules were generated 8 Save the record by assigning some parameter name to the record in the input box on the toolbar DOCNUMBER 066 April 14 2005 Issue 2 Page215 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 12 5 Screen Fields Descriptions for Raw Material E BatchMaster Manufacturing MSDS Schedule Generation KE laj x E File Edit View Help Module Special Functions Windows x D ell axla A 4l gt rif lgl Di Schedule Basis _ OC Masters a 1 Process Cell Repo 1 QC Reports Selection Criterion Schedule Type Raw Material H a 3 MSDS Item Key From Q O Boilerplate Gro al
170. Select the boilerplate group and the boilerplate key for the first boilerplate to be replaced 3 Select the boilerplate group and the boilerplate key for the second boilerplate to be replaced 4 Select the boilerplate group and the boilerplate key for the replacement boilerplate 5 Enter the reason for the replacement 6 Select the Status of the replacement boilerplate 7 Click on the Save button to save the record DOCNUMBER 066 April 14 2005 Issue 2 Page 187 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 4 Supplementary File A supplementary file is a collection of MSDS boilerplates The Supplementary files are used in determining which boilerplates will be printed on a MSDS The following conditions must be fulfilled for the boilerplates from a supplementary file to be printed ona MSDS e The Supplementary File should be applicable to the MSDS e A bookmark should have been inserted on the MSDS template file the Microsoft Word Document Template for the Boilerplate Group of the Boilerplate contained in the Supplementary File The applicability of the Supplementary Files is determined as follows at the time of MSDS Schedule Generation Schedule Type Applicable Supplementary Files Supplementary File of Template type attached to the formula at the Formula Entry screen Supplementary File of Formulas type attached to the Formula at the Supplementary File screen Master
171. TURN flues IV Transfer to Super Batch SuperBatch zl I Allocate Auto Lot Assignment SELECT IN RANGE I Fill From Inventory oat Fee Jee te Oni Ste Plan Sit _ Flan Endt ep Jesg e _ Location 1 EE EE EE EE a aea D Demand Fenc 08 2404 M CONFIRMEL 08 28 04 0912 04 2 222 F O Demand Fene 08 2404 CONFIRMEL 08 29 04 0943 04 2 222 0000 C Demand Een 08 2404 CONFIRMEL 09 30 04 0914 04 2 222 0000 08 24 04 CONFIRMEL 09 31 04 0915 04 2 222 000 D fc 08 24 04 CONFIRMEL 09 01 04 0916 04 2 222 000 DN Maintain MPS 08 24 04 CONFIRMEL O9 01 04 0916 04 2 222 0000 F O Company Cale D Planning Cale O MPS Setup D Pull MPS Iter O MPS Order R Q MRP 1 MPP Reports 7 Praress Pall wl al 7 D EE EEN Select All Unselect All Warehouse Transfers Club Orders Figure 10 5 5 Planning Worksheet Button 14 6 Demand Fence 1 MPS Purchase Order The Demand Fence 1 MPS Purchase Order option provides a way to define the order status for a MPS Purchase Order having status as Exception and falling under any of the periods of Demand Fence 1 and Demand Fence 2 With Demand Fence 1 MPS Purchase Order one can convert the order status of a selected MPS order and MPS item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MPS Purcha
172. The following steps can be taken to create a Physical Property Formula 1 Click on the Insert button 2 Enter a name at the field P roperty Name 3 Enter an Equation for the property analysis by either typing or by double clicking the various operands and operators on this screen 4 Enter an Adjust Equation for the property analysis by either typing or by double clicking the various operands and operators on this screen 5 Enter the Minimum Value 6 Enter the Maximum Value 7 Click on the Save button to save the Physical Property Formula 23 3 Comparative Properties Analysis The Comparative Properties Analysis screen provides a way to compare the properties of selected formulas With Comparative Properties Analysis one can select up to three formulas and make them displayed in columns next to one another for a property by property comparison If the analysis needs to be printed BatchMaster Enterprise generates a Crystal Report of the comparison 23 3 1 Screen Fields Descriptions ER BatchMaster Manufacturing Comparative Properties Analysis gt d laj x E File Edit View Help Module Special Functions Windows l x Cot S al x ea 4 gt vif L Routing Reports Tame 2 FORMULA L Production Maintain Downtime mast Formula E for Me db _ Production Utilities 0 0000 0 0000 _ Production Report MPS C MRP 1 MRP Reports 1 Process Cell Modu 1 OC Masters 1
173. This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to production batch Batch Type This can be one of Mix Fill or Assembly depending on the assembly type of the associated BOM Process Cell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this item Hours Required This value is assigned by the system during Run MRP This value can be changed at the Process Cell Formula Capacity screen The value can also get modified when orders get clubbed Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked DOCNUMBER 066 April 14 2005 Issue 2 Page 135 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Exception H any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders
174. URCHASE Al k Boilerplate Ove O Supplementary Customer Key From HOMECURRENCI A S GEN ce Customer Key To HOMECURRENC2 ID Hazard Print R D Hazard Print C Printed Date From 17 07 04 Material Safety Printed Date To 17 07 04 gt ID SARA Process IN MSDS Master O 4 Print MSDS TD Customer Histe OD Update Custor O MSDS Setup SL BOM Utilities SL MSDS Reports oh Laboratory SL Laboratory Utilities m 1 1 ahoratan Rennt al f gt Figure 14 11 6 MSDS Schedule Generation MSDS Customer History Schedule Type MSDS Customer History This setting is used to generate a schedule based on MSDS Customer History Item Key From This Item key specifies the lower limit of the range of item keys for use as filter criteria during processing This Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available item key via the lookup Item Key To This Item key specifies the upper limit of the range of item keys for use as filter criteria during processing This Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available item key via the lookup Customer Key From This Customer key specifies the lower limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by typing or selecte
175. Vap Pressure mm Hg x Geh c Vap Pressure Temp aterial Safety TN SARA Process Lower Explosive Limit e Ge al Upper Explosive Limit che rint oiling Point O Print MSDS Boiling Poi O Customer Histe DN Update Custor Flash Point DN MSDS Setup Flash Pt Method Used SL BOM Utilities SL MSDS Reports SL Laboratory E 11 sbotsten e D Figure 14 5 1 CAS Number Master Screen General Information Tab General Information Trade Secret This field indicates whether this material is regarded as a trade secret by a Company This field is for reference purpose only Chemical Name This field stores the chemical name by which this material is known Other Information This field stores any other related information for this material Properties Vap Pressure mm Hg This field stores the pressure of a saturated vapor of this material in terms of millimeters of mercury Vap Pressure Temp This field stores the temperature in degrees Fahrenheit F or degrees Celsius C to which this material was subjected when the Vapor Pressure mm Hg was measured DOCNUMBER 066 April 14 2005 Issue 2 Page 192 of 274 BatchMaster Software Lower Explosive Limit This field stores the value of the lowest concentration by volume in air at which this material will burn or explode if an ignition source is available Upper Explosive Limit This field stores the value of the highest concentration by volume in air at which this mate
176. WGUNJANC C Program Files BatchMasterE nterprise SS ID Customer Histe s 0 Update Custor MS Word Save File Path NGUNJANCAC Documents and Settings Administrator Deskt B MSDS Setup Ignore Material Key Supplementary File D Ignore Template Supplementary File E KL BOM Utilities MSDS Reports C Laboratory Ignore Material Class Supplementary File SW Ignore Formula Class Supplementary File IW a Laboratory Utilities Emergency Phone 65 30679400 Bl 1 1 ahnratern Sal Last Schedule ID Ignore Formula Key Supplementary File Vv Ignore Material Hazard Supplementary File I D I m Figure 14 15 1 MSDS Setup Screen Print MSDS Defaults Line Spacing When more than 1 BP in a Section This field stores the number of lines to be placed in between boilerplates when there is more than one boilerplate in a particular section of a MSDS Abort or Ignore if Boilerplate Group is Missing An error occurs while printing MSDS when no boilerplates that can be fetched from the associated supplementary file for a bookmark of a Boilerplate Group on the MSDS template file The user can specify on this field whether in case of such an error the system should either a Abort the printing of the MSDS or b Ignore the error and continue generating the MSDS Boilerplate to Use if None for a Section This field stores the name of the Boilerplate Group and the associated boilerplate ID that is to be used if there are no boilerplates req
177. a Hazard Type Print Criteria Screen 1 Complete the Hazard ID From and To range using the lookup buttons next to the fields 2 Complete the Hazard Type From and To range using the lookup buttons next to the fields DOCNUMBER 066 April 14 2005 Issue 2 Page 235 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 22 9 Material Safety Information Report The Material Safety Information Report screen provides a way to generate a report showing the material safety associated with specific items using the Material Safety Information screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 9 1 Generating a Material Safety Information Report 1 Complete the Item From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Proces
178. a Location from the lookup at this screen 3 Set the Item Type as one of Manufacture or Purchase 4 Modify the Economic Order Quantity if needed 5 Ifthe Default Vendor field is enabled select or modify the Vendor 6 Change the Lot Sizing Method if needed 7 Click the Save button on the toolbar to save the record DOCNUMBER 066 April 14 2005 Issue 2 Page 106 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 10 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Butyl Alcohol N Butanol Display Unit LBS 1 Location Detail ee H 1 249 oe Main Wareho 356 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 10 10 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No SCENE 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry
179. aeeeeeeeaaaaeeeeeeenaaes 181 21 MSDS iets eege 181 21 1 BOLERPLATEGpOUp titt tttt ttrt rtttE AEAEE E EEEE EEEA EEEE EEEEEEE EEEE EEEE EEEE EEEE EEE EEEE EEE 182 21 1 1 Screen Fields Description 183 21 1 2 Creating a Boilerplate Group 183 21 2 BOILERPLATE MAINTENANCE a nnnenneetnannetittttrttrtttr tertre t ttrt rr EErEE EEEE EEE AEAEE EEEE EEEE EEEn E rnEeE 183 21 2 1 Mandatory INpUlS sns ete aie a E E Le Ae 185 21 2 2 Scr en Fields D amp SCripti nS ng tdi ie ear EE 185 21 2 3 Cr ating a Botlerpiete NEEN eieiei aai aaaa an ENEE EENS n 185 21 3 BOILERPLATE OVERRIDE eege ege e e r eea e E EEEN E 186 21 3 1 Ee ele n 186 21 3 2 Screen Fields Descriptions 12 ccccceeeeeeeeeeneee cee eeeeceeeeeeaeeeteaeetessaeeeessaeessaaeeesesaesees 186 21 3 3 Defining a Boilerplate Override 10 1 ceeeececeten cette cece neee tees cana nee ee eeaan nae eeeeeanaateeeeeeanaes 187 21 4 SUPPLEMENTARY PILE eege sc onenes ee Zeg 188 21 4 1 Mandatory IN DUTS TE 190 21 4 2 Screen Fields Description 190 21 4 3 Creating a Supplementary Pie 191 21 5 CAS NUMBER MASTER suste dee ENEE ERAN ENNEN EE Seg eer 191 21 5 1 Screen Fields Descriptions tesserae ie ili aor apa event een Aerie 192 21 5 2 Creating a CAS Number Master 197 21 6 HAZARD TYPE MAINTENANCE siise reri einerrencninnn rennen aarne ae a Enae EE 197 DOCNUMBER 066 April 14 2005 Issue 2 Page 8 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufa
180. ain MPS C Company Cale D Planning Cale IN MPS Setup IN Pull MPS Iter ID MPS Order R C1 MAP B MRP Reports Select All Unselect Al Warehouse Transfers i EEN 1 Praress Cell Mad D Figure 10 4 3 Transfer PO Button DOCNUMBER 066 April 14 2005 Issue 2 Page79 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E E x ltem Key BUTANOL Stock UOM LBS Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail 1 249 ae 356 Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order l Quantity Commit To Sales Quantity Commit To Production Figure 10 4 4 View Item Location window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold i Multiple Bins Requirement Yes or No 2 Lot Bin Number Details SCENE a Bin Number b Lot Number c Received Date the date on which the lot was received d Expiry Date e Quantity On hand f Quantity Committed g Vendor Lot Number h Vendor Key i Lot Status j User Id k Record Date DOCNUMBER
181. al HMIS stands for Hazardous Material Information m CAS Number Master CAS Number i 63 25 2 1 General Information 2 Safety Info 3 Safety Info continued 40EL gt HMIS Values Health foMinmal Chronic Factor Gage zl Flammability 2Modeate O Reactivity 2Moderte zl Personal Protection E Safety Glasses Gloves Dust Respirator i zl m Material Hazard r MatHazTypelD Add Line BS Delete Line System The valid values are 0 4 or a blank space e 0 Minimal e 1 Slight e 2 Moderate e 3 Serious e 4 Severe DOCNUMBER 066 Issue 2 April 14 2005 Page 193 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing A blank space in this field indicates that no HMIS Health rating is applicable to this material Chronic Factor This field stores whether or not this material is carcinogenic An asterisk in this field indicates that this material is carcinogenic A blank space in this field indicates that this material is not carcinogenic Flammability This is the HMIS Flammability rating for this material The valid values are 0 4 or a blank space e 0 Minimal e 1 Slight e 2 Moderate e 3 Serious e 4 Severe A blank space indicates that no Flammability rating is applicable to this material Reactivity This is the HMIS Reactivity rating for this material The valid values are 0 4 or a blank space e 0 M
182. alue here can be selected as one of a Closed If this option is selected only those batches whose status is Closed will get purged b Cancelled If this option is selected only those batches whose status is Cancelled will get purged c All If this option is selected batches with status Closed or Cancelled will get purged DOCNUMBER 066 April 14 2005 Issue 2 Page 35 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Cancelled on or before This date has significance only when the option selected at the Batch Status field is Cancelled or All The batches that have been cancelled on this date or a date earlier than this date will get purged 12 6 2 Purging Super Batches 1 Select a super batch at the Batch From field 2 Select a super batch at the Batch To field 3 Select a date at the Start Date From field 4 Select a date at the Start Date To field 5 Set the value of the Batch Status field as needed 6 Click on the Process button on the toolbar to purge the selected super batches 7 A report is displayed stating the success of the operation 13 Production Reports 13 1 Batches in Process Report The Batches in Process Report screen provides a way to generate a report showing the batches in process One can use the option s filtering parameters to define the report Once BatchMaster
183. an be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line wil automatically be set to the earliest planned date of the combined lines 15 7 2 Working with Planned MRP Purchase Order 1 Select a MRP purchase order record on this screen 2 Change the status for the MRP purchase order The status can be set to one of Planned Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid DOCNUMBER 066 April 14 2005 Issue 2 Page141 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 For Planned Orders modify the confirmation start date as needed 4 For Planned Orders modify the confirmation end date as needed 5 For Planned Orders modify the confirmed quantity of the MRP purchase order as needed 6 For Planned Orders club order lines together by clicking on the Club Orders button 7 Save the Planned MRP Purchase Order record 15 7 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Ken BUTANOL Steck UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail a ee ee Bees Be sgee Commit to
184. and Fence 2 MPS Purchase Order lal x E File Edit View Help Module Special Functions Windows lj x Cell axle l ele el 1 Production ltem Key fi C Production Uti Location Fao Fptnp HO Production Re de Ey MPS Unit Ka D Forecast E O Run MPS D MPS Planr ee Plan End Dt Plan Qty Confirm Start Confirm End D Transfer M m DN Trenster M SA SR E 31 07 04 31 07 04 ID Demand Fi EE R L Demand Fi Be aor 26 07 04 CONFIRMEL 31 07 04 31 07 04 50 0000 31 07 04 31 07 04 In 6 IM 07 04 CONFIRMEL 31 07 04 31 07 04 50 0000 31 07 04 31 07 04 ID Demand Fi m D Maintain M SES eect R chon 2 50 0000 31 07 04 31 07 04 Ly Company L i0 C Planning C Ce ee ee ee A MPS Setu ps 210 26 07 04 CONFIRMEL 01 08 04 50 0000 01 08 04 O Pull MPS I 4 JN 26 07 04 CONFIRMEL 01 08 04 TE 50 0000 E Th 01 08 04 D MPS Order_ 5T CI MAP DESS m C MRP Report E x eports i SL Process Cell M I H C GC Masters Select All UnSelect Al Delete Line Exception Em Planned Confirmed Club Orders H C Process Cell R m i 1 OF Bette gt Ko al Figure 10 8 1 Demand Fence 2 MPS Purchase Order Screen Item Key This is the Item Key associated with the Item Location for which the Demand Fence 1 MPS Purchase Order is displayed Location This is the Location Key associated with the Item for which the Demand Fence 1
185. antity Amount DN MPS Planr D Transfer M PE Cost Method Ee D Demand Fi Forecast Start Date 08 07 04 M O Demand Fi ID Demand Fi O Demand Fi D Maintain M Forecast key Location Tan Teo Tac 7 10 2004 Cy Company Ju TT Active CY Planning C O MPS Setup O Pull MPS C MPS Order C MRP MPP Reports 1 Process Cell M _ GC Masters 1 Prarase et ha Add Line Delete Line SE EE EE EEN Figure 10 1 1 Forecast Entry Screen Item Key This field stores the item key for which the forecast is being defined The lookup in this field is restricted to those items that have their order method defined as MPS or MPP at the item master screen Unit of Measure This is the stock unit of the item selected in the Item Key field maintained at the Item Master screen This is a read only field and this value is defaulted when an item is selected The unit of measure can be changed by clicking on the Toggle Units button on the toolbar Planning Calendar This field stores the planning calendar key which is associated with the item key This is a mandatory field Cost Method This field is enabled when the forecast type is amount The cost method can be one of Base Average Standard or Last The cost is taken from the Item Location screen The quantity of the item to be forecasted is then automatically calculated using the forecast amount and the cost as per the selec
186. any of the rows have their boxes checked such rows get deleted when this button is clicked DOCNUMBER 066 April 14 2005 Issue 2 Page 127 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Exception If any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 15 3 2 Working with Demand Fence 2 MRP Purchase Order 1 Select a MRP purchase order record on this screen 2 Change the status for the MRP purchase order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the c
187. arameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 22 7 MSDS Print Range Report The MSDS Print Range Report screen provides a way to generate a report showing the material hazard print ranges defined using the MSDS Print Range screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 7 1 Generating a MSDS Print Range Report Screen 1 Complete the Range ID From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 22 8 Hazard Type Print Criteria The Hazard Type Print Criteria screen provides a way to generate a report showing the hazard type print criteria created using the Hazard Type Print Criteria Maintenance screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 8 1 Generating
188. art Date From field 4 Select a date at the Start Date To field 5 Set the value of the Batch Status field as needed 6 Click on the Process button on the toolbar to purge the selected batches 7 A report is displayed stating the success of the operation 12 6 Purge Super Batches The Purge Batches option provides a way to purge a Super Batch from production history With Purge Batches one can specify which super batches need to be removed permanently from production history One can use the option s filtering parameters to define the purge Once BatchMaster Enterprise processes the purge parameters it displays the results as a report one can print or save The purged super batches can be viewed at the Production History Summary Report and the Production History Detail Report DOCNUMBER 066 April 14 2005 Issue 2 Page 34 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 6 1 Screen Field Descriptions ER BatchMaster Manufacturing Purge Super Batches d la sl E File Edit View Help Module Special Functions Windows l x Salal axel A ale p Purge Super Batches H Formula Reports lt zB Of Materials Sen Bee OT poe AN C Costing To e S H Costing Utilities j _ Costing Reports bezan SSCS EI Routing Reports Start Date pi 05 24 04 ba A Pr
189. as as those properties display on the Line Items tab of the Physical Property Analysis screen One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 25 4 1 Generating a Physical Property Search Report 1 Complete the Formula Key From and To range using the lookup buttons next to the fields 2 Complete the Formula Class From and To range using the lookup buttons next to the fields 3 Complete the Formula Status From and To range using the lookup buttons next to the fields 4 Select the Search Filter Key using the lookup button next to the field 5 Set the Search Level to top or bottom 6 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 7 Click on the Process button on the toolbar to create a report 25 5Physical Property Equation Report The Physical Property Equation Report screen provides a way to generate a report showing the physical property equations used in BatchMaster Enterprise One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export DOCNUMBER 066 April 14 2005
190. as needed When the process button is clicked the critical report will be generated as of this apply date 5 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 6 Click on the Process button on the toolbar to create a report 13 19 2Transferring Materials to a Purchase Requisition using a Super Batch Critical Material Report The following steps can be followed to transfer the critical items to a purchase requisition 1 Click the Transfer to Purchase Requisition button on the tool bar of the critical report 2 If the Vendor field is blank on this grid then specify a Vendor by typing or selecting it from the lookup at this field This Vendor Key is defaulted from the Item Location screen A Branch Key of the BatchMaster Enterprise Company should have been associated with this Vendor on the Vendor Master screen 3 Check the box adjacent to the items for which Purchase Requisition needs to be generated 4 Enter a values at the Max number of lines in PR to specify the maximum lines that can be added to asingle purchase requisition any additional lines will be carried to additional purchase requisitions as needed 5 Check the boxes for the lines that should be transferred to a purchase requisition 6 Click the Transfer to Purchase Requis
191. aster Enterprise 7 25 User s Guide Volume III Manufacturing Location This the Location Key associated with the Item for which the Planned MRP Production Order is displayed Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MRP Order No This is the system generated number for the MRP order Plan Run Dt This is the date when the MRP order was generated Order Status The Order Status on this screen can be one of the following 1 Planned These orders before being transferred to Production Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MRP Planned MRP Orders get erased when Run MRP is processed 2 Firm Planned These orders before being transferred to Production Orders need to be Confirmed The Orders that are Firm Planned will not be erased when Run MRP is processed 3 Confirmed The Orders that are Confirmed are ready to be transferred to a production order and will not be erased when Run MRP is processed 4 Transferred These orders have already been transferred to a production batch Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is proc
192. at the item location screen The sources of demand for Run MPS are 1 Forecast depending on the setting for the Demand Range on the MPS Setup screen 2 Sales Orders and Warehouse Transfers Out depending on the setting for the Demand Range on the MPS Setup screen DOCNUMBER 066 April 14 2005 Issue 2 Page57 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 Dependent Demand from Planned Firm Planned and Confirmed orders of higher level MPS Items 4 The quantity by which On Hand Quantity is less than the Safety Stock as defined at the Item Location 5 MPS type raw materials remaining to be issued to production batches that are not on hold The sources of supply for Run MPS are 1 Only for the first Period The quantity by which the On Hand quantity exceeds the Safety Stock as defined at the Item Location 2 For 2 Period onwards PAB of the preceding period 3 Scheduled Receipts from a Purchase Orders b Production Orders Production Batches c Warehouse Transfers In d Firm Planned Orders e Confirmed Orders The quantity to be ordered is determined by subtracting the supply quantity from the demand quantity and then adjusting for EOQ if the EOQ is applicable For this purpose a The EOQ is applicable if the Lot Sizing Method is set to EOQ at the item master screen b The value of EOQ is taken from the Maintain MPS Item screen If the orders are created outside the dema
193. ata iew 1 Bill Of Materials lt _ Costing Cl Costing Utilities Le Costing Reports A Routing Reports C Production C Production Utilities HA Production Report w vgDailyLoc mt a 5 MPS wi DateEntered f MRP FGLOC M DaysOnLocAtzen CI MAP Repost AEA E Selen H Process Coll Mod AP_AVG_PURCHAS FGLOC Mi BuyerlD LA QC Masters AP_AVG_PURCHAS INLOC M User H 0 Process Cell Repe AP_B INLOC User2 eo e N ae C MSDS AP_D INLOC vi User5 C BOM Utiities APE INLOC vi Usef Hee SE PURCHAS GE ges GE AP_FINISHED_GOO FGLOC s fee gt Laboratory tities AP_FINISHED_GOO INLOC J Usert0 C Laboratory Report APP INLOC vd User C MPS Reports AP_O INLOC v 23 General Table Vie ou Select All Uo SelectAll Unselect All Figure 17 1 3 Transfer to MS Excel Button DOCNUMBER 066 April 14 2005 Issue 2 Page 274 of 274
194. atch Weight Size This field has the same value as does the Order Weight field on this screen UOM This field displays the unit associated with the quantity to be produced by an MPS Order for a line in the grid Order Weight This field displays the Total Order Weight of a batch that would need to be created to fulfill the MPS Order for a line in the grid Order Volume This field displays the Total Order Volume of a batch that would need to be created to fulfill the MPS Order for a line in the grid Batch Time Hr For the selected date this is the number of hours during which this Process Cell is scheduled to be used for this MPS Order Hours From This field displays the start time of the process cell for this MPS Order on the grid Hours To This field is automatically determined by adding the Batch Time Hr to the Hours From Formula ID This field displays the formula key associated with an MPS Order if the Batch Type for that MPS Order on the MPS Planning Worksheet is Mix Formula Desc This field displays the formula description associated with the formula for a line in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page 165 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Item Key Depending on the Batch Type for an MPS Order as shown on the MPS Planning Worksheet this field displays the Assembly key associated with an Assembly type batch or the Intermediate key
195. ate Planned Orders as TD Demand Fence ID Demand Fence Demand Start Date f28 07 04 Planned TD Demand Fence CY MRP Order Rar Demand End Date 27 08 04 C Firm Planned 4 Planned MRP F Gamm MRP Run Date 28 07 04 C Confirmed C Planned MRP F O Transfer MAP F O Transfer MAP F MRP Reports 1 Process Cell Modul 1 OC Masters 1 Process Cell Repor C QC Reports C MSDS M Itilities M Figure 11 1 Run MRP Screen H E a Select Item Range for MRP Run From MRP Item This field specifies the lower limit of the range of item keys for use as filter criteria during processing The lookup in this field is restricted to items maintained as MRP items using the Item Location screen This MRP Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available MRP item key via the lookup To MRP Item This Item key specifies the upper limit of the range of item keys for use as filter criteria during processing The lookup in this field is restricted to items maintained as MRP items using the Item Location screen This MRP Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available MRP item key via the lookup From Location This Location key specifies the lower limit of the ran
196. ate finished goods to new target values for a formula s physical properties perform complete analysis of up to three formulas on screen and create equations for the defined physical properties In addition to the ability to change formulas to compare formuas and to create alternate formula scenarios the Laboratory group offers Intermediate Rollup a utility which gives users the means to resolve an ongoing difficulty for process manufacturers the evolution of in house intermediates as they are used in master formulas With it it is possible to adjust the physical properties of an intermediate to reflect changes or adjustments without having to reformulate the master formula incorporating those intermediates Finally the Laboratory group provides users with a range of reports each of which serves to set forth critical information about how specific physical properties are used across a range of formulas 23 1 Physical Property Analysis The Physical Property Analysis screen provides a way to analyze the physical properties of formulas based on the physical properties of the formula s ingredients With Physical Property Analysis screen one can 1 Identify characteristics of a formula from the Formula Master Tab 2 Examine markup factor loss factor loss constant and all three types of costs from the Cost Tab 3 Examine the output formula the MSDS boilerplate template associated with the formula and the HMIS settings from the Safet
197. ate or material file types The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 5 1 Generating a Supplementary File Report 1 Complete the Key From and To range using the lookup buttons next to the fields 2 Select the Status as required 3 Select the File Type as required 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report DOCNUMBER 066 April 14 2005 Issue 2 Page 234 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 22 6MSDS Hazard Type Report The MSDS Hazard Type Report screen provides a way to generate a report showing material hazard types created using the MSDS Hazard Type screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report one can print or export 22 6 1 Generating a MSDS Hazard Type Report Screen 1 Complete the Hazard Type From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report p
198. atory Se GB Wlan Add Line DE EE E E E E E E E E EN Delete Line C Laboratory Utilitie 1 Laboratory Repor _ MPS Reports 1 General Table Vi e Di 4 al D Figure 15 5 Physical Property Search Filter Screen Search Filter Key This is the key that uniquely identifies the Search Filter This is a mandatory field This field can hold up to two numeric characters Description This is the description of the Search Filter Equation This is a system generated read only field The contents of the field are automatically updated as the user enters or changes the equation on the grid below this field Add Line Clicking this button inserts a line in the Search Filter grid Delete Line Clicking this button deletes the selected line s from the Search Filter grid And Or The first line BatchMaster Enterprise adds to the field defines the qualifier of And Or field as IF Only the lines which follow the first line can have qualifiers of And or Or Using this field the number of opening parentheses used in the search filter criteria can be maintained One can choose up to three parentheses Type This field determines what type of value is available for lookup in the Type Key field This field has 4 options a Physical Property b Weight c Volume d QC Target DOCNUMBER 066 April 14 200
199. ave their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines Multiples of EOQ For the rows that have their boxes checked clicking on this button converts the value in the Plan Quantity field to an integral multiple of the Economic Order Quantity of that item 15 4 2 Working with Demand Fence 1 MRP Production Order 1 Select a MRP Production order record on this screen 2 Change the status for the MRP Production order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the confirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MRP Production order as needed 6 For Exception Orders to club order lines together click on the Club Orders button 7 For Exception Orders club lines together and convert the added quantity of these lines to an integral multiple of EOQ if so des
200. average daily location amount and the average date of calculation The maximum amount of the item on location and the total DOCNUMBER 066 April 14 2005 Issue 2 Page 236 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing amount in the system can also be viewed BatchMaster Enterprise automatically tracks SARA Tier and Tier Il information for the SARA Tier UI Tracking report each time the SARA Processing screen is used with the Period End criteria selected The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 11 1Generating a SARA Tier UU Tracking Report 1 Complete the Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 22 12 SARA Title Ill Tier Report The SARA Tile Ill Tier Report screen provides a way to generate a SARA Title Ill Tier report summarizing the inventory quantities including maximum amount average amount and the number of days on s
201. ay be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available customer key via the lookup Customer Key To This Customer key specifies the upper limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available customer key via the lookup Batch Status This is the status of a Batch The user can either select a specific batch status or select the All option for use as filter criteria during processing Selecting the All option has the same effect as selecting all the batch statuses The default value of this field is All 21 12 10 Generating a Schedule of Production Finished Good type 1 Select the Schedule Type as Production Finished Good 2 Enter the Batch No From Leaving this field blank has the same effect as entering the first available batch 3 Enter the Batch No To Leaving this field blank has the same effect as entering the last available batch 4 Enter the Item Key From Leaving this field blank has the same effect as entering the first available item Production Finished Good 5 Enter the Item Key To Leaving this field blank has the same effect as entering the last available item Production Finished Good 6
202. button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Planned If any of the rows have their boxes checked the status of those rows gets changed to Planned when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to dub the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 15 8 2 Working with Planned MRP Production Order 1 Select a MRP Production order record on this screen 2 Change the status for the MRP Production order The status can be set to one of Planned Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Planned Orders modify the confirmation start date as needed 4 For Planned Orders modify the confirmation end date as needed 5 For Planned Orders modify the confirmed quantit
203. by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to production batch Batch Type This can be one of Mix Fill or Assembly depending on the assembly type of the associated BOM Process Cell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this item Hours Required This value is assigned by the system during Run MPS This value can be changed at the Process Cell Formula Capacity screen The value can also get modified when orders get clubbed Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page 102 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked
204. cal density This is based on the assumption that the volumes are linearly addable But in some cases Total Volume of Formula is not equal to Total Volume of its ingredients reason being a shrinkage or bulk expansion during the process The density override field if its value is non zero stores the density that is used instead of the density calculated by the above described method A zero value in this field means that the density override is not applicable Notes These are special Comments Reminders in a formula DOCNUMBER 066 April 14 2005 Issue 2 Page 242 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 1 4 Screen Fields Description Tab 2 Cost la x 16 x ER BatchMaster Manufacturing Physical Property Analysis E File Edit View Help Module Special Functions Windows Cor ta S Allge 4 gt i ale Sei Routing Formula Formula Key Quality Control Enlarge View 1 Production Production Utilities Formula Reports mn STANDAR SE Bil OFM 5 S Description Formula A for Melnvalid record can be saved Cost Method 8NOAAD 1 aterial on the Maintain Downtime master Z wt CH Costing View Mode BY Quantity KL Costing Utilities SL Costing Reports 1 Formula Master 3 Safety 4 Line Items 5 Byproducts Routing Reports i Markup Factor x 100 2 0000 Loss Factor x 100 0 0100
205. cation Key From and To range using the lookup buttons next to the fields 5 Select Completion Date From and To range using the drop down arrows respectively 6 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 7 Click on the Process button on the toolbar to create a report DOCNUMBER 066 April 14 2005 Issue 2 Page 44 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 13 16 Production Summary Report The Production Summary Report screen provides a way to generate a report showing the total production by volume or by weight for end items The Production Summary Report also includes Completion date Customer Key and unit raw material cost by system weight or by system volume One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 16 1 Generating a Production Summary Report 1 Select Measure In as By Weight or By Volume 2 Select the Report Type as Production Summary Report or Production Summary Report History 3 Select the Batch From and To range using the lookup buttons next to the fields 4 Select the Formula From and To range using the lookup buttons next to the fiel
206. cessed This is a read only field New Checking this button restricts the lookup criteria to records with status new Processed Check this button to restrict the lookup criteria to records with status processed Details Grid Test ID This is the Test ID associated with the test selected at this row Operation This field decides the operation that will be performed on the quality control record The value in this field cannot be modified once the record has been processed To update or delete tests for an Item Formula whose record status is processed a new record has to be inserted The value of this field can be set to one of the following 1 Insert Set the operation field to this value when inserting a record for the first time DOCNUMBER 066 April 14 2005 Issue 2 Page 176 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 2 Update Set the operation field to this value when modification needs to be made to the already defined QC tests for Items Formulas 3 Delete Establishing this value in the operation field will delete the test defined at this line for the Items Formulas QC Type This is the measurement type of the test results The value of this field can be set to one of the following 1 Pass Fail Value The result value of the test can be either Pass or Fail 2 Numeric Value The result value has to be a numeric value 3 Alphanumeric Value The result value can be alp
