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QAD 2008 Enterprise Edition User Guide: Manufacturing

1. 00 0002 eee 259 Milestone and Non Milestone Operations 4 260 Before Tracing Subcontracted WIP Material 260 Lot Sizing Restrictions 0 0 0 cee cee eee 260 Inventory Lot Quantity Issuing Restrictions 261 Inventory References 2 0 0 cece eee eee 262 Lot Splitting and Combining 0 00 e eee eee 262 Custom Lot Serial Number Formats 00000 000 263 AQAD Contents Xi Maintaining Accurate System Configuration Information 263 Setting Up WIP Lot Trace 1 0 eee eee 264 Defining Control Program Settings 00 0 0 0008 265 Registering Routing Exceptions 0 00 eee eee eee eee 268 Registering BOM Exceptions 0 0 0 2 eee eee eee eee 272 Working with WIP Lot Trace seeeeeeeeee eee nee 274 Using WLT Data Collection Frames 0 00000 e eee 275 Using WLT with Work Orders eese eee 284 Using WLT with Advanced Repetitive 00 00008 291 Using WLT with Purchasing 0 2 0 0 eee eee eee eee 294 Using WLT with Repetitive 20 0 0 0 eee eee eee 298 Reporting WIP Lot Trace Data 0 0 2 eee ee 299 Chapter 11 Quality Management sse 303 Introduction ciu eet UR ce egre eder Unde ues 304 Setting Up Quality Management eeeeee eee 305 Setting Up Control Programs 0 0 eee eee eee
2. 0 0 0 enuen rarr 38 Manufacturing Lead Time 20 0 0 eee ee eee ee 39 Subcontract Operations 0 0 ee cece eee ae 40 Yield i025 si 500d web ER tied ewiwaddengude hewg hd tdvea ses 41 Yield Percent i eris tunt ee Ee UR e e ob ua 41 Operation Based Yield 0 0 0 eee eee eee 42 FAQAD Contents v Chapter 4 Formulas and Processes 45 Introduction suisses pr ee ees asad ERA CR ORE Sea Vea qp d ae 46 Defining Formulas leeeeeeeeee eh 47 D tining Processes iiber ebb Dr cR a ek A ERR E CI 50 Process Formula Maintenance 0 0 0 cece eee eee 51 Chapter 5 Co products and By products 53 Intr duction ses sira ess aha teh admis ed tees has COH RR COO CRECODAG de 54 OVERVIEW ices ese detec e oe oe e descen e n se Roe ets t pea he ee 55 More About Co products and By products 00 57 Co product By product Workflow eeeeeeeeeee 58 Setting Up a Co By product Operation sssssa susana rrr 58 Setting Up Mix Variance Accounts 0 000 cece eee eee 59 Setting Up Sites and Locations for the Base Process 59 Setting Up Work Centers 20 0 0 ccc eens 60 Setting Up Product Lines 60 Setting Up Item Status Codes for the Base Process 60 Setting Up the Base Process Item 0 0 0c ee ee eee 60 Setting Up Items for Co products and By products 61
3. One for sample size One for quantity accepted One for quantity rejected Item specifications can be maintained in the Product Change Control module The effective date is used to phase in changes managed with product change orders Setting Up Procedures A quality procedure consists of one or more operations generally inspection or testing operations linked to a work center Define quality procedures in Procedure Maintenance 19 2 1 Quality procedures are used by quality orders in the same way routings are used by work orders Quality Management 309 Fig 11 5 zx Procedure Quality Order Maintenance Go To Actions Maintenance 19 2 1 Quality Order 1003 Batch 5 Item Number WLT18 P1 WIP Lot Std Rep Unit of Measure EA Parent 1 Type I Site 10000 Auto Issue V Quantity Pending 100 0 Start Date 02 27 2007 Quantity Accepted 0 0 Release Date 02 27 2007 Quantity Rejected 0 0 Due Date 02 27 2007 Effective Date 02 27 2007 Status c Procedure test P PO Job Project Remarks Operation lead time indicates the time stated in decimal hours this test operation normally takes Operation time is independent of the number of units being tested Make sure you enter it consistently as either time per unit or time per test batch Note There is no integration between quality procedures and capacity requirements plan CRP You can link each operation of a procedure to one or more items in the Procedu
4. Subcontract Shipping Control v X Subcontract Shipping Control Go To Actions Unassigned Suppliers v Manual Shipper Update v Scrap Unreturned Material Unassigned Suppliers Indicate if you want to restrict subcontractors to those specifically assigned to a routing operation when you create the subcontract shipper No the default You can specify only subcontractors associated with the routing and operation when creating the subcontract shipper Yes You can specify subcontractors not associated with the routing and operation when creating the subcontract shipper Note You specify scheduled orders for a specific routing and operation in Subcontract MRP 46 Maint 5 5 1 21 You specify discrete purchase orders