207. ciated lookup on this screen Leaving this field blank has the same effect as selecting the last available Schedule ID via the lookup Re Use Schedule ID Check this box to print a MSDS for the second or subsequent time If this box is un checked then only the pending schedules will be used Refresh Schedules Clicking this button displays the schedules depending as per the setting on the Re Use Schedule ID box Select All Clicking this button selects all the schedules displayed in the grid for generation of their MSDSs Select None Clicking this button unselects all the schedules displayed in the grid for generation of their MSDSs Fields on the grid Sel Clicking this field selects or unselects a Schedule ID for generation of the MSDS Sch ID This field displays the Schedule ID against which a MSDS is being generated Item or Formula This field displays an Item or a Formula depending upon the type of the Schedule for which a MSDS is generated for a line in the grid Customer This field displays the Customer associated with a Schedule ID depending upon the schedule type for a line in the grid Description This field displays either the description of an Item or a Formula depending upon the type of the Schedule for which a MSDS is generated for a line in the grid Batch No This field displays the Batch Number associated with a Schedule ID depending upon the schedule type for a line in the grid Order No This feld
208. clubbing it with other orders MPS Order No This is the system generated number for the MPS order Plan Run Dt This is the date when the MPS order was generated Order Status The Order Status on this screen can be one of the following 1 Exception These orders before being transferred to Production Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MPS Exception MPS Orders get erased when Run MPS is processed or when the Replan MPS button is clicked 2 Firm Planned These orders before being transferred to Production Orders need to be Confirmed The Orders that are FIRM PLANNED will not be erased when Run MPS is processed or when the Replan MPS button is clicked 3 Confirmed The Orders that are Confirmed are ready to be transferred to Production Orders and will not be erased when Run MPS is processed or when the Replan MPS button is clicked Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan End Dt This is the Plan End Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified
209. clubbing it with other orders MPS Order No This is the system generated number for this MPS order Plan Run Dt This is the date when Run MPS generated this order Order Status The Order Status on this screen can be one of the following DOCNUMBER 066 April 14 2005 Issue 2 Page 69 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 1 Planned These orders before being transferred to Purchase Orders or Production Orders will need to be Confirmed Since BatchMaster Enterprise has a regenerative MPS Planned MPS Orders get erased when Run MPS is processed or when the Replan MPS button is clicked 2 Firm Planned These orders before being transferred to the Purchase Order or Production Order will need to be Confirmed The Orders that are Firm Planned will not be erased when Run MPS is processed or when the Replan MPS button is clicked 3 Confirmed The Orders that are Confirmed are ready to be transferred to a batch or a purchase order and will not be erased when Run MPS is processed or when the Replan MPS button is clicked 4 Transferred These orders have already been transferred to a purchase order or a batch Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan End Dt This is the Plan End Date that is recommended by the system when Run MPS is processed or when the
210. creen Planning Calendar Key This is the key that uniquely identifies the planning calendar This is a mandatory field Planning Calendar Description This is the description of the Planning Calendar Demand Range One Days Per Period The value in this field is the number of days that a period would consist of Number of Periods The value in this field is the number of periods contained in Demand Range 1 Demand Range Two Days Per Period The value in this field is the number of days that a period would consist of Number of Periods The value in this field is the number of periods contained in Demand Range 2 Demand Range Three Days Per Period The value in this field is the number of days that a period would consist of Number of Periods The value in this field is the number of periods contained in Demand Range 3 DOCNUMBER 066 April 14 2005 Issue 2 Page 110 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Totals Number of Days in Calendar The value in this field is the total number of days in this planning calendar This value is arrived at by adding for all three demand ranges the product of the days per period and the number of periods This is a read only field Number of Periods in Calendar The value in this field is the total number of periods in this planning calendar This value is arrived at by adding for all three demand ranges the number of periods This is a read
211. creen as well as to calculate the costs associated with production of the end item produced by the formula Cost Unit This displays the standard or last or average cost of the byproduct The user can toggle the cost from standard to last to average by clicking the Toggle Costs button on the toolbar Ext Cost This field displays the extension cost for the byproduct line This value is calculated by multiplying the Quantity Produced with the Cost Unit Add Line Clicking this button adds a line at the bottom of the byproduct lines Delete Line Clicking this button deletes the selected byproduct line s from the formula Insert Line Clicking this button inserts a newline above the selected line on this tab DOCNUMBER 066 April 14 2005 Issue 2 Page 250 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Total Weight This field displays the sum total of the weights of all the lines in the System Weight UOM Total Volume This field displays the sum total of the volumes of all the lines in the System Volume UOM Weight Volume This field displays the density of the by product produced using this formula The density is calculated by dividing the Total Weight by Total volume Cost Weight This field displays the cost per unit weight of the by product being produced using the formula This value is calculated by dividing the Total By Product Cost by the Total Weight Cost Volume This field dis
212. cription This is the description associated with a Master Format key Report Template Filename This field stores the path of the MS Word Template file that is used to print a MSDS This path can point to a file on the local machine or a machine on the network Revision Date This field stores the date on which a Master Format key was modified The user may enter the Revision Date by typing or by selecting it from the displayed calendar Reason for Revision This field stores the reason for revising a Master Format key 21 11 2Creating a MSDS Master Format 1 Click the Insert button 2 Enter a unique Master Format key and the description 3 Enter the path of the MS Word Template file DOCNUMBER 066 April 14 2005 Issue 2 Page210 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 4 5 Select a status for the Master Format key Click on the Save button to save a MSDS Master Format record 21 12 MSDS Schedule Generation This screen can be used to generate Schedule ID s from which MSDSs may be printed subsequently Printing a MSDS is a two step process MSDS Schedule Generation is the first step while Print MSDS is the second step Schedules can be generated via any of the following 1 Master Formula The data for the schedule is fetched from the Formula Entry screen 2 Finished Good The data for the schedule is fetched from the BOM Entry screen and the Material Safe
213. ct All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked 14 3 5 Screen Field Descriptions Tab 4 WH Transfers ER BatchMaster Manufacturing Planning Worksheet EI x E File Edit View Help Module Special Functions Windows l x Delale axel alal zlgl el J Manufacturing Formula 1 Formula Utilitie 1 Routing ItemKey JAP FINISHED_GOOD Curr On Hand Safety Stk 227 0000 Item For Production level 1 Location FGLOC Unit Er 1 Formula Repor CH Bill Of Material IV Included in last MPS run Replan MPS 1 Costing 1 Costing Utilities 1 Costing Repor 1 Routing Repor 1 Production Production Util 1 Production Re E MPS O Forecast E C Run MPS Ba MPS Plan O Transfer M O Transfer M 4 Demand Fi ID Demand Fi O Demand Fi O Demand Fi SelectAll Un SelectAll Delete Line D Maintain M A Pamnanu M al Figure 10 3 4 MPS Planning Worksheet WH transfers Tab Select Transfer No Line No Transfer Qty 1 1 N E E E E E EE EE EE EE EE E EN Select When this box is checked for a row that row becomes available for deletion via the Delete Line button When this box is un checked for a row that row becomes unavailable for deletion via the Delete Line but
214. ct an Item Key at the Item Key To field as needed 4 Select various filter criteria as needed 5 Select a Scheduling Formula at the Schedule formula key field 6 Select Append or Create option at the Append Create Schedule field 7 Click on the Process button on the toolbar to generate a schedule 8 If a prompt Do you want to delete previous schedules appears enter Yes or No as needed DOCNUMBER 066 April 14 2005 Issue 2 Page 15 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 2 Transfer SO To Batches The Transfer SO To Batches option provides a way to transfer sales orders to Batches or Super Batches With Transfer SO To Batches one can specify the sales orders that the user wants to transfer to batches select specific line items on the sales orders or a range of line items on the sales orders and create batches by transferring them The batches created here can be viewed and modified at the Batch Entry screen 12 2 1 Mandatory Inputs A Bill of Materials for the Item Locations on the selected range of sales orders should have been created and released 12 2 2 Screen Field Descriptions FF batch taster Manulactunng Transier SO To 12 x ere Cot yew Det Nodie Spec Puretons ge WIER SIE SE Aalrirl alel alel Fron D RE a SONo Te Metier Al i i A Formulas D s i Aoro i J Formals Repote IH J BON Ut
215. cturing 21 6 1 Screen Fields Description 197 21 6 2 Creating a Material Hazard Type ccccccseseeeceeeeneeeeeeeeeeeee tees sana neeeeeeaaaaeeeeeeeanaaaees 198 21 7 HAZARD PRINT RANGE MAINTENANCE ceeeeeeeeeeeeseeeeseeeeaeeeesee seeeeeeaeeeaeeenes 198 21 7 1 Screen Fields Descriptions es Sege ie A ei eee ee eats 198 21 7 2 Creating a Hazard Print Range Table 199 21 8 HAZARD PRINT CRITERIA MAINTENANCE n l a nnaenseneieeetteretttettttrtttrtt rttr rrentrrtrrttn rentre renne meen 199 21 8 1 Mandatory e 200 21 8 2 Screen Fields Description 200 21 8 3 Creating a Hazard ZGechon E 201 21 9 MATERIAL SAFETY INFORMATION nsenseinaneeetettt ettette t rttr t ttrt e rttr rttr A EEEE EEEren EEEn EE EEEn EEEn E EEEn 201 21 9 1 Mandatory Inputs TEE 202 21 9 2 Screen Fields Descriptions ANEN 202 21 9 3 Creating Material Safety Information for an ltem iieeccccctt tee eeee cent eeeeeeeeennteeeeeeeennnes 207 21 10 SARA PROCESO ING EN 207 21 10 1 Screen Fields DeSCIIDUONS icici oii ieee eee eid oie 208 21 10 2 Performing Period End SARA Processing cccccceeeeeeeeentteeeeeeeenaaaeeeeeeeeaaaateeeeeeanees 209 21 10 3 Performing Year End SARA Proceseing cette teee cane eeeeenneneeeeeneieaa 209 21 11 MSDS MASTER FORMAT c secceecccseecececesecaeecseeecesoseesossegseseescseeeeseeceeeseeeesesesaeeeseeees 209 21 11 1 Screen Fields Descriptions hie ie A ie 210 21 11 2 Creating a MSDS Master Fomat cece eee e eect en e
216. cturing Check All Clicking this button marks all the material lines on Tab 4 The quantities of the marked lines are updated in response to any subsequent changes in the Property Values on Tab 4 ER BatchMaster Manufacturing Physical Property Analysis 16 x E File Edit View Help Module Special Functions Windows x Ci co a Alle 4 gt mi lgl GE C Routing Reports Formula Key Quality Control Enlarge View WEEN Description ost Method STANDARD oO Production Utilities a C Production Report Recalculate Property BO Py Suan C MPS LG MAP Ta SE G __ SequenceNum Tope itemKev e Property Value PRE Material Ap AND PURCHASE ORG SOL 33 3333 C QC Masters Material AP_FIFO_PURCHASE C Process Cell Repe Material __ AP_STD PURCHASE em Fo C QC Reports Labor AP_LABOR_10 wl Nothing MSDS C BOM Utilities C1 MSDS Reports y Laboratory D D Physical Prope D Comparative F 4 Liteon ee Name Formula Totas 5 z Formula Totals Physical Prope Adine Delte Line Total Weight GRM 36 0000 H Laboratory Utilities 5 5 Total Volume CC 18 5607 1 1 Laboratory Report Create Lire _Irset Line GRM CC 1 9396 MPS Reports Color if Physical Cost GRM 22 038537 d f Property Value not Cost CC 42 745446 C General Table Vie between Min and Total AM Cost 793 39 i i bai Maximum Value D b Figure 15 1 11 Check
217. d from the ReqDate field on the Tab 4 of the Sales Order Entry screen Item type This is the Item type associated with this item via the Item Master screen Assembly Type This indicates the Type of the BOM associated with this line item The value here can be one of E Tor A for Finished Good Intermediate or Assembly types of BOM respectively Select All Clicking this button selects all the line items displayed at the grid by checking the adjacent boxes Deselect All Clicking this button unselects all the selected line items at the grid by un checking the adjacent boxes Warehouse Transfers Using this button the user can create a Warehouse Transfer order for the selected Sales Orders instead of transferring them to a Batch Clicking this button opens a pop up window where the user can enter the Location and choose Inventory Transfer or Inventory Move option If an item is available at or procured via another location of the company it may be desirable to obtain the item from that location to fulfill demand rather than creating a new batch Once a Warehouse Transfer has been created for such an order the same order cannot be transferred to a batch DOCNUMBER 066 April 14 2005 Issue 2 Page 18 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 2 3 Transferring Sales Orders to Batches 1 Select a Sales Order at the From field using the
218. d End Date field of that line in the grid 5 If needed change the Process Cell This can be done by typing the value in this field or by selecting a process cell using the associated lookup button on the grid 6 To change the relative sequence for a MRP Order modify the sequence at the Process Line field and click on Re sequence Process Line button The re sequenced process lines will get displayed in the grid 7 Click on the Save button to save the schedule 8 To see the schedule in the form of a graph click on Tab 2 Chart Display 17 2 5 Special Functions Fetch Data This button must be clicked to fetch the Process Cell Schedule for any date and Process Cell combination ER BatchMaster Manufacturing Process Cell Scheduling fa File Edit view Help Module Special Functions Windows 1 Costing C Costing Utilities Date Process Cell CESS_CELL_ For Mix wii fRiocess Cell Type Mix 19 07 04 mie d EK EEN C Costing Reports C Routing Reports 1 Production 1 Production Utilities 1 Production Report MPS 1 MRP 1 MRP Reports 23 Process Cell Modt fo Capacity Utilize DN QC Masters J Process Cell Repo C GC Reports _ MSDS 1 BOM Utilities C MSDS Reports C Laboratory 1 Laboratory Utilities 1 Laboratory Report C MPS Reports
219. d STANDARD Production Utilities eege 1 Production Report Recalculate Property mee Mode By Quantity CJ MPS et EE peere HIERT EN KL Process Cell Mod JE AP_AVG PURCHASE Item Fo H QC Masters Material AP_FIFO_PURCHASE en Fo Process Cell Repc EE Material AP_STD_PURCHASE _ Item Fo 1 QC Reports Labor AP_LABOR_10 Wi Nothing C MSDS C BOM Utilities C MSDS Reports Laboratory GB D Physical Prope IN Comparative F eens re Mere Fome Tova D Physical Prope Delete Line Total Weight GRM 36 0000 mp Laboratory Utilities 3 Total Yolume CC 18 5607 C Laboratory Report Create Line _ Inset Line GRM CC 1 9396 i MPS Reports Color if Physical Cost GRM 22 038537 Spol Property Value not Cost CC 42 745446 1 General Table Vie between Min and Total RM Cost 793 39 SS Maximum Value al D Figure 15 1 8 Toggle Costs Button DOCNUMBER 066 April 14 2005 Issue 2 Page 253 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Size Formula This button is enabled when the focus is on Tab 4 or Tab 5 Upon clicking this button a Size Formula popup window is displayed with two options Weight and Volume Selecting one of these options entering a value and clicking OK resizes the formula accordingly The formula line items of Material Type and the byproducts if any are sized accordingly The size formula is not saved until th
220. d at the Material Safety Information screen Filename This is the file name that will be used to save the MSDS being generated This is a mandatory field Save Path This is the path where the MSDS will be saved as a Word document This path can point to either the local machine or a machine on the network This path can be entered by typing or selecting it via the associated button on the screen This is a mandatory field View Document Check this box to view the MSDS document on the screen when the MSDS is generated DOCNUMBER 066 April 14 2005 Issue 2 Page 225 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Debug Mode Check this box if one wishes to generate the MSDS in Debug mode In such a case an explanation will be provided on the MSDS regarding the data sources that were used to create the MSDS including the MSDS Setup Tab 1 keywords and boilerplate keys Schedule ID From This Schedule ID specifies the lower limit of the range of schedules for use as filter criteria during processing This Schedule ID may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available Schedule ID via the lookup Schedule ID To This Schedule ID specifies the upper limit of the range of schedules for use as filter criteria during processing This Schedule ID may be entered by typing or selected via the asso
221. d via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available customer key via the lookup Customer Key To This Customer key specifies the upper limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by typing or selected via the DOCNUMBER 066 April 14 2005 Issue 2 Page221 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing associated lookup on this screen Leaving this field blank has the same effect as selecting the last available customer key via the lookup Printed Date From This Printed Date specifies the lower limit of the range of printed dates for use as filter criteria during processing This Printed Date key may be entered by typing or selected via the displayed calendar on this screen The default value of this field is the current server date Printed Date To This Printed Date specifies the upper limit of the range of printed dates for use as filter criteria during processing This Printed Date key may be entered by typing or selected via the dsplayed calendar on this screen The default value of this field is the current server date 21 12 12 Generating a Schedule of MSDS Customer History type 1 Select the Schedule Type as MSDS Customer History 2 Enter the Item Key From Leaving this field blank has the same effect as entering the first available It
222. date for this line will automatically be set to the earliest planned date of the combined lines 14 5 2 Transferring MPS Production Orders 1 Select a MPS Item at the From field using the lookup button at this field 2 Select a MPS Item at the To field using the lookup button at this field 3 Select a location at the From field using the lookup button at this field 4 Select a location at the To field using the lookup button at this field 5 Click on the Fetch Production Orders button on the toolbar to fetch the Production Orders for the specified range Processing the range fetches those MPS Production Orders whose status is Confirmed 6 If it is desired that the batches for the intermediates of the selected production order should also be created then check the Transfer to Super Batch box DOCNUMBER 066 April 14 2005 Issue 2 Page 84 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing a H one wishes that the intermediates related to the Super Batch are taken from the available inventory check the Fill from Inventory box 7 If it is desired to allocate the raw materials for the production orders being transferred check the Allocate box 8 If one wishes that the assignment of lots be done automatically check the Auto Lot Assignment box If this box is not checked then the lots will not be assigned only the quantity wil
223. defaulted values may be changed 2 Enter the Formula Key and the Description 3 Enter a Formula Class and a Formula Status if not present for this formula 4 Enter the Line Items on Tab 4 5 Enter the byproduct information if any on Tab 5 DOCNUMBER 066 April 14 2005 Issue 2 Page251 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 6 Add values at the optional fields as needed 7 Click the Save button to save the formula 23 1 10 Special Functions Toggle Units This button is enabled when the focus is on Tab 4 or Tab 5 Clicking on this button toggles the units as follows 1 If the focus is on a Material line item on Tab 4 the values of the Qty Required and the Cost Unit fields get toggled 2 If the focus is on a line item on Tab 5 the values of the Qty Produced and the Cost Unit fields get toggled FF BatchMaster Manufacturing Physical Property Analysis j E lej xj la x Formula Key CH Production Description _ Production Utilities 41 _ Production Report H 0 MPS KC MRP J aeina egen Property vae po Process Cell Mod Ee AP AVE 5_ PURCHASE Item For i 44 4444 TE QC Masters Material AP_FIFO_PURCHASE hen For eo Process Cell Repc Material amp P_STD_PURCHASE Item For QC Reports Labor AP_LABOR_10 _WI Nothing MSDS BOM Utilities C MSDS Reports y Laboratory
224. der option provides a way to define the order status for a MPS Production Order having status as Exception and falling under any of the periods of Demand Fence 1 and Demand Fence 2 With Demand Fence 1 MPS Production Order one can convert the order status of a selected MPS order and MPS item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Tansfer MPS Production Order option The confirmation dates can be established as well If a user has access to the Demand Fence 1 MPS Production Order option the user should also have access to the Demand Fence 2 MPS Production Order option which typically has more restricted order confirmation authority This screen automatically includes all those orders that are displayed on the Demand Fence 2 MPS Production Order 14 7 1 Screen Fields Description ER BatchMaster Manufacturing Demand Fence 1 MPS Production Order 4 EI x aa File Edit View Help Module Special Functions Windows lej x olsa axel al algl el 1 Production ltem Key ASSEMBLY_1 Assembly One pa Aurea Location Foto FGLOC z Production Re ee SS GH MPS Unit EACH L Forecast E D Run MPS D MPS Planr _ MPS Plan run Dt_ Order Status Plan Start Dt Plan End Dt ee O Transfer M O Transfer M 26 07 04 EXCEPTION 26 07 04 26 07 04 7 04 26 07 04 O Demand Fi k E
225. dified when Run MRP is processed The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to purchase order Vendor This is the Vendor for the purchase order If a vendor is associated with this Item Location via the Item Location screen then via Run MRP the vendor key is defaulted here from the Primary Vendor Key field of the Item Location screen This value can be modified here Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Planned If any of the rows have their boxes checked the status of those rows gets changed to Planned when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders c
226. displays the Order Number associated with a Schedule ID depending upon the schedule type for a line in the grid HMIS Codes This field displays the HMIS Code associated with a Schedule ID depending upon the schedule type for a line in the grid Spec Grav This field displays the Specific Gravity associated with a Schedule ID depending upon the schedule type for a line in the grid Formula This field displays the Formula associated with a Schedule ID for a line in the grid Formula Class This field displays the Formula Class associated with the Formula for a line in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page 226 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing WHIMIS This field displays the WHIMIS information associated with a Schedule ID for a line in the grid Template Key This field displays the Template key associated with a Schedule ID for a line in the grid Date Printed This field displays the date on which a MSDS was last generated for a specific Schedule ID 21 13 3 Generating a MSDS 1 Enter a MSDS Master Format key by typing or selecting it via the available lookup on the screen The Template file path associated with the MSDS Master Format key is defaulted at the Template File Path field Specifying a Master Format key is mandatory 2 Enter a Language by typing or selecting it via the available lookup on the screen Specifying a Language is mandatory
227. ds 5 Select the Customer From and To range using the lookup buttons next to the fields 6 Select Completion Date From and To range using the drop down arrows respectively 7 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 8 Click on the Process button on the toolbar to create a report 13 17 Labor Transactions Report The Labor Transactions report gives details of labor transactions of a batch This report includes details of quantity accepted rejected quantity line status employee details of machine including details of start date time and elapsed time One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 17 1Generating a Labor Transactions Report 1 Select the Batch Number From and To range using the lookup buttons next to the fields 2 Select the Assembly Item From and To range using the lookup buttons next to the fields 3 Select the Order Type as one of Mix Fill Assembly or All using the dropdown menu in the field 4 Select the Labor Transaction Status by checking the box next to the respective statuses DOCNUMBER 066 April 14 2005 Issue 2 Page45 of 274 BatchMaster Software BatchMaster Enterprise
228. e Save button is clicked IF BatchMaster Manufacturing Physical Property Analysis I l E File Edit Yiew Help Module Special Functions Windows 18 x olelalel x al gt lgl Za SC Routing Reports Formula Key Clos Quality Contra Enlarge View W Description eet Cost Method STANDARD Production Utilities 1 K Zu Quantity Si Production Report Recalculate Property nan eut Mode By Quantity MPS MRP 1 Formula Master _ MRP Reports SeqguenceNum itemkey Process Cell Modi m Perrera Material AP G_PURCHASE ofge JEC Masters Material AP_FIFO_PURCHASE C Process Cell Repe Material AP_STD_PURCHASE QC Reports Labor AP_LABOR_10 _ Wi Nothin MSDS C BOM Utilities MSDS Reports CH Laboratory O O Physical Prope e Comparative F De Geesen Name Ironie Totals S 5 S ormula Totals D Physical Prope EH Delete Line Total Weight GRM 36 0000 Laboratory Utilities z S Total Yolume CC 18 5607 E Create Gel Insert Line GRM CC 1 9396 H O MPS R Color if Physical Cost GRM 22 038537 i Gee Property Value not Cost CC 42 745446 H General Table Vie between Min and Total AM Cost 793 39 A Maximum Value al I Figure 15 1 9 Size Formula Button DOCNUMBER 066 April 14 2005 Issue 2 Page 254 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Check Uncheck Clicking this button mar
229. e formula on Tab 2 of the Material Safety Information or CAS Number Master screen A material is considered to be hazardous only if a Material Hazard Type ID has been attached to it at the Material Safety Information or the CAS Number Master screen b The Material should be reportable A material is considered reportable if its quantity in the formula meets at least one of the threshold requirements on this screen namely Include by Wt gt Include by Vol gt and Include Top n Ingredients c The Hazard Section ID preceded with the characters TBL_ should be inserted as a book mark on the corresponding Microsoft Word Document Template file used to generate the MSDS For example if the Hazard Section ID is USAMSDSII then the corresponding bookmark would be TBL_USAMSDSII The Hazard Section to be printed on a MSDS should be added under tab 2 of the Material Safety Information screen d The Hazard section ID prefixed with the characters HRZ_ and followed by one of ICH IVT IWT ICS IVP OEL keywords can be inserted as a bookmark in the Word Document Template file used to generate the MSDS For example if the hazard section id is SECTIONA and it is required to print the chemical name of a reportable component in one of the tables in the MSDS the column header in the table should be the bookmark HRZ_SECTIONA_ICH DOCNUMBER 066 April 14 2005 Issue 2 Page 199 of 274 BatchMaster
230. e Batch weight in system weight unit multiplied by the Amount of the Labor Key of the applicable row multiplied by the Factor of the Overhead Key of the same row Labor Key Variable Costs This is the Labor Key of the fixed costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Amount Variable Costs This is the cost amount for the formula labor additional key of the variable costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Overhead Key Variable Costs This is the Overhead Key of the variable costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Type Variable Costs The Overhead Key consists of two types Type This is the Ove rhead Key of type for setup costs This value is entered automatically when the associated overhead key is entered This is a read only field This value is used for cost analysis in the Costing module as well as to calculate the costs associated with production of the end item produced by the formula The Batch weight in sys
231. e Save button on the toolbar to save the report parameters 6 Click on the Process button on the toolbar to create a report 13 21 Material Usage Report DOCNUMBER 066 April 14 2005 Issue 2 Page 48 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing The Material Usage Report screen provides a way to generate a report showing the quantity of items used by volume or by weight in production Using Material Usage Report screen provides a way to generate details of item including the material cost and quantity weight or volume In addition the report displays the average of cost and usage on a monthly and annual basis One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 21 1 Generating a Material Usage Report 1 Select as needed one of Raw Material Usage Report or Raw Material Usage Report History options 2 Select as needed one of By Weight or By Volume 3 Select the Item Key From and To range using the lookup buttons next to the fields 4 Select the Location From and To range using the lookup buttons next to the fields 5 Select the Item Class From and To range using the lookup buttons next to the fields 6 Select Activity Date From and To range using the drop down arrows 7 Check box to enable Suppress if Zero Usage 8 To
232. e Schedules for the specified range 4 lf one wishes that the batches for the intermediates of the selected item location should also be created then check the Transfer to Super Batch box a If one wishes that the intermediates related to the Super Batch are taken from the available inventory check the Fill from Inventory box If the Available Quantity of an intermediate suffices the required quantity then a Sub batch is not created for this intermediate If the Available Quantity of an intermediate is less than the required quantity then a Sub batch is created for the remaining quantity For this purpose the Available Quantity is equal to On Hand Quantity plus On Order Quantity in Production minus Committed to Production If this box is not checked the Fill From DOCNUMBER 066 April 14 2005 Issue 2 Page 29 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Inventory option is turned off In such a case the available quantities of any related intermediates are ignored when the super batch is created If one wishes to allocate the raw materials for the batches being created check the Allocate box If one wishes that the assignment of lots be done automatically check the Auto Lot Assignment box If this box is not checked then the lots will not be assigned only the quantity will be allocated If one wishes that purchase requisitions be cr
233. e and a Plan End Date This specifies a range of Planning period The Orders for the selected range of Hem Locations falling within this range of Plan Dates will be processed for the change of status 6 Select a status at the Change Status From field The Orders having this selected status will qualify for the change of status 7 Select a status at the Change Status To field The status of the Orders from the filtered orders that have the status as specified at the From field will change to this status 8 Click on the Process button on the toolbar to change the status 15 7 Planned MRP Purchase Order The Planned MRP Purchase Order option provides a way to update and edit the planned purchase orders generated by MRP Run With Planned MRP Purchase Order one can make specific changes to a planned purchase order modifying the order s defining details The user can also delete the planned purchase order entirely DOCNUMBER 066 April 14 2005 Issue 2 Page 139 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 7 1 Screen Fields Description ER BatchMaster Manufacturing Planned MRP Purchase Order E la sl Ga File Edit Yiew Help Module Special Functions Windows la x BE axie d lt ol ri sl el i 1 Costing Reports AP_AVG_PURCHASE Item For Production
234. e of the Boilerplate Group and ID that is to be used if there are no reportable materials to be printed on a MSDS This boilerplate can be printed on the MSDS based on the Boilerplate Group bookmark on the MSDS template file provided that the Boilerplate Group and Boilerplate ID and are listed on an applicable supplementary file Maximum Number of Boilerplates per MSDS This field stores the total number of Boilerplates that may be printed per MSDS Company Key for Chemtrec MSDS This is the identification code assigned by Chemtrec to a Company Last SARA Posting Date This is the date on which last SARA processing was done BatchMaster Enterprise automatically maintains this date each time SARA processing is done MS Word Template Path This field stores the path of the MS Word Template file that can be used to print a MSDS MS Word Save File Path This field stores the default output path of the printed MSDS MS Word document Ignore Material key Supplementary File This field stores whether to ignore while printing a MSDS the Supplementary Files of Materials type Ignore Formula key Supplementary File This field stores whether to ignore while printing a MSDS the Supplementary Files of Formulas type Ignore Material Class Supplementary File This field stores whether to ignore while printing a MSDS the Supplementary Files of Material Classes type Ignore Template Supplementary File This field stores whether to ignore while printi
235. e senna 111 14 13 2 Screen Fields Description 112 14133 Maintaining MPS ZGetun eect teen eran ene nets eee ee ante een nant eeeenaneteeee a 114 14 14 PULL MIPS EE 114 14 14 71 Screen Fields Description 115 14 14 2 Using Pull MPS ltems screen 116 14 15 MPS ORDER RANGE DPOCESGING caeeeeeeeeeseeeeseeeeeeeeseeeeeseeseeeeseeeseeegs 117 14 15 1 Screen Fields Description 117 14 15 2 Processing a Range Of MPS Orders cccccccceeeeeeeee cnn neeeeeeeea nae eeeeeeeaaaaeeeeeeeaaeeeeeeeaa 118 15 Us 118 15 1 SI Ode 118 15 1 1 Mandatory INDUtS E 119 15 1 2 Screen Fields Description 120 15 1 3 ProC Ssing E 121 15 2 DEMAND FENCE 1 MRP PURCHASE OpDER ceeeeeeesaeeeaeeesaeeesaeeeeaeceeaeeeeas 122 15 2 1 Screen Fields Description 122 15 2 2 Working with Demand Fence 1 MRP Purchase Order 124 15 2 3 Special Te EE 125 15 3 DEMAND F ENCE 2 MRP PURCHASE OpDER seeeeeeeeeeeesaueesaeeesaueesanceeaeeeees 126 15 3 1 Screen Fields Description 126 15 3 2 Working with Demand Fence 2 MRP Purchase Order 128 15 3 3 Special FUNCIONS EE 129 15 4 DEMAND FENCE 1 MRP PRODUCTION OpDER rentene 130 15 4 1 Screen Fields DOSCHPUON ee gust eel eaten ees ea 130 15 4 2 Working with Demand Fence 1 MRP Production Order 132 15 4 3 Sp cial FUNCTIONS EE 133 15 5 DEMAND FENCE 2 MRP PRODUCTION OpDER tennene 134 15 5 1 Screen Fields Description 134 15 5 2 Working with Demand Fence 2 MRP Production Order 136 15 5 3 Special FUNCTIONS EE 137 1
236. e their boxes checked such rows get deleted when this button is clicked DOCNUMBER 066 April 14 2005 Issue 2 Page 98 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Exception If any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 14 8 2 Working with Demand Fence 2 MPS Purchase Order 1 Select a MPS purchase order record on this screen 2 Change the status for the MPS purchase order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the confirmation end date
237. eated for the raw materials for the batches being created check the Create Purchase Req box If one wishes to assign batch number manually for each or some of the line items do so using the ellipse button adjacent to the BatchNo field If one wishes to assign batch number to one or more line items manually in one go then i Select the lines by clicking on them while holding the Ctrl or Shift button down ii Click on the Select In Range button iii Select Manual Entry option iv Enter the batch number v Click OK If one wishes to create a Warehouse Transfer order for the selected schedules instead of creating batches for them a Select the lines by clicking on them while holding the Ctrl or Shift button down b Click on the Warehouse Transfers button c On the popup window that opens enter the Location and choose Inventory Transfer or Inventory Move Click OK Note If an item is available at or procured via another location of the company it may be desirable to obtain the item from that location to fulfill demand rather than creating a new batch 10 Click on the Transfer to Batch button to create batches for the selected line items DOCNUMBER 066 April 14 2005 Issue 2 Page30 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 4 4 Special Functions Transfer To Batch Clicking on this button transfers the generated schedules to
238. ecial Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Oty On Hand _ ty On Order E Warehouse 4 1249 9899 0 0000 0 0000 2 JMaN Main Wareho A 356 0000 0 0000 0 0000 3 _ SLECH BIEN AJ 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 10 6 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No Faompapgp 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status oe 2900p DOCNUMBER 066 April 14 2005 Issue 2 Page 92 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing j User Id k Record Date 14 7 Demand Fence 1 MPS Production Order The Demand Fence 1 MPS Production Or
239. ecifies the lower limit of the range of locations Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations Leaving this field blank has the same effect as selecting the last available location via the lookup Plan Start Date This specifies the lower end of the Plan Dates Leaving this field blank has the same effect as entering January 01 1900 DOCNUMBER 066 April 14 2005 Issue 2 Page 138 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Plan End Date This specifies the upper end of the Plan Dates Leaving this field blank has the same effect as entering the current Server date Change Status From The Orders having this selected status will qualify for the change of status The value in this field can be one of Exception Planned Firm Planned or Confirmed Change Status To The status of the selected Orders will change to this status upon processing The value in this field can be either Firm Planned or Confirmed 15 6 2 Processing a Range of MRP Orders 1 Select a MRP Item at the From field from the lookup at this field 2 Select a MRP Item at the To field from the lookup at this field 3 Select a Location at the From field from the lookup at this field 4 Select a Location at the To field from the lookup at this field 5 Enter a Plan Start Dat
240. ected at the Batch Status field Auto Lot Assign Checking this box enables automatic assignment or creation of lots at the time of changing the batch status This box is enabled only when the Batch status field is set to e Allocate e Issue e Part Close e Close DOCNUMBER 066 April 14 2005 Issue 2 Page 22 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 3 3 Processing a Range of Batches 1 Select a Batch status at the Batch status field 2 Select a batch at the From field Leaving this field blank has the same effect as selecting the first available batch via the lookup 3 Select a batch at the To field Leaving this field blank has the same effect as selecting the last available batch via the lookup 4 H one wants the assignment of lots to be done automatically check the Auto Lot Assignment box 5 Click on the Fetch Batches button on the toolbar The batches that qualify for the status selected at the Batch status field get displayed in a grid 6 The user can sort the various batches on the grid by clicking any of the column headers The sorting order ascending or descending can be toggled by clicking the same grid header again 7 Select the batches whose status needs to be changed by checking the adjacent boxes Selecting unselecting all the lines in a go can be done by clicking the Select All Unselect Al
241. ed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is processed The value in this field is defaulted from the value of the plan end date field in the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed Plan Qty This is the Plan Quantity recommended by the system The value in this field is defaulted from the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed Assembly Type The value in this field is defaulted from the value of the Assembly Type field at the BOM Entry screen The possible values are for intermediate F for finished good and A for assembly type of BOM Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Warehouse Transfers Click this button to create a Warehouse Transfer order for the selected MPS Orders instead of transferring them to a Production Order Orders can be selected by checking the select box for the order lines On the popup window that opens enter the Location and choose Inventory Transfer or Inventory Move to perform warehouse transfer DOCNUMBER 066 April 14 2005 Issue 2 Page 154 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing
242. ed Batch End Date This is the date that would default to the End Date field on the Scheduling Item screen when the schedule is created Schedule Formula Key This is the key associated with the Scheduling Formula that is to be used for generating the schedules for the selected Item Locations This is a mandatory field Append Create Schedule The values at this field can be one of the following 1 Create This setting specifies that a new schedule is created and is not appended to an existing one When the user generates schedules with this setting the user is prompted to specify whether to keep or delete old schedules for the item locations for which new schedules are created If the user does not allow the deletion of the existing schedules a new schedule will not be created When a schedule is created the Order Quantity of the schedule at the Scheduling Item screen gets set to the Quantity to Schedule as specified at the selected Scheduling Formula 2 Append If this option is selected the scheduled quantity will get appended to the scheduled quantity of the existing schedule if any When a schedule is appended the Order Quantity of the schedule at the Scheduling Item screen gets incremented by the Quantity to Schedule as specified at the selected Scheduling Formula 12 1 3 Generating a Schedule 1 Select a Schedule Type at the Schedule Type field 2 Select an Item Key at the Item Key From field as needed 3 Sele
243. ed MRP Prox DN D Transfer MAP Proc H MRP Reports Process Cell Module C QC Masters 1 Process Cell Reports C QC Reports C MSDS 1 BOM Utilities i I MSNS me 4 AP_AVG_PURCHASE 600 0000 30 07 04 Item For Produc FGLOC Figure 11 9 3 Transfer PO Button Selectall All 4 A Unselect All Warehouse Transfers Club Orders d The PO details for the item include the following Processing Date Processing Time Vendor key PO number MPS Order Number Item Key Location UOM Order Quantity Request date SCHEER ia Set DOCNUMBER 066 Issue 2 April 14 2005 Page 150 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item View Item Location x ltem Key BUTANOL Stock UOM LES Description N Butyl Alcohol N Butanol Display Unit LBS 1 Location Detail e iisem ee Dn Dn Hard Qty On Ouer Commit to Sale i ee H 1 249 9899 0 0000 0 0000 vu E Wareho 356 0000 d WE H BITTEN A 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 11 9 4 View Item Location window The inventory details of an Item Location include the following 1 L
244. ed to close It can be modified When a Process Cell Schedule is saved after changes the Confirm End date of the MRP Order as seen on the Planned MRP Production Order is changed to the Schedule End Date saved in this field Process Cell This field displays the Process Cell associated with an MRP Order for a line in the grid It can be modified When a Process Cell Scheduling is saved after changes the Process Cell of the MRP Order on the Planned MRP Production Order is set to the Process Cell saved in this field Allocated Date This is the date on which this process cell is scheduled to be used for this MRP Order Batch Volume This field has the same value as does the Order Volume field on this screen Batch Weight Size This field has the same value as does the Order Weight field on this screen UOM This field displays the unit associated with the quantity to be produced by an MRP Order for a line in the grid Order Weight This field displays the Total Order Weight of a batch that would need to be created to fulfill the MRP Order for a line in the grid Order Volume This field displays the Total Order Volume of a batch that would need to be created to fulfill the MRP Order for a line in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page 166 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Batch Time Hr For the selected date this is the number of hours during which this Process
245. eeee eee canna neeeeeeaaaaaeeeeeaaaaanees 210 21 12 MSDS SCHEDULE GENERATION 211 21 12 1 Screen Fields Descriptions for Master Formula 212 21 12 2 Generating a Schedule of Master Formula type cccccccseeeeeeee eee nnneeeeeeeenaneeeeeeeeenees 213 21 12 3 Screen Fields Descriptions for Finished Good 214 21 12 4 Generating a Schedule of Finished Good iwpe ee eeeeeee canna eeeeeeenaes 215 21 12 5 Screen Fields Descriptions for Raw Material 216 21 12 6 Generating a Schedule of Raw Material type ccccccseeeeeeeeeeenteeeeeeeeeannneeeeeeeeennaaees 216 21 12 7 Screen Fields Descriptions for Production Formula 217 21 12 8 Generating a Schedule of Production Formula epe 218 21 12 9 Screen Fields Descriptions for Production Finished Good 219 21 12 10 Generating a Schedule of Production Finished Good pe 220 21 12 11 Screen Fields Descriptions for MSDS Customer History 221 21 12 12 Generating a Schedule of MSDS Customer History type cccceeeeeeeeeeeeeeeeeeeenneeees 222 21 12 13 Screen Fields Descriptions for BatchMaster Order History 223 21 12 14 Generating a Schedule of BatchMaster Order History type ssuseeeeeneeneeeneennennn 224 21 13 RINT Aere ch cae eeepc fcc emer chante 224 21 18 17 Mandatory Inputs civsvececzcs ce irinin cca EES rinine anaia i aanita irina iai 224 21 13 2 Screen Fields Descriptions 112 c cccceceeeee cee cece neeeeceeeescaeeeeaueeeeaaceeessaeessaeeeeseaeeeees 225 CA EE NC Wee EE
246. eeeetanaaneeeeeeaaa 66 14 3 4 Screen Field Descriptions Tab 3 Cust Order 67 14 3 5 Screen Field Descriptions Tab 4 WH Transfers nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnn nnne 68 14 3 6 Screen Field Descriptions Tab 5 Planned Prod Org 69 14 3 7 Screen Field Descriptions Tab 6 Planned Purch Or 72 14 3 8 Using the Planning Worksheet aseeeeeeesneeeensnneeeersnnneeernrrrnnrnrrrrnnnrnrrrnnrnrnrnannnnneennnnt 74 14 3 9 Special FUNCHONS EE 75 14 4 TRANSFER MPS P URCHASE ORDER 0cccccccseeeeeeeeeeeeeeeeseeceeeeeeeeeeeeeseeeeseneseeeeseeeeeeeeseeesaeeeaeees 76 14 4 1 Screen Fields Description 76 14 4 2 Transferring MPS Purchase Orders cccccccccteeeee eee nn teee teens nanan eeeeeeanaeeeeeeeeaneneeaaaas 78 14 4 3 Special Functions 10 cccccccceeecceeeee cece eeeee tees cates see eecaaeseaaeesneeesseeeesaeeseaeeessateseseeesseees 79 14 5 TRANSFER MPS P RODUCTION ORDER 0cccceeeceeeeeeeeceeeeeeeeeeeeseeeeeeeeseeeeeeesseeeeeeesesseeeeeeensees 81 14 5 1 Screen Fields Description 81 14 5 2 Transferring MPS Production Orders ante eeeeeeeneeeeeeeenanneeeeeanaas 84 14 5 3 Special FUNCHONS EE 86 14 6 DEMAND FENCE 1 MPS PURCHASE ODER 88 14 6 1 Screen Fields Description 89 14 6 2 Working with Demand Fence 1 MPS Purchase Order 91 14 6 3 Special FUNCTIONS 10 cccccccceeeceeeeeeceeenceeeeceeesaeeeeseeescaeeseaaeesseeesaaeeesaeeseaaeessanesesesesseee 92 14 7 DEMAND FENCE 1 MPS PRODUCTION ORDER
247. em 3 Enter the Item Key To Leaving this field blank has the same effect as entering the last available Item 4 Enter the Customer Key From Leaving this field blank has the same effect as entering the first available customer 5 Enter the Customer Key To Leaving this field blank has the same effect as entering the last available customer 6 Enter the Ship Date From Leaving this field blank has the same effect as entering the current server date 7 Enter the Ship Date To Leaving this field blank has the same effect as entering the current server date 8 Click on the Process button Depending upon the filter criteria the schedules are generated for the Customers A report displays all those customers for which schedules were generated 9 Save the record by assigning some parameter name to the record in the input box on the toolbar DOCNUMBER 066 April 14 2005 Issue 2 Page 222 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 12 13 Screen Fields Descriptions for BatchMaster Order History ER BatchMaster Manufacturing MSDS Schedule Generation i i S EI x File Edit View Help Module Special Functions Windows l x Cfo a axe aa lel z m Schedule Basis QC Masters i Schedule T Batchmaster Order Hist x GO Process Cell Repo chedule Type atchmaster Order History SL QC Reports r Selection Criterion Ta ae SH Sa
248. emand Range on the MPS Setup screen 2 Sales Orders and Warehouse Transfers Out depending on the setting for the Demand Range on the MPS Setup screen 3 Dependent Demand from Planned Firm Planned and Confirmed orders of MPS Items and higher level MRP Items 4 The quantity by which On Hand Quantity is less than the Safety Stock Quantity as defined at the Item Location 5 MRP type raw materials remaining to be issued to production batches that are not on hold The sources of supply for Run MRP are 1 Only for the first Period of the planning horizon The quantity by which the On Hand quantity exceeds the Safety Stock as defined at the Item Location 2 For 2 Period of the planning horizon onwards PAB of the preceding period 3 Scheduled Receipts from a Purchase Orders b Production Orders c Warehouse Transfers In d Firm Planned Orders e Confirmed Orders The quantity to be ordered is determined by subtracting the supply quantity from the demand quantity and then adjusting for EOQ if the EOQ is applicable For this purpose 1 The EOQ is applicable if the Lot Sizing Method is set to EOQ at the item master screen 2 The value of EOQ is taken from the Item Location screen If the orders can be created outside any demand fences without using a date less than the Server date then Planned Orders get created The planned orders so created can automatically get changed to firm planned orders or confirmed orders depending on the opt
249. emand generated from warehouse transfers out 6 Click on Tab 5 This Tab displays the Production Orders generated as a result of this MPS Run Various dates quantities and statuses for line items can be modified if so desired 7 Click on Tab 6 This Tab displays the Purchase Orders generated as a result of this MPS Run Various dates quantities and statuses for line items can be modified if so desired 8 Click on the Save button to save the changes DOCNUMBER 066 April 14 2005 Issue 2 Page 74 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 3 9 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Oty On Hand _ ty On Order E Warehouse 4 1249 9899 0 0000 0 0000 2 JMaN Main Wareho A 356 0000 0 0000 0 0000 3 _ SLECH BIEN AJ 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 10 3 7 View Item Location window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity
250. ence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed Conf Start Dt The value in this field is defaulted from the value of the confirmed start date field in the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed DOCNUMBER 066 April 14 2005 Issue 2 Page 148 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Conf End Dt The value in this field is defaulted from the value of the confirmed end date field in the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Warehouse Transfers Click this button to create a Warehouse Transfer order for the selected MRP Orders instead of transferring them to a Purchase Order Orders can be selected by checking the select box for the order lines On the popup window that opens enter the Location and choose Inventory Transfer or Inventory Move to perform warehouse transfer w Warehouse Transfer Detail xj Warehouse Transfer Detail Location piati x Ze Inventory Transfer Inventory Move OK Cancel Figure 11 9 2 Warehouse Transfer Detail Window If an item is available at or
251. er Enterprise 7 25 User s Guide Volume III Manufacturing Date The value in this field for a line defines the date of the day of the week for the selected year This is a read only field Day The value in this field for a line is the day of the week corresponding to the date for the selected year This is a read only field 14 11 2 Creating a Company Calendar 1 Select the Year for which the company calendar has to be created 2 Check in the Select Weekly Holidays list the days of the week that will be weekly holidays 3 Click on the Process button on the toolbar to create the list of holidays The calendar so created is displayed at the List of Holidays section All the days earlier than the current date are displayed in the blue color and the check boxes for these days are checked The weekly holidays are marked with red color and the checkbox is checked for these holidays 4 To mark any other holiday check the corresponding box at the List of Holidays section 5 To change a holiday to a working day uncheck the box for that date 6 Click the Save button on the toolbar to save the record 14 12 Planning Calendar The Planning Calendar Setup option provides a way to create a calendar that the various MPS options use when making calculations and estimations about forecast demand purchase and production With Planning Calendar Setup one can define up to three demand ranges and establish periods within those
252. er History 4 BatchMaster Order History 21 15 1Screen Fields Descriptions ER BatchMaster Manufacturing Update Customer History a E x aa File Edit View Help Module Special Functions Windows l x a axl Ar algl MSDS Schedule Date Selection GC Masters 1 _ Process Cell Repo QC Reports y MSDS D Boilerplate Gro D Boilerplate Mai b Boilerplate Owe D Supplementary IN CAS Number h ID Hazard Type kh O Hazard Print R CY Hazard Print C ID Material Safet IN SARA Process O MSDS Master In MSDS Schedt IN Print MSDS ID Customer Histe MSDS Schedule Date From O MSDS Setup 1 BOM Utilities C MSDS Reports Laboratory 1 Laboratory Utilities mE Rent Z D ES EEN D Figure 14 14 Update Customer History Screen MSDS Schedule Date From This is the lower end of the date range during which the schedules were generated from which the MSDSs were printed This is a mandatory field The To date i e the upper end of the date range is considered to be the current Server date 21 15 2Updating Customer History 1 Enter the MSDS Schedule Date 2 Click on the Process button A record for such a schedule which was generated during the specified date range and has got a MSDS printed is either appended or updated at the Customer History DOCNUMBER 066 April 14 2005 Issue 2 Page 229 of 274 BatchMaster Software BatchMas
253. er for the selected MPS Orders instead of transferring them to a Purchase Order 8 Club the purchase orders if so desired 9 Click on the Transfer PO button to transfer the selected orders to purchase orders 14 4 3 Special Functions Transfer PO Clicking this button transfers the planned purchase orders to Purchase Order BatchMaster Enterpise generates a crystal report giving details of the purchase order generated The PO details for the item include the following 1 Processing Date 2 Processing Time 3 Vendor key 4 PO number 5 MPS Order Number 6 Item Key 7 Location 8 UOM 9 Order Quantity 10 Request date ER BatchMaster Manufacturing Transfer MPS Purchase Order la x ES File Edit View Help Module Special Functions Windo leie alx es wll BatchMaster Manufacturi h x x m Select MPS Item Location A veier S Transfer PO SL Routing Reports To Pa eter b From REED 3 Production Utilitie Location 2 Production Fever To been tw ale Yl Reed Bordall Ey MPS Max No ofLinesinPO Im ID Forecast Entr De leet ESen eein on Reatiy eo Tt DR 4 MPS raw materi d b ER G Set 10 0000 03 18 04 ID Transfer MPS Be MPS raw materi 10 0000 09 18 04 Gro So EE DN Demand Fenc e MPS raw materi 10 0000 09 18 04 O Demand Een MPS raw materi 10 0000 09 18 04 Li Demand Fem ER MPS raw materi 10 0000 09 18 04 D Maint
254. er was generated Order Status The Order Status on this screen can be one of the following 1 Exception These orders before being transferred to Production Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MRP Exception MRP Orders get erased when Run MRP is processed 2 Firm Planned These orders before being transferred to Production Orders need to be Confirmed The Orders that are Firm Planned will not be erased when Run MRP is processed 3 Confirmed The Orders that are Confirmed are ready to be transferred to a production order and will not be erased when Run MRP is processed Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is processed Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Dt
255. erial is readily combustible and presents a potential fire hazard Sudden Release of Pressure Hazard Check this box if this material will react violently when pressure is suddenly released on the container in which it is kept Reactivity Hazard Check this box if this material will react possibly violently when combined with certain other materials Immediate Health Hazard Acute Check this box if this material presents an immediate and or severe health hazard should some one come in contact with it Contact may be interpreted as physical contact on the skin inhalation ingestion etc Delayed Health Hazard Chronic Check this box if this material presents a long term delayed and or recurring health hazard should some one come in contact with it Contact may be interpreted as physical contact on the skin inhalation ingestion etc Pure Check this box if this material is Pure Mixture Check this box if this material is a Mixture Solid Check this box ifthis material is a Solid Liquid Check this box if this material is a Liquid Gas Check this box if this material is a Gas DOCNUMBER 066 April 14 2005 Issue 2 Page 205 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing SARA Information grid Type This field stores the storage type represented by a letter of this item for a line in the grid Pressure This field stores the pressure represented by a number associated wth a s
256. erial or labor line item This value is used for cost analysis as well as to calculate the costs associated with production of the end item produced by the formula Cost Unit This displays the standard or last or average cost of the material The user can toggle the cost from standard to last to average by clicking the Toggle Costs button on the toolbar Ext Cost This field displays the extended cost for the material or labor line item This cost is calculated by multiplying the Quantity Required with the Cost Unit of the item Loss This displays the line loss for this specific material line item in the formula This number is entered and interpreted as a fraction not as a percentage Sys Wt This field displays the conversion in System Weight with respect to Qty Required Sys Vol This field displays the conversion in System Volume with respect to Qty Required Group ID This is the Group ID of this line for the purpose of mix control via utilizing a customized report rpt file for printing Batch Tickets Mixing of materials can be better organized via Group ID s Selected materials may be premixed before being combined with the remaining ingredients Formula lines that need to be combined to make a Premix will all share the same Group ID Each premix has its own Group ID The various premixes are then combined with any remaining ingredients to make the Final Mix The largest Group ID indicates the Final Mix The totals of weight
257. erials to a Purchase Requisition using a Super Batch Critical Material Report 47 13 19 3 Screen Field Description in Transfer Critical Items To Purchase Requisition grid 47 13 20 CRITICAL BATCHES AND RAW MATERIAL HERORT trentenne nnt 48 13 20 1 Generating Critical Batches and Raw Material Henn 48 13 21 MATERIAL USAGE REPORT ANEREN REENEN 48 13 21 1 Generating a Material Usage Heport cece cee rn tne eeeeee enna eeeeeeeeeetteeeeenaaeeeeeeaaaas 49 14 WPS ie cdeccdesedvacdecedeacdesedsecdenccececcaeceedeadesaedvaeeseeetlasdeducedecedddedccdecdedduedadeduddGucubvsseueseuddedseedeenseuys 49 14 1 FORECAST ENTRY E 50 14 1 1 Mandatory lee 50 14 1 2 Screen Fields Description 51 14 1 3 Using Forecast ENUY eresien aia AEE ed ee EE a aiee 52 DOCNUMBER 066 April 14 2005 Issue 2 Page 4 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 1 4 Special FUNCIONS escenes ai e A e A EE E A a 53 ISS RUNMPS ooann epea Ee Eaa a eaaa eaea aa E N N aaa eaaa EE NEN 57 14 2 1 Eet Eelere 58 14 2 2 Screen Fields Description ege eee ok ae ee ed Ss 59 14 2 3 An Example of Aun EE 60 14 2 4 Processing a RUN MP 62 14 3 MP S PLANNING WORKSHEET ssysccvsciicenceaibitelstisnncunedeencessntctutemnatoets a EE aE EE 62 14 3 1 Mandatory NPU EE 62 14 3 2 Screen Field Descriptions Header and Tab 1 Summary sceceesseoeeeenneeeeeennnnreennnnneenn 63 14 3 3 Screen Field Descriptions Tab 2 Forecaetl eee eteeeeenneee
258. ers When a Generate Schedule is processed these sales orders are used if the Scheduling Formula involves the Quantities O1 or O2 that come from sales orders Leaving this field blank has the same effect as selecting the Server Date DOCNUMBER 066 April 14 2005 Issue 2 Page 14 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Start Order Requested Delivery Date From This is the date that specifies the lower limit of the range of requested delivery dates as specified on Tab 4 of the Sales Order Entry screen for which a schedule has to be generated for the selected range of Item Locations Leaving this field blank has the same effect as selecting January 01 1900 This value has significance only when the selected scheduling formula involves a quantity from Sales Order Entry Start Order Requested Delivery Date To This is the date that specifies the upper limit of the range of requested delivery dates as specified on Tab 4 of the Sales Order Entry screen for which a schedule has to be generated for the selected range of Item Locations Leaving this field blank has the same effect as selecting the Server Date This value has significance only when the selected scheduling formula involves a quantity from Sales Order Entry Default Generated Batch Start Date This is the date that would default to the Start Date field on the Scheduling Item screen when the schedule is created Default Generat
259. escription eis Ga File Edit Yiew Help Module Special Functions Windows la x Cy coe ta I a x es n a gt rif lgl SCH Formula Report 1 or process ID Ki Created By A M New J Processed SL Bill Of Material B A Costing Status NEW Requested By IR H Costing Utilities SL Costing Reporl SL Routing Repor SL Production e Alphanumeric Value 0 0000 Aine ca GE Gei Ce Value 2 0000 1 5000 mm Set O MRP Hc MRP Reports SL Process Cell M QC Masters O oC Test D Q fai gt Apply QC to Following Formula Items 0 Item Formula Description z Formula SCH SET FORMULA A E Formula for Melnvalid record can be saved on the Maintain Downtime master C Item SL QC Reports MSDS GL BOM Utilities Add Line SL MSDS Report a Laboratory 2 Delete Line m ratan IIZ al i yo af E Figure 13 4 Quality Control Process Screen QC Process ID This is the process ID associated with the quality control tests for the selected items formulas This is a mandatory field Created By This field stores the name of the person who created the quality control process Requested by This field stores the name of the person who requested the quality control process Status This field stores the status of the quality control process It can be one of new or pro
260. essed Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to production batch Batch Type This can be one of Mix Fill or Assembly depending on the assembly type of the associated BOM Process Cell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this item Hours Required This value is assigned by the system during Run MRP This value can be changed at the Process Cell Formula Capacity screen The value can also get modified when orders get clubbed Select All Clicking this button checks the boxes for all the rows in the grid DOCNUMBER 066 April 14 2005 Issue 2 Page 144 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Unselect All Clicking this
261. f the end item produced by the formula The value of Hours on this line is multiplied by the Factor of the Overhead Key to calculate the cost contribution of this overhead Type This is the Overhead Key of type for fixed costs This value is entered automatically when the associated overhead key is entered This is a read only field This value is used for cost analysis in the Costing module as well as to calculate the costs associated with production of the end item produced by the formula The value of Hours on this line multiplied by the Amount of the Labor Key is multiplied by the Factor of the Overhead Key of the same line to calculate the cost contribution of this overhead Factor Fixed Costs This value is entered automatically when the associated overhead key is entered This is a read only field Hours Setup Costs This is the value of the hours of the setup costs for the formula This value is used for cost analysis in this screen as well as to calculate the costs associated with production of the end item produced by the formula Labor Key Setup Costs This is the Labor Key of the setup costs for the formula Amount Setup Costs This is the cost amount for formula labor additional key of the setup costs for the formula This value is entered automatically when the associated labor key is entered This is a read only field This value is used during cost analysis of the formula on the Product Cost Analysis screen a
262. ffective use of the plant s equipment for current production load while also making it possible for one to manage the ability to respond to future demand To accomplish these goals BatchMaster Enterprise provides the Process Cell Module and its two options Capacity Utilization and Process Cell Scheduling Capacity Utilization administers the assignment of defined process cells to specified batch tickets the Process Cell Scheduling option manages the schedule for assigned process cells In BatchMaster Enterprise capacity planning is a rough cut capacity planning procedure focusing upon the use of resource profiling to manage capacity As part of the procedure the specific capabilities of a process cell to produce a batch of a given finished good are used to define the cell s output and scheduling Once this definition is complete one can establish the burden on a single process cell or across a range of process cells as their combined capacities make up the productive capacity of the entire manufacturing facility DOCNUMBER 066 April 14 2005 Issue 2 Page 160 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 17 1 Capacity Utilization This screen provides users with a way to view the commitment for a selected process cell against a calendar Week The Capacity Utilization option limits the process cells by acknowledging only those process cells that are associated with batches 17 1 1 Screen
263. firmed DOCNUMBER 066 April 14 2005 Issue 2 Page77 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Conf Start Dt The value in this field is defaulted from the value of the confirmed start date field in the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed Conf End Dt The value in this field is defaulted from the value of the confirmed end date field in the planned Purchase Order tab of the Planning Worksheet or from the Demand fence 1 and 2 MPS Purchase Order screens depending on where the order was confirmed Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Warehouse Transfers Click this button to create a Warehouse Transfer order for the selected MPS Orders instead of transferring them to a Purchase Order Orders can be selected by checking the select box for the order lines On the popup window that opens enter the Location and choose Inventory Transfer or Inventory Move to perform warehouse transfer w Warehouse Transfer Detail x m Warehouse Transfer Detail Location yati x Ze Inventory Transfer Inventory Move OK Cancel Figure 10 4 2 Warehouse Transfer Detail Window If an item is available at or procured via another location of the com
264. for use as filter criteria during processing This Formula Class may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available formula class via the lookup Formula Class To This Formula Class specifies the upper limit of the range of formula classes for use as filter criteria during processing This Formula Class may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available formula class via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page212 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Formula Status From This Formula Status specifies the lower limit of the range of formula statuses for use as filter criteria during processing This Formula Status may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available formula status via the lookup Formula Status To This Formula Status specifies the upper limit of the range of formula statuses for use as filter criteria during processing This Formula Status may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available formula status via the lookup Formula Description This
265. formulas Equation This field stores the Physical Property Equation for the Formula The user can enter the equation here by either typing or by double clicking the various operands and operators on this screen This equation is used to calculate the value of the physical property of a formula Adjust Equation This field stores the Physical Property Adjust Equation for the Formula The user can enter the adjust equation here by either typing or by double clicking the various operands and operators on this screen This equation is used to calculate the factor which is multiplied with the line items weight so as to proportion them to achieve a targeted property value Minimum Value This stores a number that is interpreted as the lower limit for the physical property value If a property value falls below this number then that property is accompanied with an asterisk at the Physical Property Analysis screen and on the reports of the Laboratory Reports module Maximum Value This stores a number that is interpreted as the upper limit for the physical property value If a property value exceeds this number then that property is accompanied with an asterisk at the Physical Property Analysis screen and on the reports of the Laboratory Reports module DOCNUMBER 066 April 14 2005 Issue 2 Page 258 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 2 2 Creating a Physical Property Formula
266. ge of locations for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available location via the lookup To Location This Location key specifies the upper limit of the range of locations for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available location via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page 120 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Select Date Range for Demand Consolidation Demand Start Date This is the Demand Start Date which is the server date and is defaulted by the system when Run MRP is processed This is a read only field Demand End Date This field specifies the upper end of the Demand Date This field is defaulted to a date that is one month ahead of the server date MRP Run Date This is the MRP Run Date which is the server date and is defaulted by the system when Run MPP is processed Skip low level coding Leave this box unchecked when the MRP is being run for an item for the first time For successive runs for the same item check this box if there is no change in the Bill of Materials for the item Checking this box skips assignment of
267. ge of super batches and their components The user can also create a unique name for a report which is used on a regular basis save that report s defined parameters and then run that defined report on a regular basis The user may find Using Super Batchwise Lot Details report helpful when it is required to determine the production information for the lots operations without having to open each super batch in one of the Super Batch screens Each report produced by Super Batchwise Lot Details Report contains the following information 1 Super Batch Number 2 Batch Number of the sub batch DOCNUMBER 066 April 14 2005 Issue 2 Page41 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Lot Number Item Key Location Key Quantity in Stock Stock Unit Quantity in Display Unit Display Unit 13 9 1 Creating a SuperBatchwise Lot Details Report 1 Complete the Super Batch No From and To range using the lookup buttons next to the fields OPNAR 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 13 10 Super Batch Explosion Report The Super Batch Explosion Report provides a way to generate a report detailing the specifics of super batch explosions One can
268. geess eege ieeeegeeereEeEeeEe GEESS EES EES eege 268 26 1 MRS PLANNING REPORT a e e cians tasweatuitanaeastidasecte cebaxciecstaaticn NN SERERA 268 26 1 1 Generating an MPS Planning Report c cceececceeeeeeee cece nee eeeeeeaaneeeeeeeeeeeteeeesnaaaees 268 26 2 MPS DEMAND REPORT 0ccceccccesececcceecccecceueeccaeseueeseusceetecsscesesecseseueeseuesesesseeseesensesenaes 269 26 2 1 Generating an MPS Demand Repott cccceectcceteteeee eee e can eeeeeeeeaannaeeeeeeeaaaaeeeeeeeenees 269 DOCNUMBER 066 April 14 2005 Issue 2 Page11 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 26 3 MPS ORDER REPORD betreien enee teen 269 26 3 1 Generating a MPS Order Heport een eteeeeeeeeneeeeeeenaaeeeeeeeenaaaaes 269 26 4 MPS SUPPLY REPORT ere ee EE gege 270 26 4 1 Generating a MPS Supply Report cccceecccettteeee eee c canteen eeeeaaaa ae eeeeeeaaaeeeeeeeeaaaaaaees 270 26 5 MPS EXPEDITE PO REPORT nnannnnnnnnnennannetieritrttttttt tertre tt ttrt ttrt tarten trr EEEE rAr n EEEren Enrere Eeee 270 26 5 1 Generating a MPS Expedite PO Henort nanan eeeeeeaaaeeeeeeeeaaeeneegs 271 27 GENERAL TABLE VIEW eegeeeeeggeedeeeeEEeeeegEeCNNEEEEEEEedEENEEENNeEeEEEEEEEENNNEENEEEEEdEeEEeE 271 SCT DATA VIEW eege EE geben 271 27 1 1 Screen Fields Descriptions 100 0 cece nee eet e een teen tee e enna ee eee tena ane eeeeeeaaaaeeeeeeeeaaaneneees 271 27 1 2 R nning Te 272 27 1 3 Special FUNCTIONS EE 273
269. h O Hazard Print R O Hazard Print C C Material Safety IN SARA Process 4 MSDS Master Dn MSDS Schedt IN Print MSDS ID Customer Histe k Update Custor DN z 1 BOM Utilities s MSDS Reports Laboratory SL Laboratory Utilities Get mm Banen Z Valid raw material types for entering material safety information T fl l Figure 14 15 2 MSDS Setup Screen Material Safety Defaults ItemType This is the Item type ItemSubType This is the Item Sub type associated with an Item type Add Line Clicking this button inserts a new line into the grid Delete Line Clicking this button deletes the selected lines 22 MSDS Reports 22 1 MSDS Setup Report DOCNUMBER 066 April 14 2005 Issue 2 Page 232 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing The MSDS Setup Report screen provides a way to generate a report showing the MSDS Setup settings defined in the MSDS Setup screen Once BatchMaster Enterprise processes the report it displays the results as a Crystal Report that one can print or export 22 1 1 Generating a MSDS Setup Report 1 Click on the MSDS Setup Report icon This Crystal Report is viewable on the screen for exporting or printing 22 2 Boilerplate Group Report The Boilerplate Group Report screen provides a way to generate a report showing the boilerplate groups c
270. h respect to which a schedule has to be generated for the selected range of items Leaving this field blank has the same effect as entering the first available location Item Location To This is the location that specifies the upper limit of the range of locations with respect to which a schedule has to be generated for the selected range of items Leaving this field blank has the same effect as entering the last available location Item Class From This is the Item Class that specifies the lower limit of the range of Item Classes with respect to which a schedule has to be generated for the selected range of Item Locations Leaving this field blank has the same effect as entering the first available item Class Item Class To This is the Item Class that specifies the upper limit of the range of Item Classes with respect to which a schedule has to be generated for the selected range of Item Locations Leaving this field blank has the same effect as entering the last available Item Class Sales Order Entry Date From This is the date that specifies the lower limit of the range of Order Dates of Sales Orders When a Generate Schedule is processed these sales orders are used if the Scheduling Formula involves the Quantities O1 or O2 that come from sales orders Leaving this field blank has the same effect as selecting January 01 1900 Sales Order Entry Date To This is the date that specifies the upper limit of the range of Order Dates of Sales Ord
271. hMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Include Property Analysis On What Page This field has three options 1 Own Page A page break is forced before printing the next property analysis 2 Same Page A page break is not forced before printing the next property analysis 3 None Do Not Print The property analysis cannot be printed Status Not Allowed in Physical Property Analysis This stores the Formula Statuses that will be excluded from the Physical Property Analysis Print Property Analysis On This field consists of two options 1 Plain Paper This option is used to print the Physical Property Analysis on a Plain Paper 2 Pre printed Stationary This option is used to print the Physical Property Analysis on pre printed stationary Print QC Results If this box is checked the QC Formula Tests along with the Target Values and Control Limits will be displayed when a physical property report is printed If the box is un checked the QC information will not be shown on the physical property report Quantity Precisions For Laboratory Report The number defined here decides the number of decimal places that will be displayed for quantities on laboratory reports Property Precisions For Laboratory Report The number defined here decides the number of decimal places that will be displayed for properties on laboratory reports 23 4 2 Creating a Laboratory Setup 1 Open the Laboratory Setup screen
272. hanumeric Upper Value This value is the upper limit for a test of Numeric type Normal Value This is the target value for a test of Numeric type Lower Value This value is the lower limit for a test of Numeric type Alpha Target This is the target value for a test of Alphanumeric type Add Line Clicking this button inserts a new line in the Details grid Delete Line Clicking this button deletes the selected line Apply QC to Following Formula Items Item Formula Key This is the Item Formula to which the tests will be attached Item Formula Description This is the description of the Item Formula Formula Check this radio button if the tests need to be attached to a formula Item Check this radio button if the tests need to be attached to an item Add Line Clicking this button inserts a new line in the Apply QC to Following Formula Items grid Delete Line Clicking this button deletes the selected line 18 4 2 Inserting QC Test Information for Items and Formulas 1 Click on the Insert button on the toolbar 2 Enter a QC Process ID 3 Click on the Add Line button within the upper Details frame 4 Select a Test ID 5 Leave the Operation as Insert 6 Enter the QC type as Pass Fail value Numeric value or Alphanumeric value DOCNUMBER 066 April 14 2005 Issue 2 Page177 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 7 If the QC Type is Numeric enter the Up
273. hat is associated with the replacement boilerplate The group name can be entered by typing or selected via the associated lookup on this screen This is a mandatory field The replacement boilerplate could be either of the following 1 One of the two contradictory or conflicting boilerplates 2 A third boilerplate which replaces the set of two contradictory duplicate boilerplates The position on the MSDS template file of the bookmark for the Boilerplate Group of the replacement boilerplate determines where this boilerplate will be printed on the MSDS Boilerplate ID This field displays the identification associated with the replacement boilerplate The replacement boilerplate could be either of the following 1 One of the two contradictory or conflicting boilerplates 2 A third boilerplate which replaces the set of two contradictory duplicate boilerplates Reason This is the reason for replacing a set of two boilerplates containing contradictory or duplicate information Status This is the status of the Boilerplate Override record The status of the boilerplate can be one of Active Inactive Marked for Deletion or Deleted The default value of this field is set to Active The replacement is effective only if the status is Active on this screen and the status of the replacement boilerplate is Active at the Boilerplate Maintenance screen 21 3 3 Defining a Boilerplate Override 1 Click the Insert button 2
274. he Capacity field of the Process Cell Formula Capacity screen If a Process cell is not associated with this formula then this field gets defaulted with 999 999 9999 CapacityUOM This field is currently not being used Intd Item This is the Item Key associated with this line item This field gets populated only when the BOM of this line item is Assembly type Intd Locn This is the location associated with this line item This field gets populated only when the BOM of this line item is Assembly type Conf Start Dt The value in this field is defaulted from the value of the confirmed start date field in the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed Conf End Dt The value in this field is defaulted from the value of the confirmed end date field in the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed Plan Run Dt This is the date when the MPS order was generated The value in this field is defaulted from the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed ItemType This is the type of the item maintained at the Maintain MPS Item or Pull MPS Item screen Order_Sta
275. he QC tests created using the QC Test Description screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 20 1 1 Generating a QC Test Master Report 1 Complete the Test Key From and To range using the lookup buttons next to the fi elds DOCNUMBER 066 April 14 2005 Issue 2 Page 180 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 20 2 Formula Test Report The Formula Test Report screen provides a way to generate a report showing the QC tests assigned to formulas using the QC Formula Tests screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 20 2 1 Generating a Formula Test Report 1 Complete the Formula Key From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of t
276. he rows have their boxes checked such rows get deleted when this button is clicked 14 3 6 Screen Field Descriptions Tab 5 Planned Prod Ord ER BatchMaster Manufacturing Planning Worksheet E l amp xj E File Edit View Help Module Special Functions Windows atl S axel Kl al mlm ele el 1 Routing Repor 1 Production 1 Production Util f 1 Production Re Location FG LOC E MPS O Forecast E O Run MPS O D Transfer M L Transfer M O Demand Fi 07 S 7 50 0000 a 07 04 O Demand Fi 19 07 04 CONFIRM E 04 z 50 0000 24 07 04 DN Demand F E m 13 07 04 CONFIRM 119 07 04 50 0000 19 07 04 e 19 07 04 CONFIRM 19 07 04 J 50 0000 19 07 04 5 Demand Fi Im 19 07 04 CONFIRM 19 07 04 7 50 0000 19 07 04 D Maintain M 6 07 P 50 0000 19 07 04 k Company C 4 Planning C O MPS Setup O Pull MPS D MPS Orde C MRP _ MRP Reports LA Process Cell M Select Al Un SelectAll Delete Line Planned Firm Planned Confirmed Club Orders 1 OC Masters ES racase Cell RZ 4P_FINISHED_GOOD Curr On Hand Safety Stk Item For Production level 1 NEE E DE EE IV Included in last MPS run Le EE al Figure 10 3 5 MPS Planning Worksheet Planned Prod Ord Tab Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or
277. he toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 20 3 Production QC Report The Production QC Report will display the pertinent information for the selected Batch Number along with the formula key test status tested by tested date test type result type result numeric result alpha target number target alpha number range low and number range high The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 20 3 1 Generating a Production QC Report 1 Complete the Batch Number From and To range using the lookup buttons next to the fields 2 Complete the Formula ID From and To range using the lookup buttons next to the fields 3 Select From and To Date range 4 Select Batch Type to All Mix Fill or Assembly 5 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 6 Click on the Process button on the toolbar to create a report 21 MSDS DOCNUMBER 066 April 14 2005 Issue 2 Page181 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing The U S Occupational Health and
278. hecking this box creates batches for the intermediates of the selected line items as well as for the line items themselves If this box is not checked then the batches will not be created for the intermediates associated with a line item Fill From Inventory This box is enabled only when the Transfer to Super Batch box is checked If this box is checked the intermediates related to the Super Batch are taken from the available inventory If the Available Quantity of an intermediate suffices the required quantity then a Sub batch is not created for this intermediate If the Available Quantity of an intermediate is less than the required quantity then a Sub batch is created for the remaining quantity For this purpose the Available Quantity is equal to On Hand Quantity plus On Order Quantity in Production minus Committed to Production If this box is not checked the Fill From Inventory option is turned off In such a case the available quantities of any related intermediates are ignored when the super batch is created Allocate If this box is checked the raw materials for the line items of the Planned Production Orders get allocated when the production orders are transferred to batches Auto Lot Assignment This box is enabled only when the Allocate box is checked If this box is checked then the assignment of lots is done automatically If this box is not checked then the lots will not be assigned only the q
279. ica axel vill als el BatchMaster Manufact SE Costing Reports H 0 Routing Report H C Production C Production Utilit H 0 Production Rep DL MPS CH MRP O Run MRP O Demand Fe O Demand Fe ltem Key bes Item For Production level 3 Location INLOC INLOC Unit E Tl CE oe D DU 120 29 07 04 EXCEPTION ik 04 3 04 04 8950 02 04 3 04 04 sit 2 J 4 Demand Fe O MRP Order O Planned MF O Planned MF D Transfer MF O Transfer MF MRP Reports zl Process Cell Mc H QC Masters _ Process Cell Re QC Reports __ MSDS _ BOM Utilities 1 MSNS wm LW Figure 11 4 1 Demand Fence 1 MRP Production Order Screen 4 gt Select All UnSelect ail Delete Lire Exception Em Planned Confirmed Club Orders Multiples of EOQ P gp Item Key This the Item Key associated with the Item Location for which the Demand Fence 1 MRP Production Order is displayed Location This the Location Key associated with the Item for which the Demand Fence 1 MRP Production Order is displayed DOCNUMBER 066 April 14 2005 Issue 2 Page 130 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing
280. ide Volume III Manufacturing 5 Complete the Formula From and To range using the lookup buttons next to the fields 6 Complete the Customer From and To range using the lookup buttons next to the fields 7 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 8 Click on the Process button on the toolbar to create a report 13 6 Transfer Sales Order To Batch Report The Transfer Sales Order To Batch Report provides the means to generate a report on sales orders transferred to a batch One can create a unique name for a report that is used on a regular basis save that report s defined parameters and then run that defined report on a regular basis Each Transfer Sales Order To Batch Report contains the following information Sales Order Number Customer Identification Item Key Location Unit Order Quantity Batch Quantity D O Ore ON 13 6 1 Generating a Transfer Sales Order To Batch Report 1 Complete the SO Number From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 13
281. il 14 2005 Issue 2 Page 270 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 26 5 1 Generating a MPS Expedite PO Report 27 27 1 Complete the MPS Item From and To range using the lookup buttons next to the fields Complete the Location From and To range using the lookup buttons next to the fields Select Expedite Statuses as required To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters Click on the Process button on the toolbar to create a report General Table View Data View This screen provides users with a way to view the SQL tables associated with BatchMaster Enterprise This may also be used to run SQL queries Several types of SQL statements can be run including Select Delete etc Since significant changes can be made to the database using this screen one should exercise great caution in running any statement other than a Select statement 27 1 1 Screen Fields Descriptions ER BatchMaster Manufacturing Data iew 5 l x ES Fie Edit view Help Module Special Functions Windows l x Diele aixi alalrlrl 1 Siss _ Formula Reports i Bill Of Materials Filter Data e Costing whee gt OI
282. ile Edit view Help Module Special Functions Windows 8 x oeae ae via ln Ee ee SEI ers ors r Physical Property Formula SL Routing Reports lt Property Number l 1 ENEE _ Production P YN TC Total Formula Cost oO Production Utilities ep Name ORG SOL T 1 999 Total Material Physical Property SL Production Report Equation E Zwei Che Adjust Equation aC MRP lust Equation 115 01 N U w 01 N MW M5 dit i H 3 MRP Report Mini Val rT y y My Volume of Marked Materials T ENRE ok EA e 8 0000 Iw Total Cost of Marked Materials 1 Maximum Value Ir oo omg M 1 999 Total Material Property Marked 2 1 QC Masters 10000 0000 lu Weight of UnMarked Materials _ Process Cell Repo uv Volume of UnMarked Materials GH QC Reports uc Total Cost of Unmarked Materials 1 p U 1 999 Total Material Property Unmarked SL MSDS N Target Physical Property SL BOM Utilities 0 Old Target Physical Property SL MSDS Reports CH Laboratory b Physical Prope h Add z Subtract k Comparative P Multiply 4 Laboratory Set Divide TD Physical Prope H _ Laboratory Utilities SL Laboratory Report SL MPS Reports 1 _ General Table View al gt Figure 15 2 Physical Property Formula Screen Property Number This displays the serial number of the Physical Property Formula The number is auto generated by the system when a new property is created Property Name This stores the name for the Physical Property of the
283. ilities 1 Costing Reports 2 5 Byproducts ___ SequenceNum Type ltemKev E rs 1 Routing Reports 1 Production 1 Production Utilities 1 Production Report C MPS C MRP 1 MPP Reports 1 Process Cell Mode C QC Masters 1 Process Cell Repo 1 QC Reports Property vae ORG SOL 0 0000 7 G 1 2 2 2 2 9 2 2 2 2 Q Msps x 1 BOM Utilities UI 1NSDS Reports Name Fomula Totals AN Add Line _Delete Line Total WeightiLB 1 6813 S Total Volume GAL 0 1678 RER Create Line Insert Line LB GAL l 10 0180 haste ees Color if Physical Cost LB 17 842879 O Comparative P Property Value not Cost GAL 178 750000 Di eg Ge between Min and Total RM Cost 30 00 k ai Figure 15 1 1 Physical Property Analysis Screen Header fields Maximum Value Formula Key This is the key that uniquely identifies the Formula This is a mandatory field Description This is the description of the Formula Quality Control Clicking this button opens the QC Formula Tests screen DOCNUMBER 066 April 14 2005 Issue 2 Page 240 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Enlarge View Clicking this button provides a zoo
284. ill not be erased when Run MRP is processed Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed Plan End Dt This is the Plan End Date that is recommended by the system when Run MRP is processed Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MRP is processed The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to purchase order Vendor This is the Vendor for the purchase order If a vendor is associated with this Item Location via the Item Location screen then via Run MRP the vendor key is defaulted here from the Primary Vendor Key field of the Item Location screen This value can be modified here Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If
285. inimal e 1 Slight e 2 Moderate e 3 Serious e 4 Severe A blank space indicates that no Reactivity rating is applicable to this material Personal Protection This is the HMIS Reactivity rating for this material The valid values are A K X or a blank space A blank space indicates that no HMIS Reactivity rating is applicable to this material Material Hazard MatHazTypelD This is the identification of a Material Hazard type for a line in the Material Hazard grid Description This is the description associated with the Material Hazard type for a line in the Material Hazard grid Add Line Clicking this button inserts a line in the Material Hazard grid Delete Line Clicking this button deletes the selected line s from the Material Hazard grid DOCNUMBER 066 April 14 2005 Issue 2 Page 194 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Tab 3 Safety Info continued ER BatchMaster Manufacturing CAS Number Master E i l x EZ File Edit View Help Module Special Functions Windows l x BAE a xlel id 4 gt ale m CAS Number Master 1 Process Cell Moc 1 GC Masters 1 Process Cell Repo C QC Reports J MSDS D Boilerplate Gro L Boilerplate Mai O Boilerplate Ove D Supplementary b D Hazard Type h O Hazard Print R O Hazard Print C L Material Safety 3 Safety Info continued
286. ion The value established here overrides the value set at the Item Location screen Economic Order Quantity This is the Economic Order Quantity for the item The value in this field overrides the EOQ defined at item location Default Vendor This is the default vendor for the MPS item This field is enabled if the Item Type is set to Purchase If enabled this is a mandatory field The value in this field overrides the vendor established at the Item Location screen Low Level Code This is the low level code for the item that is the lowest occurrence largest numeric value of this item location in the hierarchy of MPS items for a Bill of Materials BOM if this is a MPS type item The hierarchy of Low Level Codes for MRP items is separate from that of MPS items Lot Sizing Method The value in this field can be one of Lot for Lot or EOQ If EOQ is selected any order quantities generated by the system will be integral multiples of the EOQ Lot for Lot means that the order quantities will not be modified to integral multiples of EOQ The value in this field overrides the value established for the item at the Item Master screen Last MPS Run Date This is the date on which MPS was last run This is a read only field 14 10 2 Maintaining a MPS Item 1 To create a new MPS Wem on this screen click on the Insert button To modify an existing record navigate through the navigation buttons or select an item from the lookup at the toolbar 2 Select
287. ion This is the description of the MPS item for the line Location This is the location key associated with the item Item Type The value in this field decides the type of the item The type can be either Purchase or Manufacture depending on which Run MPS will generate Purchase Orders or Production Orders respectively The Item Type can be selected as Manufacture only if a Released BOM exists for the selected Item Location The value established here overrides the value set at the item Location screen Lot Sizing Mthd The value in this field can be one of Lot for Lot or EOQ If EOQ is selected any order quantities generated by the system will be integral multiples of the EOQ Selecting Lot for Lot means that the order quantities will not be modified to integral multiples of EOQ The value in this field overrides the value established for the item at the Item Master screen Economic Ord Qty This is the Economic Order Quantity for the item The value in this field overrides the EOQ defined at item location DOCNUMBER 066 April 14 2005 Issue 2 Page115 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Vendor This is the default vendor for the MPS item This field is enabled if the Item Type is set to Purchase If enabled this is a mandatory field The value in this field overrides the vendor established at the Item Location screen UOM This is the stock UOM for the Item Location Selec
288. ion Location Fom Foot ayes i C Production Utities To Feroc aye LOC SL Production Reports MPS h E MRP _ SELECT IN RANGE O Run MRP D Demand Fence 1t ree A 2 For Produc ee 50 0000 z ALTERNATE_A Item For Produc FGLOC GAM 50 0000 11 11 61 Q BEE 59 ALTERNATELA Item For Produc FGLOC GAM 50 0000 11 11 61 Demand Fence 1 t 60 ALTERNATE_A _ ItemForProduc FGLOC DRM 50 0000 11 11 61 DN Demand Fence 2t ALTERNATE_A Item For Produc FGLOC 50 0000 CY MRP Order Range ALTERNATE A Item For Produc FGLOC 50 0000 T D d MRP P F E Item For Produc FGLOC GAM 50 0000 11 11 61 ae ei Item For Produc FGLOC DEM 50 0000 11 11 61 O Planned MAP Proc ES AUTERNATE A _ Item For Produc FGLOC GAM 50 0000 11 11 61 D Transfer MAP Pur 98 ALTERNATE_A Item ForProduc FGLOC GRM 100 0000 22 22 HH 108 ALTERNATE_A len For Produc FGLOC GRM 50 0000 11 11 61 109 ALTERNATE_A Item For Produc FGLOC GRAM 50 0000 11 11161 MRP Reports 110 ALTERNATE_A len For Produc FGLOC GAM 50 0000 11 11 61 SL Process Cell Module ALTERNATE_A lem For Produc FGLOC 50 0000 SL QC Masters SL Process Cell Reports C1 QC Reports H I MSNS Select All Unselect All Warehouse Transfers Club Orders Se Figure 11 10 1 Transfer MRP Production Order Screen Select MRP Item Location MRP Item From The lookup at this field displays only those MRP items for which there exists at least one Confirmed Production Order This specifies the lower limit of the range of MRP items
289. ion selected at the Run MRP screen If the orders cannot be created outside any demand fences without using a date less than the Server date then exception orders get created Run MRP cannot make planned orders for items that are needed on the Server date or earlier For example if a Sales Order has a line item with the ReqDate as the Server date then the demand arising from that line item cannot be used for generating planned MRP orders In such cases exception orders are created 15 1 1 Mandatory Inputs Data should have been maintained at these screens before Run MRP is processed 1 Item Location 2 MPS Setup DOCNUMBER 066 April 14 2005 Issue 2 Page119 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 1 2 Screen Fields Description ER BatchMaster Manufacturing Run MRP E i laj x E File Edit view Help Module Special Functions Windows 8 x DIS Ged Ge alles iq 4 gt gt i lgl r Select Item Range for MAP Run C Costing Utilities TETEE nE Costing Reports From MRP Item ALTERNATE A al Ee acy aortas ey reas SL Deia To MFP Item PP tem For Production level 3 SL Production 1 _ Production Utilities SS i FGLOC BL Production Reports From Location FGLOC al SL MPS To Location JRMLOC A RMLOC GH MRP E Fun MAP i C Demand Fence r Select date range for demand consolidation p Gener
290. ired 8 Save the Demand Fence 1 MRP Production Order record DOCNUMBER 066 April 14 2005 Issue 2 Page 132 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 4 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Oty On Hand _ ty On Order E Warehouse 4 1249 9899 0 0000 0 0000 2 JMaN Main Wareho A 356 0000 0 0000 0 0000 3 _ SLECH BIEN AJ 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 11 4 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No sa oaoo D 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status sao ong DOCNUMBER 066 April 14 2005 I
291. is button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Planned If any of the rows have their boxes checked the status of those rows gets changed to Planned when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders For rows tat have their Select boxes checked the orders of such rows get clubbed together Only Planned Orders can be clubbed together For clubbing rows and combining the values for all the fields of the rows being clubbed the system searches for the row that has the earliest Confirm End Dt If multiple rows have a common earliest Confirm End Dt then the system picks the row having the lowest MPS Order No amongst them When orders get clubbed the clubbed rows get replaced with a single row on which the following fields are set as follow MPS Order No This is set to the MPS Order No of the row picked as explained above Plan Start Dt This is set to the Plan Start Dt of the row picked as explained above Plan End Dt This is set to the Planned End Dt of the row picked as explai
292. ite for the SARA hazard information With SARA Title IIl Tier lI provides the option of selecting location and hazard type based on either system weight or system volume Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 12 1Generating a SARA Title Ill Tier Report 1 Complete the Location using the lookup button next to the field 2 Complete the Hazard Type using the lookup button next to the field 3 Click on the button to enable By System Weight or By System Volume 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 22 13 SARA Title Ill Tier Il Report The SARA Title Ill Tier Il Report screen provides a way to generate a report summarizing specific hazardous ingredient information for each material including Chemical Abstract Service CAS number physical hazards health hazards composition storage codes maximum and average amount of inventory on hand and the number of days on site The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export DOCNUMBER 066 April 14
293. ition button on the toolbar 13 19 3Screen Field Description in Transfer Critical Items To Purchase Requisition grid Select When this box is checked for a row that row becomes available for Transfer to Purchase Requisition Batch Number This is the number that uniquely identifies the Batch Item Key This displays the critical items associated with the end item being produced in the batch Location This is the location associated with the Item Key Qty Ord This is the quantity to be ordered for the critical Item This field is editable QtyOnHand This displays the On Hand quantity of this critical item DOCNUMBER 066 April 14 2005 Issue 2 Page47 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing FormulalD This is the formula with which the critical item is associated This is the formula that is to be used for producing the end item of the batch DispUOM This field displays the stock unit for the Quantity Ordered Desc1 This field stores the Description or text associated with the value of the Item Key on the same row Vendor This displays the Vendor The Vendor Key is defaulted from the Item Location screen This is a mandatory field A Branch Key of the BatchMaster Enterprise Company should have been associated with this Vendor on the Vendor Master screen Select All Clicking Select All button checks all the critical items in the displa
294. ity to be issued One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 14 1_ Generating a Pick List Report 1 Select the Batch From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 13 15 Production Cost Summary Report The Production Cost Summary Report screen provides a way to generate a report showing the summary of total production costs for production batches One can use the option s filtering parameters to define the report choosing between the Production Cost Summary or History of Production Cost Summary and date range criteria Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 15 1 Generating a Production Cost Summary Report 1 Click the Production Cost Summary Report or Production Cost Summary Report History 2 Select the Formula Key From and To range using the lookup buttons next to the fields 3 Select the Item Key From and To range using the lookup buttons next to the fields 4 Select the Lo
295. k on the Process button on the toolbar to create a report 13 13 Raw Material Requirement Analysis The Raw Material Requirement Report screen provides a way to generate a report showing the quantities of formula items and BOM Line items required to produce a specific quantity of an end item With this report one can also size requirement of raw material for a Batch or a Super Batch One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 13 1_Generating a Raw Material Requirement Report 1 Select the Finished Good Key using the lookup button next to the field 2 Enter the Quantity 3 Select Batch or Super Batch DOCNUMBER 066 April 14 2005 Issue 2 Page43 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 13 14 Pick List Report The Pick List Report lists the items required to make the selected batches Any applicable serial lot bin numbers of the items are also displayed for allocated or issued items The Actual Quantity should be interpreted as the quant
296. key via the lookup Customer Key To This Customer key specifies the upper limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available customer key via the lookup Batch Status This is the status of a Batch The user can either select a specific batch status or select the All option for use as filter criteria during processing Selecting the All option has the same effect as selecting all the batch statuses The default value of this field is All 21 12 8Generating a Schedule of Production Formula type 1 Select the Schedule Type as Production Formula 2 Enter the Batch No From Leaving this field blank has the same effect as entering the first available batch 3 Enter the Batch No To Leaving this field blank has the same effect as entering the last available batch 4 Enter the Formula Key From Leaving this field blank has the same effect as entering the first available production formula actual formula used in a Batch 5 Enter the Formula Key To Leaving this field blank has the same effect as entering the last available production formula actual formula used in a Batch 6 Enter the Customer Key From Leaving this field blank has the same effect as entering the first available customer 7 Enter the
297. ks or un marks the Material lines that have been highlighted on Tab 4 The quantities of the marked lines are updated in response to any subsequent changes in the Property Values on Tab 4 ER BatchMaster Manufacturing Physical Property Analysis BB File Edit view Help Module Special Functions Windows oela x DEI lel Si Routing Reports lt Production Production Utilities Production Report Formula Formula Key Quality Control Enlarge View Cost Method STANDARD View Mode By Quantity ary Description Recalculate Property MPS EN es ZE Ces ER Keen br i Bees 8 PRE Material AP_AVG_PURCHASE Item Fo ORG SOL 33 3333 H 0 QC Masters Material ltem Fo C Process Cell Repc Material AP_STD_PURCHASE_ Item Fo QC Reports Labor AP_LABOR_10 Wi Nothing Aw BOM Utilities _ MSDS Reports B 44 Laboratory D O Physical Prope D Comparative F De ER Name Ironie Totals i S A Formula Totals t eee peer ena SE ry ies S otal Volume 7 EERE Creste Line Inset Line L 1 9396 MPSA Color if Physical Cost GRIM 22 038537 n Property Value ng Cost CC 42 745446 H General Table Vie eel ed Total RM Cost 793 39 aximum alue al I gt Figure 15 1 10 Check Uncheck Button DOCNUMBER 066 Issue 2 April 14 2005 Page 255 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufa
298. l button 8 If one wants to manually assign create lots do so using the Maintain Serial lot button on the toolbar 9 Click on the Change Batch Status button DOCNUMBER 066 April 14 2005 Issue 2 Page23 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 12 3 4 Special Functions Change Batch Status Clicking this button will set the status of the batches selected in the grid to the status set at the Change Status To field ER BatchMaster Manufacturing Batch Range Processing Ga File Edit Yiew Help Module Special Functions Windo oela alzle wl a gt rif BS EG EN EEST f Select Batch l _ Formula Reports _ a Bill Of Materials Change Batch C Costing Status Button l Costing Utilities Fro To 000000000000005 C Costing Reports Batch No HA Routing Reports Production kW Auto Lot Assign E E Production Utilities O GenerateSche Jl BatchNo BatchType Formulald _ ItemKey Location Descriptio _ FH Bj test02 M 85650 Formula for O Transfer S0 T Z Ges Zeen ZE IN RH DI ooo0000000001 MRPFORMULE Formula to te D Create Batche 4 O 0000000000001 MRPFORMULE Formula to te Di PurgeBatche 2 TC omg MRPFORMULE Formula to te k Purge Super B FL Production Report SL MPS H C MRP a MRP Reports 1 Process Cell Modu KL QC Masters FL Process Cell Repo HA QC Repo
299. l Inclasskey Costing Reports 1 Routing Reports 1 Production Production Utilities Steal ProdactoniFienai AvgDailpLocAmt a DateEntered C MPS L m FGLOC DaysOnLocAtzen H MAP TotAmtlns ie ee ALTERNATE_A FGLOC otdmtinSys d eports AP_A INLOC OverrideMaxStk LJ Process Cell Modt AP_AVG_PURCHAS FGLOC BuyerlD C QC Masters AP_AVG_PURCHAS INLOC Userl is Process Cell Repc APB INLOC Ve C QC Reports AP_C INLOC we i e MSDS AP_D INLOC fee AP_E INLOC ser AP_F INLOC User AP_FIFO_PURCHAS FGLOC User8 AP_FINISHED_GOO FGLOC User AP_FINISHED_GOO INLOC User10 APP INLOC Uer Ap D INLOC Select Al Unselect Select Al Unselect All BOM Utilities C MSDS Reports C Laboratory H 0 Laboratory Utilities FL Laboratory Report FL MPS Reports LH General Table Vie ch al I Figure 17 1 2 Transfer to MS Word Button DOCNUMBER 066 April 14 2005 Issue 2 Page 273 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Transfer to MS Excel When this button is clicked the Save As popup window is displayed If the user enters a file name and click OK BatchMaster Enterprise generates an Excel file containing the information that was present in the grid ER BatchMaster Manufacturing D
300. l 14 2005 Issue 2 Page 90 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Multiples of EOQ For the rows that have their boxes checked clicking on this button converts the value in the Plan Quantity field to an integral multiple of the Economic Order Quantity of that item The value of EOQ defined at item location is overridden by the value established at the Maintain MPS Item or Pull MPS Item screens 14 6 2 Working with Demand Fence 1 MPS Purchase Order 1 Select a MPS purchase order record on this screen 2 Change the status for the MPS purchase order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the confirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MPS purchase order as needed 6 Club the orders if so desired 7 For Exception Orders club certain lines together and convert the added quantity of these lines to an integral mutiple of EOQ if so desired 8 Save the Demand Fence 1 MPS Purchase Order record DOCNUMBER 066 April 14 2005 Issue 2 Page91 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 6 3 Sp
301. l be allocated 9 Click on the Warehouse Transfers button to create a Warehouse Transfer order for the selected MPS Orders instead of transferring them to a Batch 10 Club order lines if so desired 11 Click on the Transfer to Batch button to transfer the selected production orders to batch If any batches are created via Finished Good type BOMs the batches will be of Mix or Fill type depending on the setting of the field Top Level Finished Good Batch to be created as on the MPS Setup screen DOCNUMBER 066 April 14 2005 Issue 2 Page85 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 5 3 Special Functions Transfer to Batch Clicking this button transfers the planned production orders to Production Batches BatchMaster Enterprise generates a crystal report giving details of the production batch generated The Production Batch details for the item include the following 1 Processing Date 2 Processing Time 3 Batch Type 4 Formula Id 5 Process Cell 6 Batch Number 7 Item Key 8 Location 9 UOM 10 Order Quantity ER BatchMaster Manufacturing Transfer MPS Production Order E File Edit Yiew Help Module Special Functions Wind BE alzlel A 4 gt ri Costing Utiities H 0 Costing Reports Routing Reports 1 Production Production Utilitie 1 _ Production Repor H E MPS m Select MPS peg Transfer to MPS Item e Batch But
302. lable MPS item key via the lookup From Location This Location key specifies the lower limit of the range of locations for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available location via the lookup To Location This Location key specifies the upper limit of the range of locations for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available location via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page 59 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Select Date Range for Demand Consolidation Demand Start Date This is the Demand Start Date which is the server date and is defaulted by the system when Run MPS is processed This is a read only field Demand End Date This field specifies the upper end of the Demand Date This field is defaulted to a date that is one month ahead of the server date The value in this field may be modified using the drop down menu present in the field MPS Run Date This is the MPS Run Date which is the server date and is defaulted by the system when Run MPS is processed This is a read only field Skip Low Level Coding Leave this box
303. lanned date of the combined lines Multiples of EOQ For the rows that have their boxes checked clicking on this button converts the value in the Plan Quantity field to an integral multiple of the Economic Order Quantity of that item 15 2 2 Working with Demand Fence 1 MRP Purchase Order 1 Select a MRP purchase order record on this screen 2 Change the status for the MRP purchase order The status can be set to one of Exception Firm Planned or Confirmed The status of an order can also be changed by checking the box on the line and then clicking the respective status button below the grid 3 For Exception Orders modify the confirmation start date as needed 4 For Exception Orders modify the confirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MRP purchase order as needed 6 For Exception Orders club order lines together by clicking on the Club Orders button if so desired 7 For Exception Orders club certain lines together and convert the added quantity of these lines to an integral multiple of EOQ if so desired 8 Save the Demand 1 MRP Purchase Order record DOCNUMBER 066 April 14 2005 Issue 2 Page 124 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 2 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item
304. lanning Calendar created via the Planning Calendar screen using the lookup button next to this field 4 Select a Forecast Type If the Amount option is selected then the field Cost Method becomes enabled 5 Ifthe option selected at the Forecast Type field is Amount then select a Cost Method as one of Base Standard Average or Last 6 Enter a Forecast Start Date 7 Click on the Add Line button to insert a new line into the grid 8 Enter a Forecast Key 9 Select a location for the selected item from the lookup in this field 10 Select a status as one of Active Inactive or Hidden 11 Enter forecast values in the grid 12 Click on the Save button on the toolbar to save the forecast DOCNUMBER 066 April 14 2005 Issue 2 Page 52 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 1 4 Special Functions Insert Forecast This button pops up a window that enables the user to insert a forecast with the same forecast quantity amount for all periods TE BatchMaster Manufacturing Forecast Entry J la x E File Edit View Help Module Special Functions Winge lej x BatchMaster Manufacturing IY Manufacturing H 0 Formula SL Formula Utilities KL Routing Si Formula Reports KL Bill Of Materials Ki Costing Si Costing Utilities Costing Reports HC Routing Rep
305. ld not be prepared based on the sodium metal and chlorine gas since the properties of NaCl are very different from each of the ingredients In such a case a separate output formula for NaCl should be created and attached here For MSDS purposes this formula may list NaCl itself as an ingredient MSDS Supplementary File This is the default MSDS Template associated with this Formula The boilerplates defined in this supplementary file attached to the formula are printed on the MSDS when applicable HMIS Health HMIS stands for Hazardous Material Identification System This is the HMIS Health Rating for this formula This displays a HMIS Health Rating as one of 0 None 1 Mild Moderate 3Serious or 4 Extreme This value is used in the MSDS module HMIS Chronic Factor This is the HMIS Chronic Indicator for the formula This value is used in the MSDS module HMIS Flammability This is the HMIS Flammability Rating for the formula This field can have a value of 0 None 1 Mild 2 Moderate or 3 Serious This value is used in the MSDS module HMIS Reactivity This is the HMIS Reactivity Rating for the formula This field can have its value as 0 None 1 Mild 2 Moderate or 3 Serious This value is used in the MSDS module DOCNUMBER 066 Issue 2 April 14 2005 Page 246 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing HMIS Personal Protection This is the HMIS Personal Protection Rating for the fo
306. ld stores the status of a boilerplate The status of a boilerplate can be one of Active Inactive Marked for Deletion or Deleted The default value of this field is set to Active Only Active boilerplates can be printed on a MSDS Boilerplate Text This is the text associated with this boilerplate 21 2 3 Creating a Boilerplate 1 Click the Insert button DOCNUMBER 066 April 14 2005 Issue 2 Page 185 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 2 Enter the Group Name the Boilerplate ID and the Language 3 Select the Status 4 Enter the Boilerplate Text 5 Click on the Save button to save the Boilerplate 21 3 Boilerplate Override This screen provides the users with a way to replace a set of two boilerplates having conflicting or duplicate information with one boilerplate This information is used by BatchMaster Enterprise during generation of a MSDS that contains two boilerplates with contradictory or duplicate information 21 3 1 Mandatory Inputs At least two boilerplates should be created 21 3 2 Screen Fields Descriptions ER BatchMaster Manufacturing Boilerplate Override i i E la sl E File Edit View Help Module Special Functions Windows lej xj oela axel aaa Ell r Conflicting Boilerplates t _ MAP Reports Group Name ag iesse and Odor OO Process Cell Mode alse SC DC Masters Boilerplate ID
307. lds 6 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the tooloar and then click on the Save button on the toolbar to save the report parameters 7 Click on the Process button on the toolbar to create a report 13 5 Production History Detail Report The Production History Detail Report screen provides a way to generate a report showing detailed information about a batch In addition to containing summary information about a batch generated reports contain detailed information about all the items contained within a batch This information includes item location quantity specifics cost specifics and cost variances One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 5 1 Generating a Production History Detail Report 1 Complete the Batch From and To range using the lookup buttons next to the fields 2 Select the Status as required 3 Check on the boxes to the left of the Print QC Info Print Lot Details Print Byproduct Info Print Finished Good Info and Print Formula Lines to enable these features as needed 4 Select Completion Date From and To range using the drop down arrows respectively DOCNUMBER 066 April 14 2005 Issue 2 Page 39 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Gu
308. le Basis its oe Res Schedule Type Production Formula S QC Reports r Selection Criterion MSDS Batch No From 000000000000000 Al O Boilerplate Gro D Boilerplate Mai Batch No To oo0000000001 14B Al k Boilerplate Ove L Supplementary Formula Key From foo AN ID CAS Number h fe TRY DO Formula Key To A O Hazard Print R UN Hazard Print C Customer Key From Bar MART Al C Material Safety Customer Key To HOMECURRENCY a y ID SARA Process EE Batch Status All e O Print MSDS ID Customer Histe D Update Custor Di MSDS Setup SL BOM Utilities H MSDS Reports H Laboratory H Laboratory Utilities CG LIT 1 aharatani Renen Zl al f gt Figure14 11 4 MSDS Schedule Generation Production Formula Schedule Type Production Formula This setting is used to generate a schedule to print the MSDS of a Production Formula the actual formula used in a Batch The data required to generate a schedule of Production Formula type is fetched from the Production batches that have not yet been purged and the Formula Entry screen Batch No From This Batch number specifies the lower limit of the range of batch numbers for use as filter criteria during processing This Batch number may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available batch number via the lookup Batch No To This Batch number specifies the lower limit of the range of batch numbe
309. lect a MPS Item at the From MPS Item field using the lookup button at this field 2 Select a MPS Item at the To MPS Item field using the lookup button at this field 3 Select a location at the From Location field using the lookup button at this field 4 Select a location at the To Location field using the lookup button at this field 5 Enter the Demand End Date The Server Date is automatically taken as Demand Start Date 6 If one wishes to skip the low level coding the box for Skip low level coding should be checked The user should be very sure before skipping low level coding If the low level codes are wrong then the MPS planning could be incorrect 7 Select a Generate Planned Orders as option from the following Any planned orders when they are generated via Run MPS will automatically get converted to the selected status a Planned b Firm Planned c Confirmed 8 Click on the Process button on the toolbar 14 3 MPS Planning Worksheet From the MPS Planning Worksheet one can see the summary as well as details of the demand and orders the forecast details warehouse transfers and customer orders The user can also manage 1 Planned MPS Purchase Orders 2 Planned MPS Production Orders 14 3 1 Mandatory Inputs Run MPS should have been processed for an Item Location DOCNUMBER 066 April 14 2005 Issue 2 Page 62 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s
310. les Order No From 00000001 A oilerplate Gro D Boilerplate Mai Sales Order No To EEN Al L Boilerplate Ove D Supplementar Customer Key From FOREIGN Al CASN h Q RRA h Customer Key To HOMECURRENCY O Hazard Print R O Hazard Print C Order Date From l 17 07 04 Q eee Order Date To hraa o racess DN MSDS Master O IN Print MSDS O Customer Histe L Update Custor Di MSDS Setup 1 BOM Utilities C MSDS Reports Laboratory 1 Laboratory Utilities I m lt r bad 3 0 0 0 al Figure 14 11 7 MSDS Schedule Generation BatchMaster Order History Schedule Type BatchMaster Order History This setting is used to generate a schedule to print the MSDS of line items on a Sales Order The data required to generate a schedule of BatchMaster Order History type is fetched from the Sales Order Entry screen and the Material Safety Information screen Sales Order No From This Sales Order number specifies the lower limit of the range of sales orders for use as filter criteria during processing This Sales Order number may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available sales order via the lookup Sales Order No To This Sales Order number specifies the upper limit of the range of sales orders for use as filter criteria during processing This Sales Order number may be entered by typing or selected via the associated l
311. lookup button at this field Leaving this field blank has the same effect as selecting the first available sales order via the lookup Select a Sales Order at the To field using the lookup button d this field Leaving this field blank has the same effect as selecting the last available sales order via the lookup Click on the Process button on the toolbar to fetch the Sales Orders for the specified range If one wishes that the batches for the intermediates of the selected line item should also be created then check the Transfer to Super Batch box a H one wishes that the intermediates related to the Super Batch are taken from the available inventory check the Fill from Inventory box If the Available Quantity of an intermediate suffices the required quantity then a Sub batch is not created for this intermediate If the Available Quantity of an intermediate is less than the required quantity then a Sub batch is created for the remaining quantity For this purpose the Available Quantity is equal to On Hand Quantity plus On Order Quantity in Production minus Committed to Production If this box is not checked the Fill From Inventory option is turned off In such a case the available quantities of any related intermediates are ignored when the super batch is created If one wishes to allocate the raw materials for the line items of the sales orders being transferred check the Allocate box
312. lue is entered automatically when the associated overhead key is entered This is a read only field Maxwt Variable Costs This is the value d the Max Weight for this row of the variable costs for the formula The variable labor cost is dependent on two factors the total batch weight and the applicable labor rate for that batch weight The variable labor is defined for a particular slab of batch weight The Max Weight DOCNUMBER 066 April 14 2005 Issue 2 Page 244 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing is the upper limit of the weight slab to which a particular row of the variable costs is applicable The lower limit of batch weight for a slab is determined based on the max weight of the preceding row For example the Max weight for the first row is 100 and the max weight of the second row is 500 In such a case the variable cost will be according to the first row if 0 lt Batch Weight 100 whereas the variable cost will be according to the second row if 100 lt Batch Weight 500 The actual variable cost in production is determined by adding together the following 1 Batch weight in system weight unit multiplied by the Amount of the Labor Key of the applicable row 2 If the overhead key is type then the Batch weight in system weight unit multiplied by the Factor of the Overhead Key of the applicable row 3 If the Overhead Key is type then th
313. m and To range using the lookup buttons next to the fields 2 Select the Status as required 3 Check on the boxes to the left of the Include Boilerplates Include Literal Text Include Labor Line Print Batch Tracking Print QC Print BOM Info Print Notes Print Byproduct Info and Print Lot Details to enable these features as needed 4 Complete the Formula From and To range using the lookup buttons next to the fields 5 Select Schedule Start Date From and To range using the drop down arrows respectively 6 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 7 Click on the Process button on the toolbar to create a report 13 3 Critical Material Report The Critical Material Report screen provides a way to generate a report showing materials that are lacking in the inventory and are needed to meet production obligations One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 3 1 Generating a Critical Material Report 1 Complete the Formula From and To range using the lookup buttons next to the fields 2 Complete the Batch From and To range using the lookup buttons next to the fields 3 Select Item Type as needed 4
314. m in view of the line items tab of the Physical Property Analysis screen in a full screen pop up window Modifications to the formula as well as the physical property values can then be made from this screen Cost Method The cost method can be one of Standard Average or Last and is toggled when the Toggle Costs button is clicked on the tool bar This method is applicable to the various fields relating to material costs byproduct costs cost per system weight unit and cost per system volume unit View Mode The View Mode can be By Quantity By Weight or By Volume The view mode is toggled when the View Mode button is clicked on the tool bar The Quantity Required field on the grid is toggled accordingly Recalculate Property Clicking this button recalculates the property values These changes are reflected on Tab 4 but are not saved to the database until the user saves the changes by clicking the Save button This button is enabled by clicking on the Line Items tab Hide Physical Property Checking or un checking this box hides or displays the Physical Properties grid on Tab 4 respectively This button is enabled by clicking on the Line Items tab Hide Formula Summary Checking or un checking this box hides or displays the Formula details grid on tab 4 respectively This button is enabled by clicking on the Line Items tab 23 1 3 Screen Fields Description Tab 1 Formula Master ER BatchMaster Manufacturing Physical Property Analy
315. mbly ProcessCell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this line item WtOrVol This displays whether the capacity of the Process Cell as displayed at the ProcessCell field of this screen is measured in weight or volume This value is defaulted from the Capacity By Weight Volume field of the Process Cell Formula Capacity screen Capacity This is the capacity of the Process Cell associated with the formula of this line item This value is defaulted from the Capacity field of the Process Cell Formula Capacity screen If a Process cell is not associated with this formula then this field gets defaulted with 999 999 9999 CapacityUOM This field is currently not being used Intd Item This is the Item Key associated with this line item This field gets populated only when the BOM of this line item is Assembly type Intd Locn This is the location associated with this line item This field gets populated only when the BOM of this line item is Assembly type Conf Start Dt This is the start date of the batch to be created for this line item This date is smaller than the Conf End Dt by the lead time days of the process cell associated with the formula being used for this line item Conf End Dt This is the end date of the batch to be created for this line item This date is defaulte
316. ment was checked 21 14 Customer History This screen provides users with a way to maintain records about the dates on which MSDSs were printed for specific items for specific customers One can also view and modify on this screen the records created via the Update Customer History screen DOCNUMBER 066 April 14 2005 Issue 2 Page 227 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 14 1 Screen Fields Descriptions ER BatchMaster Manufacturing Customer History lej sl aa File Edit Me Help Module Special Functions Windows x Co coe ta alzls lt gt if ole Ae Customer History Information s QC Masters a I Customer BARMART SL Process Cell Repo a A KL DC Reports Bargain Mart Stores Inc GH MSDS O Boilerplate Gro ltem Clap D Boilerplate Mai ltem For Production level 3 OD Boilerplate Owe DN Supplementar MSDS Ship Date 17 07 04 bal ID CAS Number h ID Hazard Type kh ID Hazard Print A CY Hazard Print C ID Material Safet IN SARA Process O MSDS Master In MSDS Sched Dn Print MSDS GB L Update Custor O MSDS Setup 1 BOM Utilities C MSDS Reports 1 Laboratory Laboratory Utilities 11 ahar ememr SE EE DEE EE Figure 14 13 Customer History Customer This field stores a Customer s key when a new record is inserted using the Customer History screen A Customer key can be entered by typing or
317. mpany Calen 5 Planning Caler C MPS Setup O Pull MPS Items k _ MRP 1 MRP Reports 1 Process Cell Modul C QC Masters 1 Process Cell Repor C QC Reports CJ MSDS 1 RAM I Militias Sai Figure 10 15 MPS Order Range Processing Screen Plan Start Date 01 07 04 Mi Plan End Date 24 07 04 Mi Change Status From EXCEPTION o Spe ES Item Key From The lookup at this field displays those MPS items for which there exists at least one Purchase Order or Production Order This specifies the lower limit of the range of MPS items for which the order status needs to be changed Leaving this field blank has the same effect as selecting the first available item via the lookup Item Key To The lookup at this field displays those MPS items for which there exists at least one Purchase Order or Production Order This specifies the upper limit of the range of MPS items for which the order status needs to be changed Leaving this field blank has the same effect as selecting the last available item via the lookup Location From This specifies the lower limit of the range of locations Leaving this field blank has the same effect as selecting the first available location via the lookup Location To This specifies the upper limit of the range of locations Leaving this field blank has the same effect as selecting the last available location via the lookup Plan Start Date This
318. mula Class T Jup ID Hazard Type h Se eer A ID Hazard Print A O Hazard Print C Formula Status From fa Al DN Material Safety Formula Status To fu BS ID SARA Process al D MSDS Master Formula Description EH 0 11505 Sched C Print MSDS C Customer Histe O Update Custor O MSDS Setup H BOM Utilities SL MSDS Reports Si Laboratory SL Laboratory Utilities D 1 abo wm gt Figure 14 11 1 MSDS Schedule Generation Master Formula Option Schedule Type Master Formula This setting is used to generate a schedule to print the MSDS of a Formula The data required including Safety Information to generate a schedule of Master Formula type is fetched from the Formula Entry screen Formula Key From This Formula key specifies the lower limit of the range of formula keys for use as filter criteria during processing This Formula key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available formula key via the lookup Formula Key To This Formula key specifies the upper limit of the range of formula keys for use as filter criteria during processing This Formula key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available formula key via the lookup Formula Class From This Formula Class specifies the lower limit of the range of formula classes
319. n be useful when one wants to have an overview of the production activity associated with a specific super batch or a range of super batches It is particularly helpful in those instances where the sub batches in a super batch are at different stages in the manufacturing flow Each report produced by Super Batch Ticket Report contains the following information Super Batch Number Low Level Code Batch Number Execution Sequence Order Status Start Date End Date 13 8 1 Generating a Super Batch Ticket Report 1 Complete the Super Batch No From and To range using the lookup buttons next to the fields NOP ON gt 2 Check on the boxes to the left of the Include Boilerplates Include Literal Text Print Batch Tracking Print QC Print BOM Info Print Notes Print Byproduct Info and Print Lot Details to enable these fatures as needed 3 Select the Status as required 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 13 9 SuperBatchwise Lot Details Report The Super Batchwise Lot Details Report provides the means to produce reports on the critical details for lots associated with each super batch and its component sub batches One can create a report for a single super batch and its components or a ran
320. nd MRP item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MRP Purchase Order option One can also establish the confirmation dates If a user has access to the Demand Fence 2 MRP Purchase Order option that user may not have access to the Demand Fence 1 MRP Purchase Order option which typically has more order confirmation authority This screen does not display those orders that are displayed on the Demand Fence 1 MRP Purchase Order 15 3 1 Screen Fields Description ER BatchMaster Manufacturing Demand Fence 2 MRP Purchase Order i E EI x Ga File Edit View Help Module Special Functions Windows 2 xj d alx alal zlgl el IESSE a Item Key WUTERMATE A Item For Production level 2 O Demand Fe oeren faoc T FGLOC O Demand Fe 4 Demand Fe E RM O Demand Fe D Maintain MF D Comparyc MAP Plan run Dt Order Status Plan Start Dt Plan End Dt Confim End DO Planning Ce UL UK 4 EXCEPTION 04 02 08 04 02 08 04 02 08 04 00 i ID MPS Setup O Pull MPS Ite DO MPS Order 3 MRP D Run MRP O Demand Fe k O Demand Fe O Demand Fe D MRP Order O Planned MF O Planned MF O Transfer MF C Transfer MF C MRP Reports Select All UnSelect al Delete Line Exception Firm Planned Confirmed Club Orders 1 Process Cell Mc 1 DC Masters D D Figure 11 3 1 Demand Fence
321. nd fences without using a date less than the Server date then the orders created are Planned Orders The planned orders so created can automatically get changed to firm planned orders or confirmed orders depending on the option selected at the Run MPS screen If the orders are created inside the demand fences without using a date less than the Server date then the orders created are exception orders Run MPS cannot make plamed orders for items that are needed on the Server date or earlier For example if a Sales Order has a line item with the ReqDate as the Server date then the demand arising from that line item cannot be used for generating planned MPS orders In such cases exception orders are generated 14 2 1 Mandatory Inputs Data should have been maintained at the following screens before running MPS 1 MPS Setup 2 Maintain MPS Item 3 Company Calendar Setup 4 Planning Calendar DOCNUMBER 066 April 14 2005 Issue 2 Page 58 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 2 2 Screen Fields Description ER BatchMaster Manufacturing Run MPS E lj x E File Edit Yiew Help Module Special Functions Windows l x HAE alzlel vill lgl D MPS Planr D Transfer M D Transfer M ID Demand Fi D Demand Fi O Demand Fi rm Select Item Range for MPS Run From MPS Item i A ToMPS len ASSEMBLY_1 aifssembly One From Location ot af GLOC To Location INLOC al NLOC
322. ned above Plan Qty This is set to the sum of the Plan Qty s of the clubbed rows Confirm Start Dt This is set to the Confirm Start Dt of the row picked as explained above Confirm End Dt This is set to the Confirm End Dt of the row picked as explained above Confirm Qty This is set to the sum of the Confirm Qty s of the clubbed rows Confirm Dt This is set to the Confirm Dt of the row picked as explained above DOCNUMBER 066 April 14 2005 Issue 2 Page73 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Vendor This is set to the Vendor of the row picked as explained above 14 3 8 Using the Planning Worksheet 1 Click on the lookup button on the toolbar to select an MPS Item 2 Click on Tab 1 All the fields on this tab are read only This tab displays for various periods information related to supply demand and orders such as Forecast Customer Orders Warehouse Transfers Out Gross Demand Dependent Demand Projected Available Balance Planned Orders Firm Planned Orders Confirmed Orders Total Order Release MPS Production Orders Purchase Orders Warehouse Transfers In ATP Cumulative ATP Exception Orders ppergraTrre e poop 3 Click on Tab 2 This Tab displays the demand generated from forecasting 4 Click on Tab 3 This Tab displays the sales orders which have contributed to the generation of demand 5 Click on Tab 4 This Tab displays the d
323. ng screen enables the user to change the status of batches in a range in one go 12 3 1 Mandatory Inputs Batches should have been created 12 3 2 Screen Field Descriptions ER BatchMaster Manufacturing Batch Range Processing A E la x E File Edit View Help Module Special Functions Windows l x AASE alzle KKALI lgl s 1 Formula Reports lt 1 Bill Of Materials Allocate S 1 Costing Set Fom fese AN i Batch No Ae to een Production WM Auto Lot Assign 3 Production Utilities ID Generate Sch D Transfer SO T B L Create Batche GB Purge Batches OD Purge Super B 1 Production Report C MPS C MRP 1 MRP Reports 1 Process Cell Mode C QC Masters Process Cell Repo C QC Reports C1 MSDS C BOM Utilities a g cl i i L D ERI I EE E EE E E EE E E EE EEN al Figure 9 3 1 Batch Range Processing Screen Batch Status This is the status that needs to be applied to the statuses of the selected batches Batch No From This is the batch that specifies the lower limit of the selected range of batches whose status can be changed to the status selected at the Batch Status field Batch No To This is the batch that specifies the upper limit of the selected range of batches whose status can be changed to the status sel
324. ng a MPS Supply Report 1 Complete the MPS Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 26 5 MPS Expedite PO Report The MPS Expedite PO Report screen provides a way to generate a report that displays suggested changes if any in the following to meet requirements of that item as per the latest processing on the Run MPS screen 1 Requested delivery dates of line items on existing purchase orders 2 Expected receipt date for warehouse transfers coming in 3 Due dates of existing production batches The report may suggest expediting delaying or canceling existing orders The user can specify to view these recommendations selectively by checking the appropriate boxes on the report screen This report also shows the suggested MPS orders with dates in view of the expedite delay cancel suggestions to meet the demand of that item The option se filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export DOCNUMBER 066 Apr
325. ng a MSDS the Supplementary Files of Template type Ignore Material Hazard Supplementary File This field stores whether to ignore while printing a MSDS the Supplementary Files of Material Hazard type Ignore Formula Class Supplementary File This field stores whether to ignore while printing a MSDS the Supplementary Files of Formula Classes type DOCNUMBER 066 April 14 2005 Issue 2 Page231 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Emergency Phone This field stores the Emergency Telephone Number to be printed on a MSDS Last Schedule ID This field stores the last Schedule ID generated at the MSDS Schedule Generation screen This is a read only field Tab 2 Material Safety Defaults If there are no filled lines on this grid Material Safety Information can be created for all items in inventory If there are any filled lines on this grid the Material Safety Information can be created for only those items that belong to the Item Types and Item Sub Types listed on this grid ER BatchMaster Manufacturing MSDS Setup E KE la x E File Edit View Help Module Special Functions Windows l x lei alzle NIAIKINL L Print MSDS Defauts 2 Material Safety Defaults QC Masters Process Cell Repo QC Reports Sy MSDS O Boilerplate Gro SS Add Line L Boilerplate Mai Delete Line O Boilerplate Ove OD Supplementar In CAS Number h O Hazard Type
326. ng a complete range of information about the formula including the line items which are its ingredients and the quality control information associated with its production DOCNUMBER 066 April 14 2005 Issue 2 Page 266 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 25 3 1 Generating a Physical Property Analysis Report 1 Complete the Formula Key From and To range using the lookup buttons next to the fields 2 Complete the Formula Class From and To range using the lookup buttons next to the fields 3 Complete the Formula Status From and To range using the lookup buttons next to the fields 4 Click on the Use Preprinted Stationary box to enable this feature 5 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 6 Click on the Process button on the toolbar to create a report 25 4Physical Property Search Report The Physical Property Search Report screen provides a way to generate a report showing the formula physical properties With Physical Property Search one can print out the physical properties associated with formul
327. ng this button deletes the selected line s from the Material Hazard grid DOCNUMBER 066 April 14 2005 Issue 2 Page 204 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Tab 3 Safety Info continued ER BatchMaster Manufacturing Material Safety Information K EI x Ga File Edit View Help Module Special Functions Windows lej xj Dlelgzl axel all lel m Material Safety Information O Production Report IECH Qes Item For Production level 2 s MPS C MAP f 1 General Intomatin 2Safetvinto 1 3SafetyInfocontinued S0EL_ SL MRP Reports SL Pescot IT Fire Hazard IT Pure H QC Masters e Process Cell Repo IV Sudden Release of Pressure Hazard IV Mixture z QC Reports IV Reactivity Hazard J Solid ates MSDS JV Immediate Health Hazard Acute IV Liquid TD Boilerplate Gro Dn Boil lerplate Mai IV Delayed Health Hazard Chronic TI Gas D Boilerplate Ove SARA Information Delayed Health Hazard Chronic Details Kam Lacan ID CAS Number h moe JA 7 4 O Hazard Type h i Add Line ID Hazard Print A ID Hazard Print C Delete Line BESSER ID SARA Process IN MSDS Master IN MSDS Sched In Print MSDS ID Customer Histe TD Update Custor TS MONS Gehin d al I D Figure 14 8 3 Material Safety Information Safety Info Continued Tab Fire Hazard Check this box if this mat
328. nly when the Allocate box is checked If this box is checked then the assignment of lots is done automatically If this box is not checked then the lots will not be assigned only the quantity will be allocated Create Purchase Req If this box is checked a purchase requisition is created for those raw materials whose quantity fall short of the quantity required for the production of this batch Select in Range Using this button the user may select an option for manual or automatic generation of batch number for the highlighted line items For transferring these highlighted line items into one batch the following must be true 1 A released BOM must exist for each of these line items 2 All these line items must use the same formula SO No This is the Sales Order number associated with the highlighted row Row No This is the line number associated with this line item on the sales order Item Key This is the item key associated with this line item of the sales order Location This is the location associated with this line item Item Location of the sales order Req Date This is the requested date of delivery associated with this line item This date is defaulted from the ReqDate field at the Tab 4 of the Sales Order Entry screen UOM This is the unit of measurement for this line item This UOM is defaulted from the SO Unit field of the Sales Order Entry screen Req Qty This is the Order quantity of
329. nned MRP Production Order zl Ge File Edit Yiew Help Module Special Functions Windows oleae Alx es wll aigle HO Routing ltem Key ALTERNATE_A Item For Production level 2 1 _ Formula Reports Location Fao Pn H Bill Of Materials Unit e Se Gate Unit E RM _ Costing Utiities HA Costing Reports O Routing Reports 3 Production Si Production Utilities H 1 Production Reports H O MPS H E MRP 4 Run MRP O Demand Fence 1 MRF O Demand Fence 2 MRF D Demand Fence 1 MRF O Demand Fence 2 MRF D MRP Order Range Pro D Planned MRP Purchas D Transfer MRP Purchas D Transfer MRP Product MRP Reports W D C Process Cell Module Figure 11 8 1 Planned MRP Production Order Screen MAP Plan run Dt_ Order Status Plan Start Dt Plan End Dt Plan ty_ Confimm Start Confirm End Cor 102 29 07 04 IPM PLANI 10 08 04 12 08 04 10 08 04 12 08 04 HH ma 29 07 04 CONFIRMEL 11 08 04 13 08 04 11 08 04 13 08 04 29 07 04 CONFIRMEC 11 08 04 13 08 04 50 0000 11 08 04 13 08 04 07 D4 1 29 07 04 PLANNED j4 50 0000 Select All UnSelect Al Delete Line Planned Firm Planned Confirmed Club Orders H AP Masters Item Key This the Item Key associated with the Item Location for which the Planned MRP Production Order is displayed DOCNUMBER 066 April 14 2005 Issue 2 Page 143 of 274 BatchMaster Software BatchM
330. nufacturing View Mode Clicking this button toggles the View Mode between By Quantity By Weight and By Volume The Quantity Required field on the grid is toggled accordingly ER BatchMaster Manufacturing Physical Property Analysis i E la x Ga File Edit View Help Module Special Functions Windows lej xj pelala axel ael El GEG EG EUT EOT Formula _ Routing Reports Formula Key Quality Control Enlarge View i a CTANDAR SE Description View Mode D CostMethod STANDARD SL Production Utilities El ITNA 7 Production Report Button ay oa SL MPS SL MRP SL MRP Reports Process Cell Modt SCH a G PURCHASE Item Fo _ QC Masters Material AP_FIFO_PURCHASE _ Item Fo SL Process Cell Repe Material AP_STD_PURCHASE Item Fo a QC Reports a Labor AP_LABOR_10 Wi Nothing SL MSDS H 0 BOM Utilities SL MSDS Reports CH Laboratory O O Physical Prope b Comparative F D Laboratory Sel Nene e DN Physical Prope Ge Delete Line Total Weight GRM 36 0000 Laboratory Utilities 5 Total Volume CC 18 5607 d KSE Create ae Insert Line GRM CC 1 9396 H C MPS Report Color if Physical Cost GRM 22 038537 1 Gr Property Value not Cost CC 42 745446 _ General Table Vie between Min and Total RM Cost 793 39 SG Maximum Value
331. o be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 16 2 MRP Supply Report The report includes the supply for the various items for which MRP was last run The supply sources listed are 1 Scheduled Receipts from batches in Production 2 Scheduled Receipts from existing Purchase Orders 3 Scheduled Receipts from Warehouse Transfers coming in 4 All MPS orders of planned firm planned and confirmed type generated via the latest processing on the Run MRP screen This excludes any firm planned or confirmed MRP orders that existed before the latest Run MRP was processed The report also lists the On Hand Quantity minus the Safety Stock The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 16 2 1 Generating a MRP Supply Report 1 Complete the MRP Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report
332. o calculate the costs associated with production of the end item produced by the formula Labor Key Fixed Costs This is the Labor Key of the fixed costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Amount Fixed Costs This is the amount for formula labor additional key of the fixed costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Overhead Key Fixed Costs This is the Overhead Key of the fixed costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Type Fixed Costs The Overhead Key type can be one of the following DOCNUMBER 066 Issue 2 April 14 2005 Page 243 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Type This is the Overhead Key of type for fixed costs This value is entered automatically when the associated overhead key is entered This is a read only field This value is used for cost analysis in the Costing module as well as to calculate the costs associated with production o
333. ocation Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No oe cm Op Cp 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id k Record Date se cm On pp ee DOCNUMBER 066 April 14 2005 Issue 2 Page151 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 10 Transfer MRP Production Orders The Transfer MRP Production Order screen can be used to transfer Confirmed MRP Production orders to production batches 15 10 1Screen Fields Description ER BatchMaster Manufacturing Transfer MRP Production Order 3 x a File Edit View Help Module Special Functions Windows l x HEITE alx Miall alglsle r Select MAP Item Location _ Costing a I From Item For Production level 2 Costing Utities MAP Item ALTERNATE A aac SC Costing Reports To ALTERNATE_A Dien For Production level 2 _ Routing Reports TER EI Product
334. ocation associated with this line item This field gets populated only when the BOM of this line item is Assembly type Conf Start Dt This is the start date of the batch to be created for this line item This date is defaulted from the Start Date field of the Scheduling Item screen Conf End Dt This is the end date of the batch to be created for this line item This date is defaulted from the Finish Date field of the Scheduling Item screen Item type This field is currently not in use Assembly Type This indicates the Type of the BOM associated with this line item The value here can be one of F I or A for Finished Good Intermediate or Assembly types of BOM respectively Select All Clicking this button selects all the line items displayed at the grid by checking the adjacent boxes Deselect All Clicking this button unselects all the selected line items at the grid by un checking the adjacent boxes 12 4 3 Creating Batches From Schedules 1 Select an item at the Item key From field using the lookup button at this field Leaving this field blank has the same effect as selecting the first available item via lookup 2 Select an item at the To field using the lookup button at this field Leaving this field blank has the same effect as selecting the last available item via lookup 3 Click on the Process button on the toolbar to fetch th
335. ocess Cell Scheduling is saved after changes the Scheduled Start Date of the Batch on the Batch Ticket screen is set to the Scheduled Start Date saved in this field Scheduled End Date This field displays the date on which this batch is scheduled to be closed This date can be modified while the batch has not been closed When a Process Cell Scheduling is saved after changes the Scheduled End Date of the Batch on the Batch Ticket screen is set to the Scheduled End Date saved in this field Process Cell This field displays the Process Cell associated with a batch for a line in the grid It can be modified When a Process Cell Scheduling is saved after changes the Process Cell of the Batch on the Batch Ticket screen is set to the Process Cell saved in this field Allocated Date This is the date on which the process cell is scheduled to manufacture this batch Batch Volume This field displays the Batch Volume of a batch as shown on the Batch Ticket screen Batch Weight Size This field displays the total Batch Weight of a batch as shown on the Batch Ticket screen UOM This field displays the unit associated with the quantity to be produced by a batch for a line in the grid Order Weight This field displays the total Order Weight of a batch as shown on the Batch Ticket screen Order Volume This is the total Order Volume of a batch as shown on the Batch Ticket screen Batch Time Hr For the selected date this is the number of hours
336. ocess Cell having status as Partially Closed Closed or Issued Capacity Utilization Details grid The details are displayed under this grid for the selected week Date This field displays the date for a line in the grid Day This field displays the day of a month for a line in the grid Total Capacity in hours This field displays the total capacity of a Process Cell that could be used for Production on a day for a line in the grid This information is fetched from the Process Cell screen under the Formula module Committed in hours This field displays the number of hours of the Process Cell allocated to the batches having status as New or Allocated Planned Order in hours This field displays the number of hours of the Process Cell allocated to the Planned Firm Planned and Confirmed MPS MRP Orders for a line in the grid Remaining in hours The value of this field is automatically calculated as the value of the Total Capacity field minus the value of the Committed field minus the value of the Planned Order field minus the value of the Utilized field Utilized in hours This field displays the number of hours utilized by the Process Cell associated with batches having status as Partially Closed Closed or Issued 17 1 2 Viewing the Capacity Utilization for a Process Cell 1 Enter or select a Process Cell This field is mandatory 2 Select
337. od as well the effective size of Time Fence 1 then becomes 6 days Time Fence 2 This is the number of days in the second Time Fence An Exception order is generated for all the MPS orders whose delivery date falls within this Time Fence Planning Calendar This is the default planning calendar which is established at this screen If no planning calendar is associated with the item via the forecast entry screen this planning calendar will be used as the default This is a mandatory field Gross Demand Calculation Demand Range 1 The value in this field decides how gross demand for a range will be calculated The value can be one of a Demand If this option is selected the Gross Demand will be calculated by adding up the following four types of demands DOCNUMBER 066 April 14 2005 Issue 2 Page 112 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing i Sales Orders ii Warehouse Transfers Transfer out from this Location iii MPS type raw materials remaining to be issued to production batches that are not on hold iv The quantity by which On Hand Quantity is less than the Safety Stock as defined at the Item Location This option is generally used for the shorter range planning b Forecast If this option is selected the Gross Demand will be equal to the demand generating only from the forecast entries of Active status This option is generally used for the longer range planning c
338. odes ID MSDS Master Co 5 FORMULA D lA Formula D for M DO MSDS Schedt FORMULA_E Formula E for M 0 FORMULA E Formula F for M L Customer Histe O Update Custor C MSDS Setup BOM Utilities C MSDS Reports Laboratory 1 Laboratory Utilities 1 aharatani eme z AP H Item For Produc 0000000000011 E 4 7 A 18 FORMULA G A Formula G for M g E 1 AP_Y E Item For Produc 000000000001 EE EE DEE EE Figure 14 12 Print MSDS Screen MSDS Master Format This is the MSDS Master Format key for a MS Word template file that is used to print a MSDS The Master Format key can be entered by typing or selecting it via the available lookup on the screen The Template file path associated with this MSDS Master Format key is defaulted at the Template File Path field This is a mandatory field Language This field stores the language that may be used to print a MSDS The Language can be entered by typing or selecting it via the available lookup on the screen This is a mandatory field Template File Path This is the path of the MS Word Template file The Template file path can point to either afile on the local machine or a machine on the network This is a mandatory field Skip printing of reportable components when chemical name is not maintained Checking this box will skip printing of a reportable component on the MSDS if its chemical name is not maintaine
339. oduction To 032404 bi l Production Utilities L Generate Sch Batch Status fe CLOSED v O Transfer S0 T Dn Batch Range f Cancelled on or before 09 24 04 gt O Create Batche ID Purge Batches O KL Production Report H C MPS H 0 MRP KE MRP Reports SL Process Cell Mode SL QC Masters H 1 Process Cell Repo SL QC Reports SL MSDS SL BOM Utilities H 1 MSNS Renate a al I D Figure 9 6 Purge Super Batches Screen Super Batch From This is the super batch that specifies the lower limit of the selected range of super batches that need to be purged Leaving this field blank has the same effect as selecting the first available batch via lookup Super Batch To This is the super batch that specifies the upper limit of the selected range of super batches that need to be purged Leaving this field blank has the same effect as selecting the last available batch via lookup Start Date From This is the date that specifies the lower limit of the selected range of dates The batches whose start date of production as displayed at the Batch Ticket screen falls within this range will get purged Start Date To This is the date that specifies the lower limit of the selected range of dates The batches whose start date of production as displayed at the Batch Ticket screen dates falls within this range will get purged Leaving this field blank has the same effect as selecting the server date on this field Batch Status The v
340. of Mix or Assembly If the Assembly Type of the BOM associated with this line item is Finished Good or Intermediate then the Batch created will be Mix type If it is Assembly the Batch type will be Assembly ProcessCell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this line item WtOrVol This displays whether the capacity of the Process Cell as displayed at the ProcessCell field of this screen is measured in weight or volume This value is defaulted from the Capacity By Weight Volume field of the Process Cell Formula Capacity screen Capacity This is the capacity of the Process Cell associated with the formula of this line item This value is defaulted from the Capacity field od the Process Cell Formula Capacity screen If a Process cell is not associated with this formula then this field gets defaulted with 999 999 9999 CapacityUOM This field is currently not being used DOCNUMBER 066 April 14 2005 Issue 2 Page 153 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Intd Item This is the Item Key associated with this line item This field gets populated only when the BOM of this line item is Assembly type Intd Locn This is the location associated with this line item This field gets populated only when the BOM of thi
341. oilerplate Owe L Supplementary B ID Hazard Type h In Hazard Print R D Hazard Print C E Material Safet D SARA Process O MSDS Master Dn MSDS Sched O Print MSDS ID Customer Histe D Update Custor Di MSDS Setup BOM Utilities Pa MSDS Reports Laboratory W I I ahnratan D Figure 14 5 4 CAS Number Master OEL Tab Add Line Delete Line Occupational Exposure Limits This field stores the Occupational Exposure Limit for this material A material can have multiple occupational exposure limits Add Line Clicking this button inserts a line in the OEL Details grid Delete Line Clicking this button deletes the selected line s from the OEL Details grid DOCNUMBER 066 April 14 2005 Issue 2 Page 196 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 5 2 Creating a CAS Number Master 1 Click the Insert button 2 Enter the various data on Tabs 1 4 as needed 3 Click on the Save button to save a CAS Number Master record 21 6 Hazard Type Maintenance This screen can be used to create a type of material hazard This information is used on the Safety Info tab of the CAS Number master screen and the Material Safety Information screen 21 6 1 Screen Fields Descriptions ER BatchMaster Manufacturing Hazard Type Maintenance E EI x f File Edit Yiew Help Module Special Functions Windows l x Ca cas ta axel Ml lt
342. okup Start Date From This is the date that specifies the lower limit of the selected range of dates The batches whose start date of production as displayed at the Batch Ticket screen falls within this range will get purged Start Date To This is the date that specifies the lower limit of the selected range of dates The batches whose start date of production as displayed at the Batch Ticket screen dates falls within this range will get purged Leaving this field blank has the same effect as selecting the Server Date DOCNUMBER 066 April 14 2005 Issue 2 Page 33 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Batch Status The value here can be selected as one of 1 Closed If this option is selected only those batches whose status is Closed will get purged 2 Cancelled If this option is selected only those batches whose status is Cancelled will get purged 3 All If this option is selected batches with status Closed or Cancelled will get purged Cancelled on or before This date has significance only when the option selected at the Batch Status field is Cancelled or All The batches that have been cancelled on this date or a date earlier than this date will get purged 12 5 2 Purging Batches 1 Select a batch at the Batch From field 2 Select a batch at the Batch To field 3 Select a date at the St
343. onfirmation end date as needed 5 For Exception Orders modify the confirmed quantity of the MRP purchase order as needed 6 For Exception Orders to club order lines together click on the Club Orders button 7 Save the Demand Fence 2 MRP Purchase Order record DOCNUMBER 066 April 14 2005 Issue 2 Page 128 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 3 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E x ltem Key BUTANOL Stock UOM LES Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail Location Description _ Statuscode Oty On Hand _ ty On Order E Warehouse 4 1249 9899 0 0000 0 0000 2 JMaN Main Wareho A 356 0000 0 0000 0 0000 3 _ SLECH BIEN AJ 12 101 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales Quantity Commit To Production Figure 11 3 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No SCENE 2 Lot Bin Number Details a Bin Number b
344. only field 14 12 3 Creating a Planning Calendar 1 Click on the Insert button on the toolbar to create a Planning Calendar 2 Enter a unique key at the Planning Calendar Key field to identify the Planning Calendar 3 Enter a description of the Planning Calendar 4 For Demand Range 1 a Enter a value at the Days Per Period field b Enter a value at the Number of Periods field 5 Define Demand Ranges 2 and 3 if needed 6 Click the Save button on the toolbar to save the Planning Calendar 14 13 MPS Setup This screen is used to establish the necessary setup for Run MPS as well as Run MRP With MPS Setup one can define the length of time fences how demand ranges calculate gross demand and the colors that demand ranges use in MPS graphic displays With MPS Setup one can use a pre defined planning calendar as well 14 13 1 Mandatory Inputs A Planning Calendar should have been created DOCNUMBER 066 April 14 2005 Issue 2 Page111 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 13 2 Screen Fields Description ER BatchMaster Manufacturing MPS Setup E 7 l x aa File Edit View Help Module Special Functions Windows lej x AIXE KKALI ole Si C Production a Defaults SL Production Utilities Time Fence 1 _ Production Reports Ls MPS Time Fence 2 6 O Forecast
345. ookup on this screen Leaving this field blank has the same effect as selecting the last available sales order via the lookup Customer Key From This Customer key specifies the lower limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available customer key via the lookup Customer Key To This Customer key specifies the upper limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available customer key via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page 223 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Order Date From This Order Date specifies the lower limit of the range of order dates for use as filter criteria during processing This Order Date key may be entered by typing or selected via the displayed calendar on this screen The default value of this field is the current server date Order Date To This Order Date specifies the upper limit of the range of order dates for use as filter criteria during processing This Order Date key may be entered by typing or selected via the displayed calendar on this
346. oolbar 2 Enter a QC Process ID 3 Click on the Add Line button within the upper Details frame DOCNUMBER 066 April 14 2005 Issue 2 Page 178 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 4 Select a Test ID 5 Set the Operation to Delete 6 Enter the QC type as Pass Fail value Numeric value or Alphanumeric value 7 If the QC Type is Numeric enter the Upper Lower and Normal values If the QC Type is Alphanumeric enter the Alpha Target 8 If the tests need to be deleted from a Formula select the Formula option and click on the Add Line button on the lower frame 9 If the tests need to be deleted from an Item select the Item option and click on the Add Line button on the lower frame 10 Select an Item or Formula key in the Apply QC to the following Formulas Items frame 11 Click on Save button 12 Click on Process button 19 Process Cell Reports 19 1 Capacity Utilization Report The Capacity Utilization Report generates a report showing the capacity measurements for all the process cells that are associated with one or more batches The report covers total capacity committed capacity remaining capacity and utilized capacity In addition to this the option of including a chart showing the capacity measurements is also available The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report
347. or a test of Numeric measuring type 18 3 2 Creating a QC Item Test 1 Click on the Insert button Clicking this button opens a lookup that displays all the inventory items 2 Select an item from the lookup 3 Maintain various rows on the grid as needed using the following steps 1 Click on the Add Line button to insert a line into the grid 2 Select a QC Test at the Test ID field 3 Select an option at the Measuring field 4 For each row on the grid enter the target test values as follows 1 If the test highlighted on the grid is numeric type enter the target test value at the Numeric Value field 2 If the test highlighted at the upper grid is alphanumeric type enter the target test value at the Alphanumeric Value field 3 If the test highlighted at the upper grid is numeric type enter control limits at the Lower and the Upper fields in the Control Limits frame 5 Click on the Save button on the toolbar to save the QC Item Test record 18 4 Quality Control Process This screen can be used to insert update or delete QC Test information for several Items and formulas simultaneously Records that have been processed on this screen will be available for lookup in the QC Formula Tests and QC Item Tests screens DOCNUMBER 066 April 14 2005 Issue 2 Page175 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 18 4 1 Screen Fields D
348. ort that one can print or export 19 2 1 Generating a Process Cell Schedule Report 1 Complete the Process From and To range using the lookup buttons next to the fields 2 Complete the Schedule Start and Completion Date range 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 19 3 Process Cell Master Report The Process Cell Master Report screen prints out the information maintained for the various process cells on the Process cell screen under the Formula module The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 19 3 1 Generating a Process Cell Master Report 1 Complete the Process Cell From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 20 QC Reports 20 1 QC Test Master Report The QC Test Master Report screen provides a way to generate a report showing t
349. orts L Production Ki Production Utilities C Production Reports Insert Forecast test PO Insert Forecast Forecast header Forecast Key fri r Forecast Location TURN A Insert Fill behavior Ta NE e Quantity Amount 22 0000 D Bun MPs Production History Date 99 17 04 0000 DN MPS Planning Y D Transfer MPS P Sales History Date O Transfer MPS P C Demand Fence IN Demand Fence TD Demand Fence C Demand Fence D Maintain MPS It TA Corps Palen al Figure 10 1 2 Insert Forecast Button and Window DOCNUMBER 066 April 14 2005 Issue 2 Page53 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Fill Forecast This button is used to change the quantity amount in the forecast The change can be in terms of an increase in percentage as well as value of the quantity amount This utility can also be used to replace all values in the Forecast Entry grid with a value specified in the Quantity Amount field in this window The Effective Start and End Dates can be used to define a date range in which the forecast being defined can be filled FE BatchMaster Manufacturing Forecast Entry olele Als Irvin Ose eaa BatchMaster Manufacturing ben A S _ r Fill Forecast Button E Fill Forecast Forecast Window
350. pany it may be desirable to obtain the item from that location to fulfill demand rather than creating a new purchase order Once a Warehouse Transfer has been created for such an order the same order cannot be transferred to a Purchase Order Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines 14 4 2 Transferring MPS Purchase Orders 1 Select a MPS Item at the From field using the lookup button at this field 2 Select a MPS Item at the To field using the lookup button at this field 3 Select a location at the From field using the lookup button at this field 4 Select a location at the To field using the lookup button at this field 5 Click on the Process button to fetch the Purchase Orders for the specified range Processing the range fetches those MPS Purchase Orders whose status is Confirmed 6 At the Max No of Lines in PO feld enter the maximum number of lines that can be added to one Purchase Order DOCNUMBER 066 April 14 2005 Issue 2 Page 78 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 7 Click on the Warehouse Transfer button if it is desired to create a Warehouse Transfer ord
351. pe ID at the Supplementary File screen This Hazard Type ID is connected to this Finished Good at the Material Safety Information screen Supplementary File of Template type attached to the formula at the Formula Entry screen Supplementary File of Formulas type attached to the Formula at the Supplementary File screen Production Supplementary File of Formula Classes type Formula attached to the Formula Class at the Supplementary File screen If there are any reportable components in the formula the boilerplates for the reportable components are also applicable Supplementary File of Template type attached to the item at the Item Master screen Supplementary File of Materials type attached to the Material at the Supplementary File screen Supplementary File of Materials Classes type attached to the relevant Item Class at the Supplementary File screen Production Finished Good Supplementary File of Material Hazard type attached to the Material Hazard Type ID at the Supplementary File screen This Hazard Type ID is connected to this Finished Good at the Material Safety Information screen If there are any reportable components in the formula the boilerplates for the reportable components are also applicable Supplementary File of Template type attached to the item at the Item Master screen Supplementary File of Materials type attached MSDS Customer to the Material at the Supplementary File History
352. pending on where the order was confirmed The vendor can be changed here using the lookup button in the field Plan Run Dt This is the date when the MRP order was generated The value in this field is defaulted from the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed Item Type This is the type of the item maintained at the Item Location screen Order_Status The value in this field is defaulted from the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed The status of all the orders is Confirmed for this screen Plan Start Dt This is the Plan Start Date that is recommended by the system The value in this field is defaulted from the value of the plan start date field in the Planned MRP Purchase Order screen or from the Demand fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed Plan End Dt This is the Plan End Date that is recommended by the system The value in this field is defaulted from the value of the plan end date field in the Planned MRP Purchase Order screen or from the Demand Fence 1 and 2 MRP Purchase Order screens depending on where the order was confirmed Plan Qty This is the Plan Quantity recommended by the system The value in this field is defaulted from the Planned MRP Purchase Order screen or from the Demand F
353. per Lower and Normal values If the QC Type is Alphanumeric enter the Alpha Target 8 If the tests need to be attached to a Formula select the Formula option and click on the Add Line button on the lower frame 9 If the tests need to be attached to an Item select the Item option and click on the Add Line button on the lower frame 10 Select an Item or Formula key in the Apply QC to the following Formulas Items frame 11 Click on Save 12 Click on Process 18 4 3 Updating QC Test Information for Items and Formulas 1 Click on the Insert button on the toolbar 2 Enter a QC Process ID 3 Click on the Add Line button within the upper Details frame 4 Select a Test ID 5 Set the Operation to Update 6 Enter the QC type as Pass Fail value Numeric value or Alphanumeric value 7 If the QC Type is Numeric enter the Upper Lower and Normal values If the QC Type is Alphanumeric enter the Alpha Target 8 If the tests need to be updated for a Formula select the Formula option and click on the Add Line button on the lower frame 9 If the tests need to be updated for an Item select the Item option and click on the Add Line button on the lower frame 10 Select an Item or Formula key in the Apply QC to the following Formulas Items frame 11 Click on Save button 12 Click on Process button 18 4 4 Deleting QC Test Information from Items and Formulas 1 Click on the Insert button on the t
354. plays the cost per unit volume of the by product being produced using the formula This value is calculated by dividing the Total By Product Cost by the Total Volume Total By Product Cost This field displays the sum of Ext Cost amount of Raw Materials 23 1 8 Modifying a Formula to obtain a desired Physical Property 1 Mark the materials lines of interest using the Check Uncheck button or the Check All button on the tool bar 2 Double click on the property value to be modified Change the value of the property Click outside this field The following happen automatically a The material quantities get recalculated accordingly b The various property values of the formula also get recalculated accordingly The Physical Property Adjust Equation is used when raw material quantities are changed to meet a physical property target value that has been specified The other property values are then recalculated using the Physical Property Equation 3 Edit specific material quantities as needed The formula totals and the various formula material properties get recalculated accordingly 4 If one wishes to save these changes to the Formula click the Save button 23 1 9 Creating a new Formula at the Physical Property Analysis screen This procedure is essentially similar to creating a formula at the Formula Entry screen 1 Click the Insert Button A new formula in inserted using the values of the Formula Defaults These
355. pplementary File Type Template K I SL QC Masters Supplementary File ID al Sa SL Process Cell Repo SL QC Reports MSDS Status Active D D Boilerplate Gro O Boilerplate Mai p Boilerplates D Boilerplate Ove L a ee BPID O CAS Number h D Hazard Type h O Hazard Print R O Hazard Print C O Material Safet D SARA Process IN MSDS Master O MSDS Sched O Print MSDS O Customer Histe D Update Custor C MSDS Setup 1 BOM Utilities C MSDS Reports 1 1 ahnratan Add Line Delete Line v EE EE 4 Figure 14 4 Supplementary File Screen DOCNUMBER 066 April 14 2005 Issue 2 Page 190 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Supplementary File Type This field stores the type of a supplementary file The type of a supplementary file can be one of Template Materials Material Class Formula Formula Class or Material Hazard The default value of this field is set to Template when a new supplementary file is inserted A Template can be attached to a Formula at the MSDS Supplementary File field under Tab 3 of the Formula Entry screen and to a Material at the MSDS Supplementary File field ID under Tab 4 of the Item Master screen Supplementary File ID This is the key for this supplementary file This is a mandatory field Status This is the status of a supplementary file The status of a supplementary file can be one
356. production of this batch Select in Range Using this button the user may manually specify a batch number for the batch to be created for the highlighted line items Item Key This is the item key associated with the item Location This is the location associated with the item location UOM This is the Stock Unit of Measurement for this line item as defined at the Item Master screen Req Qty This is the Order quantity of this item location This quantity is defaulted from the Order Quantity field of the Scheduling Item screen Weight This is the Order weight arrived at by converting the order quantity as defaulted from the Order Quantity field of the Scheduling Item screen fom the Stock unit of the item location to the System Weight Unit Volume This is the Order weight arrived at by converting the order quantity as defaulted from the Order Quantity field of the Scheduling Item screen from the Stock unit of the item location to the System Volume Unit FMKey This is the formula key associated with the BOM of this item location BatchNo If the user has manually entered the Batch Number using the ellipse button adjacent to this field then the Batch Number so entered gets displayed here The line items that have been assigned a common batch number are clubbed in a single batch The line items that have not been assigned any batch number are clubbed with those line items that use the same formula a
357. ption Formula A for Melnvalid record can be saved Cost Method STANDARD on the Maintain Downtime master e wt View Mode 8 Quantity 1 Costing Utilities 1 Routing Reports 1 Production bhe Se EE Q Production Utilities i E It For Prod om IC 0 2500 L e S 1 Production Report C MPS C MRP _ MRP Reports 1 Process Cell Modu C QC Masters 1 Process Cell Repo 1 OC Reports 1 4 0 0 A H P 0 A e E L P bi J P bi J m O MSDS 1 BOM Utilities i See ame yproduct Totals _ MSDS Reports Add Line Total Weight LB Laboratory Total Volume GAL Delete Line LB GAL 12 365200 D Physical Prope Cost LB SE retin Cost GAL 370 955999 C Comparative P Total Byproduct Cost 7 500000 In rm gt Figure 15 1 6 Physical Property Analysis Screen By Products Tab Item Key This displays the material key for the byproduct Text This displays the description of the Item Key field Location Key This displays the Location for Item Key Qty Produced This is the quantity of the material to be produced as a byproduct This quantity is interpreted according to the value of the Unit field Unit This field displays the unit in which the Quantity Required is expressed O H This is the Overhead Key associated with the byproduct This value is used during cost analysis of the formula on the Product Cost Analysis s
358. r fields in the Control Limits frame 5 Click on the Save button on the toolbar to save the QC Formula Test record 18 3 QC Item Tests Using the QC Item Tests screen one can associate one or more QC tests with an item These QC tests can then be applied to these items via the Quality Control Process screen The QC Item Tests screen can also be used to specify the Measuring type the target values and the control limits for each of the tests associated with an item DOCNUMBER 066 April 14 2005 Issue 2 Page173 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 18 3 1 Screen Fields Descriptions ER BatchMaster Manufacturing QC Item Tests 3 j la x A File Edit View Help Module Special Functions Windows lej xj Ca coe ta alzlel gt vif Formula Repor 1 Bill Of Material _ Costing 1 Costing Utilities 1 Costing Repor _ Routing Repor 1 Production Production Util 1 Production Re C MPS C MRP 1 MAP Reports 1 Process Cell M J QC Masters O ac Test D L GC Formul C OC item T O Quality Cor _ Process Cell R 1 QC Reports i SL MSDS SCH BOM Utilities MSDS Report SL Laboratory e Kgl peer I qaa Item For Production level 1 Add Line Delete Line D EE EE E E E E E E E E EEN
359. rchase requisitions as needed 5 Check the boxes for the lines that should be transferred to a purchase requisition 6 Click the Transfer to Purchase Requisition button on the toolbar 13 3 3 Screen Field Description in Transfer Critical Items To Purchase Requisition grid Select When this box is checked for a row that row becomes available for Transfer to Purchase Requisition Batch Number This is the number that uniquely identifies the Batch Item Key This displays the critical items associated with the end item being produced in the batch Location This is the location associated with the Item Key Qty Ord This is the quantity to be ordered for the critical Item This field is editable QtyOnHand This displays the On Hand quantity of the critical item FormulalD This is the formula with which the critical item is associated This is the formula that is to be used for producing the end item of the batch DispUOM This field displays the stock unit for the Quantity Ordered Desc1 This field stores the Description or text associated with the value of the Item Key on the same row Vendor This displays the Vendor The Vendor Key is defaulted from the Item Location screen This is a mandatory field A Branch Key of the BatchMaster Enterprise Company should have been associated with this Vendor on the Vendor Master screen Select All Clicking Select All button checks all the critical i
360. rder No This is the system generated number for the MPS order Plan Run Dt This is the date when the MPS order was generated Order Status The Order Status on this screen can be one of the following 1 Exception These orders before being transferred to Production Orders need to be Confirmed Since BatchMaster Enterprise has a regenerative MPS Exception MPS Orders get erased when Run MPS is processed or when the Replan MPS button is clicked 2 Firm Planned These orders before being transferred to Production Orders need to be Confirmed The Orders that are FIRM PLANNED will not be erased when Run MPS is processed or when the Replan MPS button is clicked 3 Confirmed The Orders that are Confirmed are ready to be transferred to Production Orders and will not be erased when Run MPS is processed or when the Replan MPS button is clicked Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan End Dt This is the Plan End Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm End Dt This da
361. rder and will not be erased when Run MPS is processed or when the Replan MPS button is clicked 4 Transferred These orders have already been transferred to a purchase order Plan Start Dt This is the Plan Start Date that is recommended by the system Plan End Dt This is the Plan End Date that is recommended by the system Plan Qty This is the Plan Quantity recommended by the system DOCNUMBER 066 April 14 2005 Issue 2 Page72 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Confirm Start Dt This date is defaulted to the Plan Start Dt when this row is created via Run MPS Fora Planned Order this date can be modified by the user Confirm End Dt This date is defaulted to the Plan End Dt when this row is created via Run MPS For a Planned Order this date can be modified by the user Confirm Qty This quantity is defaulted to the Plan Qty when this row is created via Run MPS For a Planned Order this quantity can be modified by the user Confirm Dt This is the date when the order was confirmed Transfer Dt This is the date when the order was transferred to a purchase order Vendor This is the Vendor for the purchase order If a vendor is associated with this Item Location via the Item Location screen then via Run MPS the vendor key is defaulted here from the Primary Vendor Key field of the Item Location screen This value can be modified here Select All Clicking th
362. reated using the Boilerplate Group screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 2 1 Generating a Boilerplate Group Report 1 Complete the Boilerplate Group Key From and To range using the lookup buttons next to the fields 2 Select the Status as required 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 22 3Boilerplate Maintenance Report The Boilerplate Maintenance Report screen provides a way to generate a report showing the boilerplate text created using the Boilerplate Maintenance screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 0 1 Generating a Boilerplate Maintenance Report Screen 1 Complete the Group From and To range using the lookup buttons next to the fields 2 Complete the Key From and To range using the lookup buttons next to the fields 3 Select the Status as required 4 To save these parameters enter the name to be assigned to the report paramete
363. red by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available item key via the lookup Item Key To This Hem key specifies the upper limit of the range of item keys for use as filter criteria during processing This Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available item key via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page219 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Location Key From This Location key specifies the lower limit of the range of location keys for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available location key via the lookup Location Key To This Location key specifies the upper limit of the range of location keys for use as filter criteria during processing This Location key may be entered by typing or selected wa the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available location key via the lookup Customer Key From This Customer key specifies the lower limit of the range of customer keys for use as filter criteria during processing This Customer key m
364. responding Microsoft Word Document Template file used to generate the MSDS For example if the Boilerplate Group Key is GRP1 then the corresponding bookmark would be BP_GRP1 Once such a bookmark has been inserted then the text of all those boilerplates that meet BOTH of the following criteria will be printed on the MSDS 1 The Boilerplate belongs to this group 2 The Boilerplate is listed on the applicable Supplementary File s DOCNUMBER 066 April 14 2005 Issue 2 Page 182 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 1 1 Screen Fields Descriptions ER BatchMaster Manufacturing Boilerplate Group d EI x E File Edit View Help Module Special Functions Windows l x BatchMaster Manufacturing f 8 Eapen H MRP Reports lt I 40 SL Process Cell Mod Group Name a as H A QC Masters Description fAppearanceandOdor BO Process Cell Repo QC Reports Status Active D 5 5 MSDS B OD Boilerplate Mai L Boilerplate Ove O Supplementary C CAS Number h ID Hazard Type h O Hazard Print R O Hazard Print C D Material Safety ID SARA Process Dn MSDS Master IN MSDS Schedt ID Print MSDS O Customer Histe ID Update Custor O MSDS Setup 1 BOM Utilities _ MSDS Reports 1 I aharatani z EE EE Figure 14 1 Boilerplate Group Screen Group Name This is the name or ID of the boilerplate group This is a
365. rial will burn or explode if an ignition source is available 2 Boiling Point This field stores the temperature in degrees Fahrenheit E which this material will boil at an atmospheric pressure of 760 mmHg Flash Point This field stores the temperature in degrees Fahrenheit F BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing or degrees Celsius CL at or degrees Celsius C at which this material gives off sufficient vapor to form a flammable or ignitable mixture with air Flash Pt Method Used This field stores the method that is used to determine the flash point of this material Tab 2 Safety Info ER BatchMaster Manufacturing CAS Number Master K a la x Ga File Edit Yiew Help Module Special Functions Windows lel x pelele axe vlalrlvl sl el BatchMaster Manufacturing _ Process Cell Mod I _ QC Masters 1 Process Cell Repo oO QC Reports MSDS O Boilerplate Gro O Boilerplate Mai O Boilerplate Ove OD Supplementary GB ID Hazard Type kh In Hazard Print R D Hazard Print C D Material Safet ID SARA Process IN MSDS Master O MSDS Sched Dn Print MSDS D Customer Histe O Update Custor In MSDS Setup _ BOM Utilities C MSDS Reports Laboratory 11 ahnraten I a D E DEE Figure 14 5 2 CAS Number Master Safety Info Tab HMIS Values Health This is the HMIS Health rating for this materi
366. rid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Planned If any of the rows have their boxes checked the status of such rows gets changed to Planned when this button is clicked DOCNUMBER 066 April 14 2005 Issue 2 Page70 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Firm Planned If any of the rows have their boxes checked the status of such rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of such rows gets changed to Confirmed when this button is clicked Club Orders For rows that have their Select boxes checked the orders of such rows get clubbed together Only Planned Orders can be clubbed together For clubbing rows and combining the values for all the fields of the rows being clubbed the system searches for the row that has the earliest Confirm End Dt If multiple rows have a common earliest Confirm End Dt then the system picks the row having the lowest MPS Order No amongst them When orders get clubbed the clubbed rows get replaced with a single row on which the following fields are set as follow MPS Order No This is set to the MPS Order No of the row picked as explained above Plan Start Dt This is set to the Plan Start Dt of the row picked as e
367. ril 14 2005 Issue 2 Page 65 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing While calculating the ATP if the demand exceeds supply for any period the difference is carried over to the immediately preceding period for adjusting the ATP value of the preceding period Cumulative ATP For any given period this is a cumulative sum of the ATPs starting from the first period of the planning horizon to the given period Exception Orders This field shows the quantity for which exception orders have been generated 14 3 3 Screen Field Descriptions Tab 2 Forecast ER BatchMaster Manufacturing Planning Worksheet E l x A File Edit Yiew Help Module Special Functions Windows l x i fo iS axle Kl ala SIP e 2 Manufacturing Item Key AP _FINISHED_GOOD Curr On Hand Safety Stk 227 0000 C Formula 1 Formula Utilitie C Routing Location oa C Unit jc C C Formula Repor C Bill Of Materiak IV Included in last MPS run Beplan MPS Costing 1 Costing Utilities C Costing Repor C Routing Repor C Production v 0000 27 07 04 1 Production Util 0000 28 07 04 Production Re 0000 29 07 04 t roduc 0000 30 07 04 2 MPS 0000 31 07 04 O Forecast E 0000 01 08 04 0000 02 08 04 D Run MPS 0000 03 08 04 D 0000 04 08 04 O Transfer M 0000 05 08 04 Transfer M 0000 06 08 04 R EE 0000 07 08 04 SIE 0000 08 08 04 C Demand Fi 0000 09 08 04 O Demand Fi TD
368. rint Range Maintenance E s i EI sl E File Edit View Help Module Special Functions Windows l x oeae axe a Ele m Hazard Print Range 1 Production Report C MPS Range Table ID JRT MRP Ze MPP Reports Description range table 1 Process Cell Mode 1 QC Masters m Range Details Process Cell Repo List As This Range 1 OC Reports d 0 to 10 We 10 to 20 I MSDS 20 to 30 O Boilerplate Gro 7 30 to 40 O Boilerplate Mai 40 to 50 Add Line O Boilerplate Ove El 50 to 75 CY Supplementary 75 to 100 C CAS Number h O Hazard Type bh D EE E E E EE E E Delete Line i O Hazard Print C C Material Safet IN SARA Process IN MSDS Master O MSDS Sched DN Print MSDS TD Customer Histe L Update Custor In z r pa al Figure 14 6 Hazard Print Range Maintenance Screen Range Table ID This field stores a unique identification of a Hazard Print Range Table This is a mandatory field Description This is the description associated with this Hazard Print Range Table Range Details grid For Percentage Through This specifies the percentages of a hazardous material that can be printed on a MSDS as a corresponding range If there is no preceding row in this table than the lower value of the percentage is taken as zero If there is a preceding row in this table than the lower value of the DOCNUMBE
369. rinting Physical Property Analysis of the Formula 2 Exclude formulas of certain statuses from the physical property analysis 3 Establish the default presentation of the Analysis of the Formula on Plain Paper or Pre printed Stationary format 4 Define the precision of Quantity and Property for Laboratory Reports 23 4 1 Screen Fields Descriptions ER BatchMaster Manufacturing Laboratory Setup E s laj x f File Edit View Help Module Special Functions Windows l x Clore aixe Aa Eel 1 Routing Reports 1 Production 1 Production Utilities 1 Production Report C MPS C MRP C MPP Reports Process Cell Mode _ OC Masters 1 Process Cell Repo 1 QC Reports C MSDS BOM Utilities C MSDS Reports 3 Laboratory L Physical Prope TD Physical Prope OD Comparative P G b Physical Prope Laboratory Utilities 1 Laboratory Report _ MPS Reports General Table Vie G Include Property Analysis on What Page Own Page SG Status Not Allowed in Physical Properties Analysis o A Print Property Analysis on Plain Paper BZ Quantity Precision for Laboratory Report 2 he Property Precision for Laboratory Report 2 ha m e E 4 DEE EE E E E E EE EE E 1 A A A al I D Figure 15 4 Laboratory Setup Screen DOCNUMBER 066 April 14 2005 Issue 2 Page 260 of 274 Batc
370. rmula This field can have one of the following values this value is used in the MSDS module A Safety Glasses B Safety Glasses Gloves C Safety Glasses Gloves Synthetic Apron D Face Shield Gloves Synthetic Apron E Safety Glasses Gloves Dust Respirator F Safety Glasses Gloves Synthetic Apron Dust Respirator G Safety Glasses Gloves Vapor Respirator H Splash Goggles Gloves Synthetic Apron Vapor Respirator l Safety Glasses Gloves Dust and Vapor Respirator J Splash Goggles Gloves Synthetic Apron Dust and Vapor Respirator K Airline Hood or Mask Gloves Full Protect ice Suit Boots X Situations Requiring Special Handling WHMIS Information WHMIS stands for Workplace Hazardous Material Information System This is the WHMIS information for this formula 23 1 6 Screen Fields Description Tab 4 Line Items On this tab one can view and modify the formula line item details and the Physical Property values of the formula ER BatchMaster Manufacturing Physical Property Analysis EI x Ge File Edit View Help Module Special Functions Windows la x pelma axe al ll ee EGLES CE EUT ET Formula H A Routing Formula Key g FORMULA_A Quality Control Enlarge View z 1 Formula Reports E STANDAR Pa Bil OFM P i Description Formula A for
371. roduction Re J MPS Lu ka ID Forecast E IN Run MPS L MPS Planr O Transfer M B e 99 26 07 04 EXCEPTION 01 08 04 O Demand Fi O Demand Fi ID Demand Fi Be Demand Ff ID Maintain M D Company 4 Planning C C MPS Setup 4 Pull MPS II C MPS Order CJ MRP C MRP Reports 1 Process Cell M 4 C QC Masters Select All UnSelect All Delete Line Exception Firm Planned Confirmed Club Orders 1 Process Cell A DE Bes DEE LI ps Rennrte a D Assembly One ltem Key I DI MPS Plan run Dt_ Order Status Plan Start Dt Plan End Dt Plan pp Jorge Start Confirm End Confirm aw ES 100 0000 01 08 04 01 08 04 100 0000 4 4 4 a Figure 10 9 1 Demand Fence 2 MPS Production Order Screen Item Key This is the Item Key associated with the Item Location for which the Demand Fence 2 MPS Production Order is displayed Location This is the Location Key associated with the Item for which the Demand Fence 2 MPS Production Order is displayed Unit This is the Stock UOM for the Item Key shown on this screen DOCNUMBER 066 April 14 2005 Issue 2 Page 101 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Grid Fields Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or
372. rs for use as filter criteria during processing This Batch number may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available batch number via the lookup Formula Key From This Formula actual formulations used in Batches key specifies the lower limit of the range of formula keys for use as filter criteria during processing This Formula key may be entered by DOCNUMBER 066 Issue 2 April 14 2005 Page 217 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available formula key via the lookup Formula Key To This Formula actual formulations used in Batches key specifies the upper limit of the range of formula keys for use as filter criteria during processing This Formula key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available formula key via the lookup Customer Key From This Customer key specifies the lower limit of the range of customer keys for use as filter criteria during processing This Customer key may be entered by yping or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available customer
373. rs in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters DOCNUMBER 066 April 14 2005 Issue 2 Page 233 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 5 Click on the Process button on the toolbar to create a report 22 4Boilerplate Override Report The Boilerplate Override Report screen provides a way to generate a report showing the boilerplate overrides created using the Boilerplate Override screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 4 1 Generating a Boilerplate Override Report 1 Complete the Group From and To range using the lookup buttons next to the fields 2 Complete the Key From and To range using the lookup buttons next to the fields 3 Select the Status as required 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 22 5Supplementary File Report The Supplementary File Report screen provides a way to generate a report showing the boilerplate groups and boilerplate IDs associated with templ
374. rts _ MSDS Select All Unselect i H 0 BOM Utilities 1 MSNS Reanarte d ai D Figure 9 3 2 Change Batch Status Button DOCNUMBER 066 April 14 2005 Issue 2 Page 24 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing View Item Location The user may click this button to view the inventory details for all the item locations of the selected line iew Item Location y x Wen Ken ALTERNATE_A Stock UOM GRM Description ltem For Production level 2 Display Unit GRAM 1 Location Detail 2 Lot Bin No Details FGLOC E Qty On Hand Oty On Order Commit to Sale EK 65 0000 245 0000 344 0000 Toggle UOM Quantity on Hand Quantity on Order Quantity Commit To Sales 344 0000 Quantity Commit To Production 0 0000 a a Figure 9 3 3 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User Id Record Date e em E aoe Se E EE Er ELE op DOCNUMBER 066 April 14
375. s Lu TiS rn eS ar Sat ar Era Di EE 5 MRP 24 07 04 EXCEPTION 11 07 04 11 07 04 86 4460 11 07 04 SERIATE 96 4460 O Run MRP k L Demand Fence O Demand Fence UD Demand Fence O MRP Order Rar DN Planned MRP F O Planned MRP F D Transfer MAP F D Transfer MRP F _ MAP Reports Process Cell Modul C GC Masters 4 _ Process Cell Repor LH QC Reports Select All UnSelect Al Delete Line Exception Eirm Planned Confirmed Club Orders Multiples of EOQ C MSDS 1 RNM I Ktilities ul D Figure 11 2 1 Demand Fence 1 MRP Purchase Order Screen EE E E E EE ER 3 Item Key This the Item Key associated with the Item Location for which the Demand Fence 1 MRP Purchase Order is displayed Location This the Location Key associated with the Item for which the Demand Fence 1 MRP Purchase Order is displayed Unit This is the Stock UOM for the Item Key shown on this screen Grid Fields DOCNUMBER 066 April 14 2005 Issue 2 Page 122 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Select When this box is checked for a row that row becomes available for deletion as well for changing the status of the order or clubbing it with other orders MRP Order No This is the system generated number for the MRP order Plan Run Dt This is the date when the MRP order was generated Order Status The Order Status on this screen
376. s Description 152 15 10 2 Transferring MRP Production Orders A 155 15 10 93 Sp cial tere 156 16 MRP REPORTS wecscceccccccnnnsnnnerdtcnadedigecanenncruuecuuusudecenccnatisidiece ge cenecacdusulvsvemongennastsccaibagencenndes 158 16 1 MRAP ORDER REPORT ee AER dEr 158 16 1 1 Generating a MRP Order Heport ANNE 158 16 2 MRP SUPPLY REPORT ee ENEE degen 158 16 2 1 Generating a MRP Supply Report 222 cccceeeeceeeeeeeeeeeeeeneeeecaeeeeeeeeeeesaeesesaeeeeesaaaeees 158 16 3 MRP DEMAND REPORT 02cccecccceeccececsececeeccueeccasseseesoucsossesescsseeecescueesceeseuseseseseesesaescnaes 159 16 3 1 Generating a MRP Demand Heport ceeeeeennneeeeeeeeseeaanaeeeeeteeeeaaaas 159 16 4 MRP PLANNING REPORT neeenenneeninee erne tertttttttttt ttnt rrtt ttt EEEE EEE EEEE EEEE EEEEE EEEE Eere nErenn 159 16 4 1 Generating a MRP Planning Report 22 0 ccccceeccsneeeceeeeeeeeeeeeeaeeesaaenesaeeeeesaaeeesaaees 159 16 5 MRP EXPEDITE PO HEpOpT ttrt tttrtnrtrrttr rrn EEn EEEn Erare rtnn nennen 160 16 5 1 Generating a MRP Expedite PO Henn 160 17 PROCESS CELL MODULE 22 cccccccceeeeeeeeeeeeeeeeeeeeeeeeeseeeeeneeeeeeeeeeeaeeeeeeeeeeaseeeeeseneeeeeeeees 160 17 1 GAPACITY UTILIZATION tee eege dee ESA 161 17 1 1 Screen Fields Description 161 17 1 2 Viewing the Capacity Utilization for a Process Cell 162 17 2 PROCESS CELL SCHEDULING ssssssesttiteettttttttttt ttt ttrt r rtt EEEE EEEE AENEA EEEE EEEE EEEE EEEE EEEn Eeer
377. s Guide Volume III Manufacturing Summary tab Forecast This represents the demand arising from Active forecasts for a given period The details regarding the forecast can be seen on Tab 2 of this screen Customer Orders This represents the demand arising from sales orders The related sales orders information can be seen on Tab 3 of this screen Warehouse Transfers Out This represents the demand arising from 1 Warehouse Transfers out that have been saved but not been processed 2 Inventory Moves that have been saved but not yet processed The details of the related warehouse transfers can be seen on Tab 4 of this screen Gross Demand As per the setting for the applicable Demand Range on the MPS Setup screen this field represents the gross demand determined from the Forecast Customer Orders and Warehouse Transfers Dependent Demand This represents the dependent demand arising from other planned firm planned and confirmed MPS Orders for higher level MPS items Projected Available Balance This represents the quantity that is projected to be on hand after subtracting the demand from the supply For this purpose the demand and the supply are taken as follows The sources of demand for calculating the PAB are 1 Forecast depending on the setting for the Demand Range on the MPS Setup screen 2 Sales Orders and Warehouse Transfers Out depending on the setting for the Demand Range on the MPS Setup
378. s Item key specifies the lower limit of the range of item keys for use as filter criteria during processing This Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available item key via the lookup Item Key To This Item key specifies the upper limit of the range of item keys for use as filter criteria during processing This Item key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available item key via the lookup Location Key From This Location key specifies the lower limit of the range of locations for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the first available location via the lookup Location Key To This Location key specifies the upper limit of the range of locations for use as filter criteria during processing This Location key may be entered by typing or selected via the associated lookup on this screen Leaving this field blank has the same effect as selecting the last available location via the lookup DOCNUMBER 066 April 14 2005 Issue 2 Page 208 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Period End Date This is date on which
379. s button on the toolbar to create a report 22 10 Print Mail Labels The Print Mail Labels screen provides a way to print mailing labels for customers contained on schedules With Print Mail Labels one can specify a date range for all the MSDS scheduled items and print labels addressed to the customers found in that date range One can also choose to have the label indicate that the mailed item should be brought to the attention of a specific person The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 10 1Generating Print Mail Labels 1 Complete the From and To Schedule Date range using the lookup buttons next to the fields 2 Click the box for Add Attention Person Name to enable this feature 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report 22 11 SARA Tier I II Tracking Report The SARA Tier UI Tracking Report screen provides a way to generate a report showing the SARA Tier and Tier Il information on a cumulative basis With SARA Tier UI Tracking one can view the location date entered the number of days the location held no amount of the item the
380. s created using a Finished Good type BOM via the Transfer MPS Production Order screen that batch will automatically be of Mix type Fill When a Batch is created using a Finished Good type BOM via the Transfer MPS Production Order screen that batch will automatically be of Fill type Allow transfer of intermediates of super batch The value in this field can be one of No MPS production orders or MRP production orders can not be confirmed for those items that are intermediates and whose demand arose only as a dependent demand from other MPS MRP orders This option would be useful if one transfers MPS Production Orders to a Super Batch and does not want to create separate duplicate batches for the intermediates Yes This setting does not restrict the confirmation of the MPS production orders or MRP production orders for those items that are intermediates and whose demand arose only as a dependent demand from other MPS MRP orders DOCNUMBER 066 April 14 2005 Issue 2 Page113 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Use multiple economic order quantities If this box is checked and multiple economic order quantities for an item have been defined then the economic order quantity for an item will be picked as the upper limit of the range in which the order quantity falls 14 13 3 Maintaining MPS Setup 1 Enter a numeric value at the field Time Fence 1 2 Enter a
381. s is a mandatory field Material Hazard Type ID This is the Material Hazard type for which a Hazard Section is to be printed on a MSDS The Material Hazard Type ID may be entered ly typing or selected via the associated lookup on this screen This is a mandatory field Include by Wt gt This field stores the minimum weight percent of a hazardous material in the formula to determine if the hazardous material is reportable on the MSDS Include by Vol gt This field stores the minimum volume percent of a hazardous material in the formula to determine if the hazardous material is reportable on the MSDS Include Top n Ingredients This field stores how many of the top hazardous ingredients line items of a formula should be printed on a MSDS The top ingredients are determined on the basis of weight percent or volume percent as specified at the Sort MSDS Components by Weight or Volume field of MSDS Setup screen DOCNUMBER 066 April 14 2005 Issue 2 Page 200 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing List Qty as For a reportable hazardous material one can specify the manner in which its quantity is to be reported on a MSDS This can be 1 Number In this case the weight or volume percentage is listed depending on the setting made at the Sort MSDS Components by Weight or Volume field of MSDS Setup screen This percentage is rounded according to the Round to Nearest
382. s line item is Assembly type Conf Start Dt The value in this field is defaulted from the value of the confirmed start date field in the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed Conf End Dt The value in this field is defaulted from the value of the confirmed end date field in the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed Plan Run Dt This is the date when the MRP order was generated The value in this field is defaulted from the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed ItemType This is the type of the item maintained at the Item Location screen Order_Status The value in this field is defaulted from the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirmed The status of all the orders is Confirmed for this screen Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MRP is processed The value in this field is defaulted from the value of the plan start date field in the Planned MRP Production Order screen or from the Demand Fence 1 and 2 MRP Production Order screens depending on where the order was confirm
383. s the one used by these line items BatchType This is the type of the batch It can be one of Mix or Assembly If the Assembly Type of the BOM associated with this line item is Finished Good or Intermediate then the Batch created will be Mix type If it is Assembly the Batch type will be Assembly ProcessCell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this line item WtOrVol This displays whether the capacity of the Process Cell as displayed at the ProcessCell field of this screen is measured in weight or volume This value is defaulted from the Capacity By Weight Volume field of the Process Cell Formula Capacity screen Capacity This is the capacity of the Process Cell associated with the formula of this line item This value is defaulted from the Capacity field of the Process Cell Formula Capacity screen If a Process cell is not associated with this formula then this field gets defaulted with 999 999 9999 DOCNUMBER 066 April 14 2005 Issue 2 Page 28 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing CapacityUOM This field is currently not in use Intd Item This is the Item Key associated with this line item This field gets populated only when the BOM of this line item is Assembly type Intd Locn This is the l
384. s together if so desired DOCNUMBER 066 April 14 2005 Issue 2 Page 149 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 9 Click on the Transfer PO button to transfer the selected orders to purchase orders 15 9 3 Special Functions Transfer PO Clicking this button transfers the planned purchase orders to Purchase Order BatchMaster Enterprise generates a crystal report giving details of the purchase order generated ER BatchMaster Manufacturing Transfer MRP Purchase Order Ga File Edit Yiew Help Module Special Functions Windows 7 ca Lael alzle KKA mJ oO Costing Reports _ Routing Reports Production Production Utilities r Select MAP Item Location tion level 3 MRP Item tion level 3 To Fi faoc o FGLOC 1 1 Production Reports Location rom FGLOC A se H Q MPS To Ivo eu C E MRP Max No of Lines in PO 10 000 O Run MRP ID Demand Fence 1t C Demand Fence 2t O Demand Fence 1t D Demand Fence 2t C MRP Order Range In Planned MAP Pur Paes SC ee ee EE WE AP_AVG_PURCHASE Item For Produc INLOC 10 0000 30 07 04 AP_AVG_PURCHASE Item For Produc INLOC 30 07 04 AP_AVG_PURCHASE AP_AVG_PURCHASE Item For Produc F LOC Item For Produc FGLOC Item For Produc FGLOC 200 0000 30 07 e AP_AVG_PURCHASE Item For Produc FGLOC 200 0000 30 07 04 IN Plann
385. s well as to calculate the costs associated with production of the end item produced by the formula Overhead Key Setup Costs This the Overhead Key of the setup costs for the formula This value is used during cost analysis of the formula on the Product Cost Analysis screen as well as to calculate the costs associated with production of the end item produced by the formula Type Setup Costs The Overhead Key consists of two types Type This is the Overhead Key of type for setup costs This value is entered automatically when the associated overhead key is entered This is a read only field This value is used for cost analysis in the Costing module as well as to calculate the costs associated with production of the end item produced by the formula The value of Hours on this line is multiplied by the Factor of the Overhead Key to calculate the cost contribution of this overhead Type This is the Overhead Key of type for setup costs This value is entered automatically when the associated overhead key is entered This is a read only field This value is used for cost analysis in the Costing module as well as to calculate the costs associated with production of the end item produced by the formula The value of Hours on this line multiplied by the Amount of the Labor Key is multiplied by the Factor of the Overhead Key of the same line to calculate the cost contribution of this overhead Factor Setup Costs This va
386. saaaaaeeeeeeaaaaaeeeeeeeaaaaeeeeeeeeaae ness 237 22 12 1 Generating a SARA Title Ill Tier Report ccceccccccetctttteeee ee eter eeeeeeaeeeeeeeeeeaaaaaeneee ts 237 22 13 SARA TITLE IIl TIER IW REPORT scssengectesiocisonedodanenetsstuekeseeaboncuteblonsddocanmnemncadseerdeueriebentas 237 22 13 1 Generating a SARA Title Ill Tier Il Report ZGoreen cceceeecee enn tteeeeeeeennneeeeeeeeanane teens 238 22 14 MSDS MASTER FORMAT HEROpnT ttire ttttttttrt tat tr trett ttrt ttrt t rentre renren neee 238 22 14 1 Generating a MSDS Master Format Report ZGcreen ee cenntee crete teeeenneneees 238 22 15 CUSTOMER HISTORY REPORT siwisssctsscchucsudad SEENEN EENEG ee E 238 22 15 1 Generating a Customer History Heport ee neeeeeeee cana eeeeeteeaaaneeeeeeeeaaa tees 238 23 LABORATORY otsccceccnscsescccdocdatetecotvenasasderesecesdead stezetecececaasatedetetece ducts tezetsaeceessawuadZeteaseeecenes 239 23 1 PHYSICAL PROPERTY ANALYSIS c 0sccccscecececeececee seeceececseseceeseseesecaueeses ANE 239 23 1 1 MANO ALOry INPUTS EE 240 23 1 2 Screen Fields Descriptions Header 240 23 1 3 Screen Fields Description Tab 1 Formula Master 241 23 1 4 Screen Fields Description Tab 2 tCost 243 DOCNUMBER 066 April 14 2005 Issue 2 Page 10 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 1 5 Screen Fields Description Tab 3 Safety ccccceececceteeneeeee eee ee eee teeee sana eeeeeeeenaaaneees 246
387. saved but not processed yet ATP This represents the quantity that is Available To Promise The calculation of ATP starts backwards that is from the ast period used for the MPS planning The sources of demand for calculating the ATP are a Sales Orders and Warehouse Transfers Out depending on the setting for the Demand Range on the MPS Setup screen b Dependent Demand from Planned Firm Planned and Confirmed orders of higher level MPS Items c The quantity by which On Hand Quantity is less than the Safety Stock as defined at the Item Location d Quantities of this MPS type raw material remaining to be issued to production batches that are not on hold e The quantity by which the demand exceeds the supply for the immediately following period if the demand exceeds the supply for the immediately following period Note that for calculating the ATP Forecast is not considered as demand The sources of supply for calculating the ATP are 1 Only for the first Period of planning horizon The quantity by which the On Hand quantity exceeds the Safety Stock as defined at the Item Location 2 For Z Period of the planning horizon onwards PAB of the preceding period 3 Scheduled receipts as long as their schedule receipt date is not less than the Server Date from Purchase Orders Production Orders Production Batches Warehouse Transfers In Planned Orders Firm Planned Orders Confirmed Orders S CH E DOCNUMBER 066 Ap
388. screen Supplementary File of Materials Classes type attached to the relevant Item Class at the Supplementary File screen Supplementary File of Template type PatonMaster attached to the item at the Item Master screen Order History Supplementary File of Materials type attached DOCNUMBER 066 April 14 2005 Issue 2 Page 189 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing to the Material at the Supplementary File screen Supplementary File of Materials Classes type attached to the relevant Item Class at the Supplementary File screen For a Boilerplate Group to be added to a MSDS the Boilerplate Group Key preceded with the characters BP_ should be inserted as a book mark on the corresponding Microsoft Word Document Template file used to generate the MSDS For example if the Boilerplate Group Key is GRP1 then the corresponding bookmark would be BP_GRP1 21 4 1 Mandatory Inputs Data should be setup at the following screens before creating a Supplementary File 1 Boilerplate Group 2 Boilerplate Maintenance 21 4 2 Screen Fields Descriptions ER BatchMaster Manufacturing Supplementary File _ EI x Ge File Edit View Help Module Special Functions Windows la x Cy cas lag lt gt if ole r Header Information 1 MRP Reports E Process Cell Modu Su
389. screen 3 Dependent Demand from Planned Firm Planned and Confirmed orders of higher level MPS Items 4 The quantity by which On Hand Quantity is less than the Safety Stock as defined at the Item Location 5 MPS type raw materials remaining to be issued to production batches that are not on hold The sources of supply for calculating the PAB are 1 Only for the first Period The quantity by which the On Hand quantity exceeds the Safety Stock as defined at the Item Location 2 For 2 Period onwards PAB of the preceding period 3 Scheduled Receipts from Purchase Orders Production Orders Production Batches Warehouse Transfers In Planned Orders Firm Planned Orders Confirmed Orders M9 E090 Tp Planned Orders This represents the quantity for which planned orders have been created via Run MPS or via Replan MPS The related details can be seen on Tab 5 or Tab 6 depending on whether the item is of purchase type or of manufacture type at the Maintain MPS Item screen Planned orders cannot be transferred to a purchase order or to a batch Planned orders get regenerated that is deleted and then re written via Run MPS and Replan MPS Firm Planned Orders This represents the quantity for which firm planned orders have been created The related details can be seen on Tabb or Tab 6 depending on whether the item is purchase type or manufacture type at the Maintain MPS Item screen The firm planned orders cannot be transferred to a DO
390. screen The default value of this field is the current server date 21 12 14 Generating a Schedule of BatchMaster Order History type 1 Select the Schedule Type as BatchMaster Order History 2 Enter the Sales Order No From Leaving this field blank has the same effect as entering the first available Sales Order 3 Enter the Sales Order No To Leaving this field blank has the same effect as entering the last available Sales Order 4 Enter the Customer Key From Leaving this field blank has the same effect as entering the first available customer 5 Enter the Customer Key To Leaving this field blank has the same effect as entering the last available customer 6 Enter the Order Date From Leaving this field blank has the same effect as entering the current server date 7 Enter the Order Date To Leaving this field blank has the same effect as entering the current server date 8 Click on the Process button Depending upon the filter criteria the schedules are generated for the line items of the Sales Orders A report displays all those line items of Sales Orders for which schedules were generated 9 Save the record by assigning some parameter name to the record in the input box on the toolbar 21 13 Print MSDS This screen can be used to generate a MSDS based upon a Schedule Note The parameters maintained at the MSDS Setup screen also affect the appearance and content of a printed MSDS Therefore the users sho
391. screen This field is defaulted to the current server date This is a mandatory field Process Cell Type This field displays the type of the Process Cell depending upon the Process Cell selected by the user This is a read only field Hours per Day This field displays the availability of the Process Cell per day for production The value at this field is taken from the Process Cell screen This is a read only field Tab 1 Process Cell Schedule Details ER BatchMaster Manufacturing Process Cell Scheduling We laj x E File Edit View Help Module Special Functions Windows Jl x Della axe Malm lr Se olay BatchMaster Manufacturing AP_MAX_PROCESS CELL or Mix O Ea x Process Cell Cat M Welle C Costing Utilities Date s070 4 Process Cell Type TE ii ET IR _ Costing Reports 0 00 LA Routing Reports 1 Process Cell Schedule Detail 2 Chart Display C Production i Details 1 Production Utilities 1 Production Report 0 MPS C MAP 1 MRP Reports 4 Process Cell Mode RS Capacity Utilize O Batch Number Batch Type Batch Status Scheduled Start Date Sche pade 000000000000017 Mix NEW 19 07 04 19 07 UE EE EE E E 4 EE EE EH Je Details 1 Laboratory Utilities 1 Laboratory Report _ MPS Reports General Table Vie
392. se Order option The confirmation dates can be established as well If a user has access to the Demand Fence 1 MPS Purchase Order option the user should also have access to the Demand Fence 2 MPS Purchase Order option which typically has more restricted order confirmation authority This screen automatically includes all those orders that are displayed on the Demand Fence 2 MPS Purchase Order DOCNUMBER 066 April 14 2005 Issue 2 Page 88 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 6 1 Screen Fields Description EE BatchMaster Manufacturing Demand Fence 1 MPS Purchase Order a File Edit view Help Module Special Functions Windows l x onela axle vlalrlgl ll el ltem Key o E Production l Production Util Location F GLOC FGLOC oO Production Re Te GC MPS Unit ka LY Forecast E O Run MPS D MPS Planr _ MPS Plan run Dt Order Status Plan Start Dt Plan End Dt Plan Qty Confirm Start Confirm End ESCH C Transfer M L Q E Ce 26 07 04 CONFIRMEL 26 07 04 26 07 04 50 0000 26 07 04 26 07 04 50 0000 O Demand Fi Pe ie CONFIRMEL 26 07 04 26 07 04 mee ERED 26 07 04 DN Demand Fi SES 26 07 04 CONFIRMEL 27 07 04 27 07 04 50 0000 27 07 04 27 07 04 R GE 9 EIS Sin perenn 27 07 04 22070 00000 27000 27000 50 0000 aintain O Company IEE SEH FIRM PLANI 27070 270 50 0000 27 07 04 27070 50 0000 S eek SES 26 07 04
393. seaaeeseaeeeesaaeeesseneessatessaaees 16 12 2 3 Transferring Sales Orders to Batches nent eeee nana eeeeeeaaaaaeeeeeeaaaes 19 12 2 4 Special Functions AANEREN nE E E EEE a E E arri E ER 20 12 3 BATCH RANGE EOCEe EIN Asbest ege eege e eege 22 12 3 1 Mandatory Inputs EE 22 12 3 2 Screen Field Descriptions 02 1ccccccceceeeeneee cae eeeeeeeeeeeaneeseaeaeeeeseeeeeaaeeseaeeessaeeeesaeeeesees 22 12 3 3 Processing a Range Of Batches ccccccccceeeeeeee ent teee eset cena eeeee naan eee eeeeeeaneteeeesaaaanenes 23 12 3 4 Special FUNCIONS EE 24 12 4 CREATE BATCHES FROM S CHEDULE sincsscccssteusincusnedecedeee dnenatiee sonetnecncnaaeduaaccedadeceded sonsetouannsioncess 26 12 4 1 Mandatory Inputs EE 26 12 4 2 Screen Field Descriptions isviiviessiassie ddEEN ENNEN SEEE AEN E 27 12 4 3 Creating Batches From Schedules eee e ee enee cette ene e ee eeaneeee senna teeetneeeeeeaanees 29 12 4 4 Special FUNCTIONS 10 ccccccccceeecceeeee cece nrar tees cess seen scaaeeeaaeesseeesaeessaeeseaaeessatesesenenseees 31 12 5 PURGE BATCHES sssnseiieietteettttttttttt rttr ttt ttrt EE EErEE EEEE EEEE EEEEE EEE EE EEEE E EEEE E EEEE E EEEE EEEE EEEE 33 12 5 1 Screen Field Descriptions 22 1ccccccceceeeeeee cae eeeeeeeeeeeaaeeseaaeeeeeceeeseaaeeesaeeessaeeeesaeeeesees 33 12 5 2 ee ele 34 12 6 PURGE SUPER ATHEN 34 12 6 1 Screen Field Descriptions 22 2 ccccccecneeeeeeeeeeee ene eeeaeenes see eeeeaaeeseaaetessaeeesaeeeeseatessaaaes 35 12 6 2
394. selecting it via the available lookup on the screen This field also displays the Customer key for previously created records Item This field stores an Item key of which a MSDS has been printed when a new record is inserted using the Customer History screen An Item key can be entered by typing or selecting it via the available lookup on the screen This field also displays the Item key for previously created records MSDS Ship Date This is the date on which a MSDS of an item is sent to a Customer The user may enter the Revision Date by typing or via selecting it from the displayed calendar 21 14 2Creating a Customer History 1 Click the Insert button 2 Enter a Customer key The name of the Customer is displayed on the screen 3 Enter an Item key The Item s description is displayed on the screen 4 Enter the MSDS Ship Date 5 Click on Save button to save the Customer History record DOCNUMBER 066 April 14 2005 Issue 2 Page 228 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 15 Update Customer History This screen inserts or updates the records regarding a Customer for whom MSDS has been printed The appended or updated record of a Customer can be viewed at the Customer History screen The following type of schedules that also have a customer key associated with them can be processed via this screen 1 Production Formula 2 Production Finished Goods 3 MSDS Custom
395. ser Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to purchase order Vendor This is the Vendor for the purchase order If a vendor is associated with this Item Location via the Item Location screen then via Run MPS the vendor key is defaulted here from the Primary Vendor Key field of the Item Location screen This value can be modified here Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Exception If any of the rows have their boxes checked the status of those rows gets changed to Exception when this button is clicked Firm Planned If any of the rows have their boxes checked the status of those rows gets changed to Firm Planned when this button is clicked Confirmed If any of the rows have their boxes checked the status of those rows gets changed to Confirmed when this button is clicked Club Orders Click on the Club Orders button to club the selected orders Orders can be selected by checking the select box for the order lines The selected lines will be combined to create a single line The planned date for this line will automatically be set to the earliest planned date of the combined lines DOCNUMBER 066 Apri
396. ser s Guide Volume III Manufacturing Material Labor Boilerplate Text Faha Item Key This field stores the value associated with the setting on the Type field 1 Raw material is entered when the Type is Material Clicking the lookup on this field displays those Item Locations that have their status as Active 2 Labor Key is entered when the Type is Labor Clicking the lookup on this field displays the Labor Additional Cost keys 3 Boilerplate Key is entered when the Type is Boilerplate Clicking the lookup on this field displays the Boilerplate Instruction keys 4 The field is disabled when the Type is Text Text This field stores the Description or text associated with the value of the Item Key on the same row 1 When the Type is Material this field stores the Item Description 2 When the Type is Labor this field stores the Description of the labor key 3 When the Type is Boilerplate this field stores the Description of the boilerplate 4 When the Type is Text this field stores user defined text Loc This displays the Location for material line item Qty Required This is the quantity of the Labor in hours or of the Material interpreted as per the Unit in the adjacent field Unit This is the unit in which the Quantity Required is interpreted This unit can be toggled by clicking the Toggle Units button on the tool bar O H This is the Overhead Key associated with this mat
397. ses IH BAO e E Costing pa Cost Utiies it J CoctnpRepots JBa ebecgs e JE e 3 Production Ues D Genese Zchrdie b E Troster to Super Bech Esrari ach z IR Oese Puche Req SELECT IN RANGE F ikede r m D Fi Fron Irvericey 5 Baich Aang Procesan C Desie Batches Fiore Sr D Batef akdeg D Asje Supe Batches j 3 Productan Fieperts 3 BacherinProcses TS Banh Ticket Repot D Oros Matera Parot 3 Production Hany Zum 73 Reduction History Dals DO mate Soles Ode Te TS Batcteaie Lot Daah R D Sues Gatch Tiete Aey D Scent atcha se Lot De D Spa Bath Esposon TS M Productte by moc D Mates hereUsed A D Bea Naid Peqen D Ret Lii Rapai ee a Desezat Waieusm Trertez Figure 9 2 1 Transfer SO To Batch Screen Oto 100 10 0000 10 03 Lk 2000 HO BUTTER d o 7 0000 7 00 BUTIER d GIE G 1000 10 7 ri Tray 1 SO No From This specifies the lower limit of the range of sales orders that need to be transferred Leaving this field blank has the same effect as selecting the first available Sales Order via the lookup SO No To This specifies the upper limit of the range of sales orders that need to be transferred Leaving this field blank has the same effect as selecting the last available Sales Order via the lookup Transfer to Super Batch Checking this box creates batches forthe intermediates of the selected line items If this box is not checked then the batches will not be created for the intermediates
398. sis sg EI x f File Edit View Help Module Special Functions Windows l x pelala axel all El 2 Formula 1 Routing Formula Key g FORMULA A Quality Control Enlarge View _ Formula Reports ache CTANDARN Ge Bill OFM P b Description Formula A for Melnvalid record can be saved Cost Method STANDARL L Bi aterials on the Maintain Downtime master zl i IAT PA 1 Costing View Mode 8y Quantity 1 Costing Utilities _ Costing Reports 1 Formula Master 4 Line Items 5 Byproducts 1 Routing Reports 1 Production Formula Class Ul ss A For Al 1 Production Utilities e e ormula Status A Active 1 Production Report a A C MPS Date Revised C MAP 1 MRP Reports Process Cell Mode Reason Revised Reverted From 30 01 03 At a C OC Masters 16 16 19 Revision No 1 Process Cell Repo 0000000002 1 QC Reports Date Last Made C MSDS Time Last Made 12 00 00 AM 1 BOM Utilities F C MSDS Repotts Default Process Cell AP Max PROCESS CELL A Zich 3 Laboratory Density Override O o 0 0000 E Physical Prong O Physical Prope Notes i O Comparative P Int eeng sl D Figure 15 1 2 Physical Property Analysis Screen Formula Tab Time Revised 12 33 36 PM i I I E 1 I i ib d l D 1 I w a E I T E I E I Formula Class This is the class of the
399. sorted on the formula key With Formula Physical Property one can create a report that includes formula physical properties but excludes formula ingredients This report is therefore condensed and discloses little confidential information One can use the screen s filtering parameters to define the report One can also specify the 1 Search level 2 Formula per page print setting Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report one can print or export 25 2 1 Generating a Formula Physical Property Report 1 Click on the Formula Key From and To range using the lookup buttons next to the fields 2 Complete the Formula Class From and To range using the lookup buttons next to the fields 3 Complete the Formula Status From and To range using the lookup button next to the fields 4 Complete the Property 1 4 range using the lookup buttons next to the fields 5 Complete the Search Level 6 Complete the New Page Each Formula 7 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 8 Click on the Process button on the toolbar to create a report 25 3Physical Property Analysis Report The Physical Property Analysis Report generates information about the physical properties associated with a formula while also providi
400. space 0 Minimal 1 Slight 2 Moderate 3 Serious 4 Severe awn gt A blank space in this field indicates that no Health rating is applicable to this item Chronic Factor This field stores whether or not this item is carcinogenic An asterisk in this field indicates that this item is carcinogenic A blank space in this field indicates that this item is not carcinogenic Flammability This is the HMIS Flammability rating for this item The valid values are 04 or a blank space 0 Minimal 1 Slight 2 Moderate 3 Serious 4 Severe awh gt A blank space indicates that no Flammability rating is applicable to this item Reactivity This is the HMIS Reactivity rating for this item The valid values are 0 4 or a blank space 0 Minimal 1 Slight 2 Moderate 3 Serious 4 Severe naw N gt A blank space indicates that no rating is applicable to this item Personal Protection This is the HMIS Reactivity rating for this item The valid values are AK X ora blank space A blank space indicates that no HMIS Reactivity rating is applicable to this item Material Hazard MatHazTypelD This is the identification of a Material Hazard type for a line in the Material Hazard grid Description This is the description associated with the Material Hazard type for a line in the Material Hazard grid Add Line Clicking this button inserts a line in the Material Hazard grid Delete Line Clicki
401. ssue 2 Page 133 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing j User Id k Record Date 15 5 Demand Fence 2 MRP Production Order The Demand Fence 2 MRP Production Order option provides a way to define the order status for a MRP Production Order having status as Exception and falling under the period of Demand Fence 2 With Demand Fence 2 MRP Production Order one can convert the order status of a selected MRP order and MRP item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MRP Production Order option The user can also establish the confirmation dates If a user has access to the Demand Fence 2 MRP Production Order option that user may not access the Demand Fence 1 MRP Production Order option which typically has more order confirmation authority This screen does not display those orders that are displayed on the Demand Fence 1 MRP Production Order 15 5 1 Screen Fields Description ER BatchMaster Manufacturing Demand Fence 2 MRP Production Order g EI x EZ File Edit View Help Module Special Functions Windows lej xj d alzlsl alal ell el i Costing Reports amp ltem Ke ALTERNATE_A Item For Production level 2 E EEN ba c rr raoe SL Production ite C Production Utit ae em oo C Production Rep SL MPS
402. sting Reports Routing Reports 1 Production 1 Production Utilities 1 Production Report 1 MPS CI MRP 1 MRP Reports 1 Process Cell Mode 1 GC Masters Process Cell Repo C QC Reports C MSDs 1 BOM Utilities h i Formula Formula Key Description FoRMULA_A Quality Control Enlarge View Cost Method STANDARD Formula A for Melnvalid record can be saved 7 on the Maintain Downtime master zl eg View Mode By Quantity 1 Formula Master 4 Line Items 5 Byproducts es 3 Safety Output Formula Key MSDS Supplementary File ID HMIS Health HMIS Chronic Factor HMIS Flammability HMIS Reactivity HMIS Personal Protection D Face Shield Gloves Synthetic Apron x WHMIS Information FORMULAE QI Formula B for Me ose aj Jee SY Maier zs rond _ MSDS Reports J Laboratory A ID Physical Prope O Comparative P Int aen Se Z Figure 15 1 4 Physical Property Analysis Screen Safety Tab DEE EE E EE E E EE EE E EE E E EE E EE EE E EE EEN Output Formula Key For the purpose of printing a MSDS an output formula key is listed here This is used when the MSDS information of the product cannot be directly determined from the formula ingredients For example the reaction of hydrogen gas and chlorine gas produces NaCl The MSDS of NaCl shou
403. sue 2 Page 42 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 3 Click on the Process button on the toolbar to create a report 13 12 Material Where Used Report The Material Where Used Report screen provides a way to generate a report of batch numbers associated with an item key that is 1 Produced as a Finished Good or Byproduct via that batch 2 Utilized by the batch as a Formula Material or Assembly Item One can also specify the statuses of the batches to be displayed on the report The user can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 12 1 Generating a Material Where Used Report 1 Select one of Finished Good Byproduct or Formula Material Assembly Items option by clicking the radio button 2 Select or unselect the various batch statuses as needed 3 Complete the Item Key From and To range using the lookup buttons next to the fields 4 Complete the Location From and To range using the lookup buttons next to the fields 5 Click on the New Page For Each Item box to enable this feature 6 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 7 Clic
404. t All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid 14 14 2 Using Pull MPS Items screen 1 Select the MPS Items to be saved by checking the box adjacent to the MPS Item line 2 Select the Item Type as one of Manufacture or Purchase 3 Change the Lot Sizing Method if needed 4 Modify the Economic Order Quantity if needed 5 Fora Purchase type item enter or modify the Default Vendor as needed 6 Click the Save button on the toolbar to complete the Pull MPS Items for the selected line items DOCNUMBER 066 April 14 2005 Issue 2 Page 116 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 15 MPS Order Range Processing The MPS Order Range Processing screen enables the user to change the status of the MPS Purchase Production Orders for a range of MPS Items in one go 14 15 1 Screen Fields Description ER BatchMaster Manufacturing Range Processing 8 xi EZ File Edit Yiew Help Module Special Functions Windows l x r Range Processing _ Production Reports Ca MPs Item Key Gi f al D Forecast Entry To ASSEMBLY 1 al embly One D Run MPS D MPS Planning From o Loc al FGLOC DN Transfer MPS F Location To eo FGLOC D Transfer MPS F A O Demand Fence D Demand Fence O Demand Fence O Demand Fence D Maintain MPS II O Co
405. tchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing this screen Changing the Request date and saving it updates the relatel demand on the planning worksheet on Tab 1 automatically but does not change the actual forecast on the Forecast Entry screen Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked these rows get deleted when this button is clicked 14 3 4 Screen Field Descriptions Tab 3 Cust Orders ER BatchMaster Manufacturing Planning Worksheet KE a x E File Edit Yiew Help Module Special Functions Windows l x or aS axel lall ll el 43 Manufacturing ltemKev AP FINISHED_GOOD Curr On Hand Safety Stk i O Formula Item For Production level 1 Formula Utilitie Routing Location oo Unit fec W E Formula Repor 1 Bill Of Material C Costing Costing Utilities 1 Costing Reporl 1 Routing Repor _ Production KE 2 2 0000 02 06 04 C Production Uti E 2 0000 02 06 04 1 Production Re CH MPS D Forecast E O Run MPS IN D Transfer M O Transfer M C Demand Fi L Demand Fi D Demand Fi Li Berend Select All Un SelectAll Delete Line D Maintain M In eem KS IV Included in last MPS run Replan MPS
406. te is defaulted with the Plan End Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Dt This is the date when this order was confirmed Transfer Dt This is the date when this order was transferred to production batch Batch Type This can be one of Mix Fill or Assembly depending on the assembly type of the associated BOM Process Cell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this item Hours Required This value is assigned by the system during Run MPS This value can be changed at the Process Cell Formula Capacity screen The value can also get modified when orders get clubbed DOCNUMBER 066 April 14 2005 Issue 2 Page 94 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of the rows have their boxes checked such rows get deleted when this button is clicked Exception H any of the rows have their
407. ted cost method Forecast Start Date This is the date from which the forecast period starts This date is defaulted to the current server date Forecast Type Quantity This box should be checked if the forecast is in terms of quantity in UOM Amount This box should be checked if the forecast is in terms of monetary amount DOCNUMBER 066 April 14 2005 Issue 2 Page51 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Forecast Entry Grid This grid is enabled after a planning calendar has been selected in the Planning Calendar field The dates on the fields in this grid are defaulted from the schedule established using the planning calendar and the forecast start date field Forecast Key This is the identification key for the forecast in this line This is a mandatory field Location This is the location for the item selected in the Item Key field for which the forecast key is applicable Status This is the status of the forecast key for the line This field can have value as Active Inactive or Hidden Only Active forecasts are considered during Run MPS or Run MRP Add line Clicking this button adds a line to the Forecast Entry grid Delete Line Clicking this button deletes the selected line 14 1 3 Using Forecast Entry 1 Click on the Insert button on the toolbar to create a new forecast 2 Type or select an Item Key using the lookup button next to this field 3 Select a P
408. ted via Run MRP will automatically get converted to the selected status a Planned b Firm Planned c Confirmed 8 Click on the Process button on the toolbar DOCNUMBER 066 April 14 2005 Issue 2 Page 121 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 2 Demand Fence 1 MRP Purchase Order With Demand Fence 1 MRP Purchase Order one can convert the order status of a selected MRP order of a MRP item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MRP Purchase Order option The user can also establish the confirmation dates If a user has access to the Demand Fence 1 MRP Purchase Order option that user should also have access to the Demand Fence 2 MRP Purchase Order option which typically has more restricted order confirmation authority This screen automatically includes all those orders that are displayed on the Demand Fence 2 MRP Purchase Order 15 2 1 Screen Fields Description ER BatchMaster Manufacturing Demand Fence 1 MRP Purchase Order E x E File Edit View Help Module Special Functions Windows 8 x lor aS axel al aigle H Costing Utilities ltem Key APE Item For Production level 3 _ Costing Reports Location IDN SL Routing Reports Une em a c Production See ele SL Production Utilities SL Production Report
409. tee canna eeeeeeeaannaeeeeeeeaaa 43 13 13 RAW MATERIAL REQUIREMENT ANALYSIS 0cccceecceeeeceeeceeeeseeseeeeeeeeceeeeeeeeseueeseneaeeeeeeeeas 43 13 13 1 Generating a Raw Material Requirement Heport 43 13 14 PICK LIST REPORT RE 44 13 14 1 Generating a Pick List Report E 44 13 15 PRODUCTION COST S UMMARY REPORT a nanea nnenoenernrrrrtttrtttrtrtnrrrr rert rrrr tarteren trn ren rennene 44 13 15 1 Generating a Production Cost Summary Heport cc cceee eee e ee eette eee eee ee eeteeeeaanneeeeeeeaaaes 44 13 16 PRODUCTION SUMMARY REPORT 2 c ecccsecececccseeceeeseetecesecseeecescusesceesaeeeseseeseescueeeesesceees 45 13 16 1 Generating a Production Summary REPOST ice eee eect en nee et ee cena ne eeeeeeeana nee eeeeeeaaa 45 13 17 LABOR TRANSACTIONS REPORT ssneeieseie tettert ttttttttt rrtt Attt trt rrr trr ErA EErEE EEEn EE err nren n EEEE 45 13 17 1 Generating a Labor Transactions Repott ccccccccccctttteeeee eee ee cette enna eeeeeeenn a neteeeeeee nena 45 13 18 FORMULA PRODUCTION HERORT rttr tttn rrtt rt rttr EErEE Errr EErEE n rnEeE renee 46 13 18 1 Generating a Formula Production Report cccceeeeeeentnteeee cece nanan eeeeeeeanteeeeeeeeaeeeeeeetaa 46 13 19 SUPER BATCH CRITICAL MATERIAL REPORT 0ccssecceeceeeeeceeeeeeeeeeeeeeeeseesaeeeseeeeeeeeseeeaeeeeas 46 13 19 1 Generating a Super Batch Critical Material Report 12 c11 cccceeeeeseeeeeeeneeeeeneeeeseneeeees 46 13 19 2 Transferring Mat
410. tem weight unit is multiplied by the Factor of the Overhead Key to calculate the cost contribution of this overhead Type This is the Overhead Key of type for setup costs This value is entered automatically when the associated overhead key is entered This is a read only field This value is used for cost analysis in the Costing module as well as to calculate the costs associated with production of the end item produced by the formula The Batch weight in system weight unit multiplied by the Amount of the Labor Key is multiplied by the Factor of the Overhead Key of the same line to calculate the cost contribution of this overhead Factor Variable Costs This value is entered automatically when the associated overhead key is entered This is a read only filed Add Line Clicking this button inserts a line in the Variable Cost grid Delete Line Clicking this button deletes the selected line s from the Variable Cost grid DOCNUMBER 066 April 14 2005 Issue 2 Page 245 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 1 5 Screen Fields Description Tab 3 Safety 18 x 16 x IS BatchMaster Manufacturing Physical Property Analysis File Edit View Help Module Special Functions Windows pelala axel gt l BatchMaster Manufacturing 1 Routing Formula Reports 1 Bill Of Materials 1 Costing 1 Costing Utilities 1 Co
411. tems in the display grid Deselect All Clicking Deselect All button un checks all the critical items in the display grid DOCNUMBER 066 April 14 2005 Issue 2 Page 38 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Max No of Lines in PR One can store a numeric value in the Max No of Lines in PR field The maximum number of lines permissible on a Purchase Requisition is 999 13 4 Production History Summary Report The Production History Summary Report screen provides a way to generate a report showing a summary of a batch s information including completion date labor cost and overhead cost Generated reports also contain on a used and yield basis information about the batch s weight and volume characteristics One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 4 1 Generating a Production History Summary Report 1 Complete the Formula From and To range using the lookup buttons next to the fields 2 Complete the Batch From and To range using the lookup buttons on the toolbar next to the fields 3 Select the Batch Status as required 4 Select Completion date Form and To range using the drop down arrows respectively 5 Complete the Customer From and To range using the lookup buttons on the toolbar next to the fie
412. ter Enterprise 7 25 User s Guide Volume III Manufacturing 2 Firm Planned These orders before being transferred to the Purchase Order need to be Confirmed The Orders that are FIRM PLANNED will not be erased when Run MPS is processed or when the Replan MPS button is clicked 3 Confirmed The Orders that are Confirmed are ready to be transferred to a purchase order and will not be erased when Run MPS is processed or when the Replan MPS button is clicked Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan End Dt This is the Plan End Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked Plan Qty This is the Plan Quantity recommended by the system Confirm Start Dt This date is defaulted with the Plan Start Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm End Dt This date is defaulted with the Plan End Dt when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the user Confirm Qty This quantity is defaulted with the Plan Qty when this row is created or modified when Run MPS is processed or the Replan MPS button is clicked The value in this field can be modified by the u
413. ter Enterprise 7 25 User s Guide Volume III Manufacturing 21 16 MSDS Setup This screen provides users with a way to define the defaults governing how BatchMaster Enterprise generates a MSDS With MSDS Setup the user can define a variety of information which will affect the appearance of a MSDS and the kind of information that will appear on the MSDS 21 16 1Screen Fields Descriptions Tab 1 Print MSDS Defaults ER BatchMaster Manufacturing MSDS Setup E i WIES E File Edit View Help Module Special Functions Windows l x oleae d alle Mare ole 1 Print MSDS Defaults SL QC Masters a TE Process Cell Repo Line Spacing When more than 1 BP in a Section 5 QC Reports S MSDS Abort or Ignore if Boilerplate Group is Missing ignore DI O Boilerplate Gro Boilerplate to Use if None for a Section Group jao A ID APO Boilerplate Mai Duplicate Material Detection D Dn Boiler plate Ove DH Chemical Name CY Supplementary Text to Print for NZA Numeric Calculation na D CAS Number h Formula Level to use for MSDS Lab Calculations Bottom zl ID Hazard Type h Dn Hazard Print R Sort Print MSDS Components by Weight or Volume Volume DI O Hazard Print C Boilerplate to use when no Reportable Materials Group jao A 1p 401 S E Maximum Number of Boilerplates per MSDS 125 focess Dn MSDS Master Company Key for Chemtrec MSDS 7899 O MSDS Sched Last SARA Posting Date 06 07 04 bi D Print Ge MS Word Template Path
414. this line item of this sales order This quantity is defaulted from the QtyOrder field of the Sales Order Entry screen Weight This is the Order weight arrived at by converting the order quantity as entered at the QtyOrder field of the Sales Order Entry screen from the SO Unit to the System Weight Unit Volume This is the Order weight arrived at by converting the order quantity as entered at the QtyOrder field of the Sales Order Entry screen from the SO Unit to the System Volume Unit FMKey This is the formula key associated with the BOM of this line item DOCNUMBER 066 April 14 2005 Issue 2 Page17 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing BatchNo If the user has manually entered the Batch Number using the ellipse button adjacent to this field then the Batch Number so entered gets displayed here The line items that have been assigned a common batch number are clubbed in a single batch The line items that have not been assigned any batch number are clubbed with those line items that use the same formula as the one used by these line items BatchType This is the type of the batch It can be one of Mix or Assembly If the Assembly Type of the BOM associated with this line item is Finished Good or Intermediate then the Batch created will be Mix type If it is Assembly the Batch type will be Asse
415. ties H C MSDS Reports BL Laboratory H MRP Order Details Process Line OrderNo Batch Type Status Scheduled Start Date Joel 1 Laboratory Utilities t 1 Laboratory Report m MPS Reports C General Table View Figure 12 2 4 Re sequence Process Line Button 18 QC Masters 18 1 QC Test Description The QC Test Description screen provides a way to create quality control tests With QC Test Description the specific characteristics of the quality control test can be defined Once a test has been defined QC test can be assigned to the formulas via the QC Formula Tests or inventory items via the QC Item Tests screen DOCNUMBER 066 Issue 2 April 14 2005 Page 170 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 18 1 1 Screen Fields Descriptions ER BatchMaster Manufacturing QC Test E E la x E File Edit View Help Module Special Functions Windows Jl x Darl tal S Al x es vldlrlnl als TE SL Formula Repor 1 Bill Of Material Tesi heen L Costing Test Description estroma ss lt s sSSCSCSCSs S sSCS 1 Costing Utilities 1 Costing Repor _ Routing Repor Production Production Util _ Production Re C MPS C MRP 1 MRP Reports Process Cell M GC Masters DN L GC Formul D QC Item Te O Quality Cor _ Process Cell R C QC Reports C MSDS
416. to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No sa EHGEE 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status sao ong DOCNUMBER 066 April 14 2005 Issue 2 Page 96 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing j User Id k Record Date 14 8 Demand Fence 2 MPS Purchase Order The Demand Fence 2 MPS Purchase Order option provides a way to define the order status for a MPS Purchase Order having status as Exception and falling under Demand Fence 2 With Demand Fence 2 MPS Purchase Order one can convert the order status of a selected MPS order and MPS item moving it from Exception to Firm Planned or Confirmed Once the order status has been set it can be transferred using the Transfer MPS Purchase Order option The confirmation dates can be established as well If a user has access to the Demand Fence 2 MPS Purchase Order option that user may not have access to the Demand Fence 1 MPS Purchase Order option which typically has more order confirmation authority This screen does not display those orders that are displayed on the Demand Fence 1 MPS Purchase Order 14 8 1 Screen Fields Description ER BatchMaster Manufacturing Dem
417. to change without notice and should not be construed as a commitment by BatchMaster Software BatchMaster Software assumes no responsibility or liability for any errors or inaccuracies that may appear in this document Neither BatchMaster Software nor anyone else who has been involved in the creation production or delivery of this documentation shall be liable for any indirect incidental special exemplary or consequential damages including but not limited to any loss of anticipated profit or benefits resulting from the use of this documentation nor the examples contained herein License Agreement Use of this product is covered by a license agreement provided by BatchMaster with the software product If you have any questions about the terms of this agreement consult the License Agree ment as it is provided in the License Folder on the CD ROM which contains the product itself DOCNUMBER 066 April 14 2005 Issue 2 Page 2 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Table of Contents 12 PRODUCTION UTILITIES E 13 12 1 GENERATE SCHEDULE enges eebe 13 12 1 1 Mandatory INpuls EE 13 12 1 2 Screen Fields Description 13 12 1 3 Generating E EE 15 12 2 TRANSFER SO TO BATCHES n0ann0e0eenoenoaooerooetoetettirttitrrttoeetttrettat troet to trett nEtr torero nee tnne e eea 16 12 2 1 Mandatory ee 16 12 2 2 Screen Field Descriptions 22 2 ccccceecenneeeeeceeeee cae eeeanetescaeee
418. ton Transfer No This is the warehouse trans fer order number associated with the row Line No This is the line number for the warehouse transfer order as stored at the SysLinSq field of the MINTXD table Transfer Qty This is the quantity that is requested via the Warehouse Transfer Order During Run MPS the Transfer Quantity is fetched from the Warehouse Transfer screen The Transfer Quantity can be changed on this screen Changing the Transfer Quantity and saving it updates the related demand on DOCNUMBER 066 April 14 2005 Issue 2 Page 68 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing the planning worksheet on Tab 1 automatically but does not change the actual Warehouse Transfer quantity on the Warehouse Transfer screen Expected Tran Date This is the date on which the Transfer Quantity of this item is expected to be transferred out During Run MPS the Request date is fetched from the Transfer Date field of the Warehouse Transfer screen This date can be changed on this screen Changing the Expected Transfer Date and saving it updates the related demand on the planning worksheet on Tab 1 automatically but does not change the actual Transfer Date on the Warehouse Transfer screen Select All Clicking this button checks the boxes for all the rows in the grid Unselect All Clicking this button un checks the boxes for all the rows in the grid Delete Line If any of t
419. ton ep om em T Wio Stock Tumers To TURN Ef Tures T ITEM to test PO T ITEM to test PO ge L Forecast Entr J O Run MPS IV Transfer to Super Batch SuperBatch D I Allocate Auto Lot Assignment SELECT IN RANGE L MPS Plannine I Fill From Inventory ID Transfer MPS R ET BE E e emana ren 08 24 04 CONFIRMEL 09 28 04 09 12 04 2 222 eg E DN Demand Fene 08 24 04 CONFIRMEL 09 29 04 09 13 04 2 222 000 EE SI Bn E T A D EE 08 24 04 CONFIRMEL 09 01 04 09 16 04 2222 0000 5 Maintain MPS 09 24 04 CONFIRMEL 09 01 04 0916 04 2 222 000 Company Cale O Planning Cale ID MPS Setup Dn Pull MPS Iter IN MPS Order R SL MRP SL MFP Reports m Det mm D Select All Unselect All Warehouse Transfers Club Orders Soc Sas L Ee WE SSS ee Figure 10 5 3 Transfer to Batch Bullen DOCNUMBER 066 April 14 2005 Issue 2 Page 86 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location E E x ltem Key BUTANOL Stock UOM LBS Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail 1 249 ae 356 Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order l Quantity Commit To Sales Quantity Commit To Production
420. ton on the toolbar to create a report 22 15 Customer History Report The Customer History Report screen provides a way to generate a report showing the customer histories created using the Customer History screen The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 22 15 1 Generating a Customer History Report 1 Complete the Customer From and To range using the lookup buttons next to the fields 2 Complete the Item From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report DOCNUMBER 066 April 14 2005 Issue 2 Page 238 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 23 Laboratory The Laboratory group serves as a component in Batch Master Enterprise s approach to using formulas in process manufacturing Through the different options of the Laboratory module one can manage adjust and evaluate the physical properties of the ingredients used in a formula With the Laboratory s options one can compare a formula and its ingredients side by side reformul
421. torage type for a line in the grid Temperature This field stores the temperature represented by a number associated with a storage type for a line in the grid Add Line Clicking this button inserts a line in the SARA Information grid Delete Line Clicking this button deletes the selected line s from the SARA Information grid Tab 4 OEL ER BatchMaster Manufacturing Material Safety Information TES Ga File Edit View Help Module Special Functions Windows 8 x Cy coe ta I al xe n a gt ri ole t 1 Production Report C MPS C MRP 1 MRP Reports _ Process Cell Mode C GC Masters 1 Process Cell Repo t C QC Reports E4 MSDS OD Boilerplate Gro IN Boilerplate Mai ID Boilerplate Ove D Supplementary D CAS Number h O Hazard Type hk CY Hazard Print R O Hazard Print C DN D SARA Process O MSDS Master O MSDS Sched IN Print MSDS TD Customer Histe OD Update Custor In mens ir Me Material Safety Information ltem key Q Item For Production level 2 1 General Information M OEL Details zs Occupational Exposure Limits Add Line Delete Line Figure 14 8 4 Material Safety Information OEL Tab Occupational Exposure Limits This field stores the Occupational Exposure Limit for this item An item can have multiple occupational exposure limits Add Line Clicking this button inserts a line in the OEL Details grid
422. tus The value in this field is defaulted from the planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed The status of all the orders is Confirmed for this screen Plan Start Dt This is the Plan Start Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked The value in this field is defaulted from the value of the plan start date field in the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed Plan End Dt This is the Plan End Date that is recommended by the system when Run MPS is processed or when the Replan MPS button is clicked The value in this field is defaulted from the value of the plan end date field in the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed DOCNUMBER 066 April 14 2005 Issue 2 Page 83 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Plan Qty This is the Plan Quantity recommended by the system The value in this field is defaulted from the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed
423. ty Information screen 3 Raw Material The data for the schedule is fetched from the Item Master screen and the Material Safety Information screen 4 Production Formula The data for the schedule is fetched from the Production batches that have not yet been purged and the Formula Entry screen 5 Production Finished Good The data for the schedule is fetched from the Production batches that have not yet been purged and the Material Safety Information screen 6 MSDS Customer History The schedules are generated based on MSDS Customer History 7 BatchMaster Order History The data for the schedule is fetched from the Sales Order Entry screen and the Material Safety Information screen DOCNUMBER 066 April 14 2005 Issue 2 Page211 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 12 1Screen Fields Descriptions for Master Formula ER BatchMaster Manufacturing MSDS Schedule Generation i EI x f File Edit View Help Module Special Functions Windows l x SI IES axla KIKALI lgl Di geess C QC Masters hee Pan E I Master F l 0 GEES Schedule Type aster Formula e _ GC Reports Selection Criterion Gy MSDS Formula Key From IK A D Boilerplate Gro DN Boilerplate Mai Formula Key To FORMULA_G A OD Boilerplate Ove ID Supplementary Formula Class From clas S A ID CAS Number h For
424. uantity will be allocated Select in Range Using this button the user may select an option for manual or automatic generation of batch number for the highlighted line items For transferring these highlighted line items into one batch the following must be true 1 A released BOM must exist for each of these line items 2 All these line items must use the same formula Select When this box is checked for a row that row becomes available for transfer to production order MPS OrdNO This is the system generated number for the MPS order This value is defaulted from the Planned Production Order tab of the Planning Worksheet or from the Demand Fence 1 and 2 MPS Production Order screens depending on where the order was confirmed ItemKey This is the Item Key for which the planned MPS production order has been generated Description This is the description of the item Location This the Location Key associated with the Item for which the planned MPS production order has been generated UOM This is the Stock UOM for the Item Key Req Qty This is the Required Quantity in stock UOM to be produced in a batch which is recommended by the system Weight This is the Order weight arrived at by converting the required quantity from the Production Order to the System Weight Unit Volume This is the Order volume arrived at by converting the required quantity from the Production Order to the System Volume Unit FMKey This is the formula ke
425. uc FGLOC GRM 50 0000 11 11 61 ALTERNATE A lem For Produc FGLOC D MPP Order Range ALTERNATE A D Planned MRP Purc Gg GRM 50 0000 11 11 61 D Planned MRP Proc ALTERNATE A lem For Produc FGLOC GRAM 50 0000 11 11 61 D Transfer MAP Pure ALTERNATE_A em For Produc FGLOC GAM 100 0000 EES ALTERNATE_A len For Produc FGLOC GAM 50 0000 11 11 61 ALTERNATE_A em For Produc FGLOC GRAM 50 0000 11 11 61 MRP Reports ALTERNATE_A ien For Produc FGLOC GRM 50 0000 11 11161 Process Cell Module ALTERNATE_A Item For Produc FGLOC GAM 50 0000 11 11 61 E E bd QC Masters H Process Cell Reports H QC Reports I H MSNS mz Select All Unselect All Warehouse Transfers Club Orders Figure 11 10 3 Transfer to Batch Button The Production Batch details for the item include the following 1 Processing Date 2 Processing Time 3 Batch Type 4 Formula Id 5 Process Cell 6 Batch Number 7 Item Key 8 Location 9 UOM 10 Order Quantity DOCNUMBER 066 April 14 2005 Issue 2 Page 156 of 274 View Item Location The user may click on this button to view the nventory details for all the item locations of the selected item iew Item Location E E xj ltem Key BUTANOL Stock UOM LBS Description N Buty Alcohol N Butanol Display Unit LBS 1 Location Detail 1 249 ae ze Toggle UOM Quantity on Hand 13 706 9899 Quantity on
426. uired for a particular Section DOCNUMBER 066 April 14 2005 Issue 2 Page 230 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Duplicate Material Detection This is the method which is used to identify the raw materials that are considered to be identical The methods of identification are based on Chemical Name CAS Number or Item key An identification method can be selected via the available lookup on the screen Text to Print for N A Numeric Calculation This field stores the text to be printed on a MSDS when a numeric laboratory calculation does not apply Formula Level to use for MSDS Lab Calculations This field stores a Formula Level t be used for Laboratory calculations such as Volatile Organic Content while printing a MSDS There are two levels a Top Master Formula only This means that the calculations are at a single level only the master formula is used b Bottom In this case the calculations are multijevel the calculations begin with the lowest level raw material Sort and List MSDS Components by Weight or Volume The following choices are available 1 Weight In this case the reported components are sorted by Weight percent and are displayed as weight percent on the MSDS 2 Volume In this case the reported components are sorted by Volume percent and are displayed as Volume percent on the MSDS Boilerplate to use when no Reportable Materials This field stores the nam
427. uld maintain the parameters at the MSDS Setup screen before printing a MSDS 21 13 1 Mandatory Inputs Data should be maintained at the following screens before printing a MSDS 1 Language 2 MSDS Schedule Generation 3 MSDS Master Format DOCNUMBER 066 April 14 2005 Issue 2 Page 224 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 21 13 2 Screen Fields Descriptions ER BatchMaster Manufacturing Print MSDS i e x Ga File Edit View Help Module Special Functions Windows lej xj oleae axe aaa ll z MSDS Print Selection Criteria C QC Masters A MSDS Master Format TEST A uerg SL Process Cell Repo Lanquage ENGLISH A ENGLISH Ta GE Template File Path _ GUNJANC C Program Files BatchMasterE nterprise USA dot w O Boilerplate Gro IV Skip printing of reportable components when chemical name is not maintained O Boilerplate Mai m Output D Boilerplate Ove Filename luede doc e g MyFile doc V View Document V Debug Mode b Supplementar Save Path S GUNJAN C C Documents and SettingssAdministrator Desktops E D CAS Number h r Schedule Selection Hazard Type h Schedule ID From 5 are RMULA_D O Hazard Print P a KAS Schedule ID To fio BW D Material Safety Re Use ScheduleID V Refresh Schedules Select All Select None SARA Process Se _ Sch it Item Or Form Typ Custom Description BatchNo lie We TOM C
428. unchecked when the MPS is being run for an item for the first time For successive runs for the same item check this box if there is no change in the Bill of Materials for the item Checking this box skips assignment of low level coding to the items in the BOM hierarchy so if no change has been made to the hierarchy then skipping reassignment of low level codes speeds up processing Generate Planned Orders as Planned This button should be clicked if it is required that the status of orders generated using Run MPS be set to Planned Firm planned This button should be clicked if it is required that the status of orders generated using Run MPS be set to Firm planned Confirmed This button should be clicked if it is required that the status of orders generated using Run MPS be set to Confirmed 14 2 3 An Example of Run MPS Item key MPSITEM On Hand Safety Stock 0 Stock Unit EACH Bucket Size 1 day EOO defined for the item 200 Gross Demand calculation as Demand Forecast r 16 09 04 17 09 04 18 09 04 19 09 04 Warehouse transfer Out MPS orders 50 25 10 22 10 250 150 25 27 300 50 5 12 33 but eoq 200 0 167 171 Su 29 283 but but eoq 200 EoQ 200 400 200 2 DOCNUMBER 066 April 14 2005 Issue 2 Page 60 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing Production Orders Purchase orders Warehouse Transfer in 0 200
429. use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 10 1 Creating a Super Batch Explosion Report 1 Complete the Super Batch No From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 3 Click on the Process button on the toolbar to create a report 13 11 Max Producible by Stock The Max Producible by Stock Report screen provides a way to generate a report showing the Maximum Producible quantity of an end item with respect to the limiting availability of an ingredient or a BOM line item One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 11 1 Creating a Max Producible by Stock Report 1 Complete the Formula From and To range using the lookup buttons next to the fields 2 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters DOCNUMBER 066 April 14 2005 Is
430. vides a broad view of planning for a MRP item The report also shows the Available to Promise ATP within a single period and on a cumulative basis This report is one of the most effective ways to gather a sense of the scope of planning for a single item across the defined planning horizon The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 16 4 1 Generating a MRP Planning Report 1 Complete the MRP Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 4 Click on the Process button on the toolbar to create a report DOCNUMBER 066 April 14 2005 Issue 2 Page 159 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 16 5 MRP Expedite PO Report The MRP Expedite PO Report screen provides a way to generate a report that displays suggested changes if any in the following to meet requirements ofthat item as per the latest processing on the Run MRP screen 1 Requested delivery dates of line items on existing purchase orders 2 E
431. xpected receipt date for warehouse transfers coming in 3 Due dates of existing production batches The report may suggest expediting delaying or canceling existing orders The user can choose to view these recommendations selectively by checking the appropriate boxes on the report screen This report also shows the suggested MRP orders with dates in view of the expedite delay cancel suggestions to meet the demand of that item The option s filtering parameters can be used to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 16 5 1 Generating a MRP Expedite PO Report 1 Complete the MRP Item From and To range using the lookup buttons next to the fields 2 Complete the Location From and To range using the lookup buttons next to the fields 3 Check Expedite Statuses as required 4 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on the Save button on the toolbar to save the report parameters 5 Click on the Process button on the toolbar to create a report 17 Process Cell Module One of the ongoing challenges of manufacturing is capacity planning Capacity planning can be broadly defined as the process of matching the plant s productive capabilities to production requirements Doing so ensures that the user is making the most e
432. xplained above Plan End Dt This is set to the Planned End Dt of the row picked as explained above Plan Qty This is set to the sum of the Plan Qty s of the clubbed rows Confirm Start Dt This is set to the Confirm Start Dt of the row picked as explained above Confirm End Dt This is set to the Confirm End Dt of the row picked as explained above Confirm Qty This is set to the sum of the Confirm Qtys of the clubbed rows Confirm Dt This is set to the Confirm Dt of the row picked as explained above Process Cell This is set to the Process Cell of the row picked as explained above Hours Required This is set to the sum of the Hours Required of the clubbed rows DOCNUMBER 066 April 14 2005 Issue 2 Page71 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 14 3 7 Screen Field Descriptions Tab 6 Planned Purch Ord ER BatchMaster Manufacturing Planning Worksheet E z a x A File Edit view Help Module Special Functions Windows l x lor axle ala ele el _ Production Util lt ltem Key Curr On Hand Safety Stk Gomm 1 Production Re C MPS L Forecast E Location Joo al Unt E O Run MPS BY PS Plan IV Included in last MPS run Beplan MPS O Transfer M EPI d Pich DO Transfer M Lsumay 2 Forecast 3 Cust Orders A WH Transfers 5 Planned Prod Ord sal d e O Demand Fi CD Demand Fi MPS Orde Plan run Dt_ Order Status Plan Start Dt Plan End Dt Plan Qt
433. y Confirm Start Confirm End ID Demand Fi i ID Demand Fi ID Maintain M O Company C b Planning C L MPS Setu IN Pull MPS 11 IN MPS Order MRP 1 IL MRP Reports Process Cell M b Capacity U O Process Ce A SelectAll Un Select ll Delete Line Planned Firm Planned Confirmed Club Orders WW Ten Lessel geepel ened T pecl ees cub cre 1 Process Cell RZ Ui Figure 10 3 6 MPS Planning Worksheet Planned Purch Ord Tab Select When this box is checked for a row that row becomes available for deletion as well as for changing the status of the order or clubbing it with other orders MPS Order No This is the system generated number for the MPS order Plan Run Dt This is the date when the MPS order was generated Order Status The Order Status on this screen can be one of the following 1 Planned These orders before being transferred to Purchase Orders will need to be Confirmed Since BatchMaster Enterprise has a regenerative MPS Planned MPS Orders get erased when Run MPS is processed or when the Replan MPS button is clicked 2 Firm Planned These orders before being transferred to the Purchase Orders will need to be Confirmed The Orders that are Firm Planned will not be erased when Run MPS is processed or when the Replan MPS button is clicked 3 Confirmed The Orders that are Confirmed are ready to be transferred to a purchase o
434. y Tab 4 Examine all the physical properties for a formula marking specific or all material lines for adjustment make adjustments to material line items toggle units of measure and toggle costs Moreover there is provision for sizing the formula and toggling the view mode for the formula from the Line Item Tab The Line Item tab is the critical area of this option 5 Examine the quantity of by product produced from the formula and the overhead and other costs associated with it from the By Product Tab The Physical Property Analysis screen will calculate the physical properties of the formulas based on the physical properties of their ingredients that have been defined in Materials Property screen of Inventory module One can change the quantity of a material line item or add a new material line item BatchMaster Enterprise will instantly reflect the effect on the formula Target values for desired physical property can be established and BatchMaster Enterprise will calculate the changes required in material quantities in order to achieve those target values Note When working with formulas through the Physical Property Analysis screen the user is working with formula records One should be aware of the potential impact on the formula before saving a significant change to an active formula through the Physical Property Analysis screen DOCNUMBER 066 April 14 2005 Issue 2 Page 239 of 274 BatchMaster Software BatchMaster Enterprise 7 25
435. y associated with the BOM of this line item DOCNUMBER 066 April 14 2005 Issue 2 Page 82 of274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing BatchNo If the user has manually entered the Batch Number using the ellipse button adjacent to this field then the Batch Number so entered gets displayed here The line items that have been assigned a common hatch number are clubbed in a single batch The line items that have not been assigned any batch number are clubbed with those line items that use the same formula as the one used by these line items BatchType This is the type of the batch It can be one of Mix or Assembly If the assembly type of the BOM associated with this line item is Finished Good or Intermediate then the Batch created will be Mix type If it is Assembly the Batch type will be Assembly ProcessCell This is the Process Cell associated with the formula via the Process Cell Formula Capacity screen being used by the BOM of this line item WtOrVol This displays whether the capacity of the Process Cell as displayed at the ProcessCell field of this screen is measured in weight or volume This value is defaulted from the Capacity By Weight Volume field of the Process Cell Formula Capacity screen Capacity This is the capacity of the Process Cell associated with the formula of this line item This value is defaulted from t
436. y grid Deselect All Clicking Deselect All button un checks all the critical items in the display grid Max No of Lines in PR One can store a numeric value in Max No of Lines in PR field The Maximum number of lines permissible on a Purchase Requisition is 999 13 20 Critical Batches and Raw Material Report The Critical Batches and Raw Material Report screen provides a way to generate a report displaying Critical Batches and Raw Materials Only Buy Type raw materials are shown here whereas the Make type items are not included in the report One can use the option s filtering parameters to define the report Once BatchMaster Enterprise processes the report parameters it displays the results as a Crystal Report that one can print or export 13 20 1 Generating Critical Batches and Raw _ Material Report 1 Select as needed from one of Batch Can be made without future receipts Batch Can be made considering future receipts Batch Cannot be made even if receipts are considered or Batch Items Shortage Report 2 Select the Batch From and To range using the lookup buttons next to the fields 3 Set the Batch Like field The value entered here enables a more specific filtration This is an optional field 4 Select Schedule start Date From and To range using the drop down arrows 5 To save these parameters enter the name to be assigned to the report parameters in the drop down field on the far right of the toolbar and then click on th
437. y of the MRP Production order as needed 6 For Planned Orders club order lines together by clicking on the Club Orders button 7 Save the Planned MRP Production Order record DOCNUMBER 066 April 14 2005 Issue 2 Page 145 of 274 BatchMaster Software BatchMaster Enterprise 7 25 User s Guide Volume III Manufacturing 15 8 3 Special Functions View Item Location The user may click on this button to view the inventory details for all the item locations of the selected item iew Item Location i x ltem Key BUTANOL Stock UOM LBS Description N Butyl Alcohol N Butanol Display Unit LBS 1 Location Detail Warehouse H 1 249 9899 Mam Wareho 356 0000 Seal Beach Toggle UOM Quantity on Hand 13 706 9899 Quantity on Order 23 0000 Quantity Commit To Sales 0 0000 Quantity Commit To Production 0 0000 Figure 11 8 2 View Item Location Window The inventory details of an Item Location include the following 1 Location Detail Status Code Quantity On Hand Quantity On Order Quantity Committed to Sales Quantity Committed to Production Transit In Quantity Transit Out quantity Quantity Oversold Multiple Bins Requirement Yes or No oe 2900p 2 Lot Bin Number Details Bin Number Lot Number Received Date the date on which the lot was received Expiry Date Quantity On hand Quantity Committed Vendor Lot Number Vendor Key Lot Status User d k Record Date

BatchMaster Enterprise 7.25 User Manual Volume IIIb

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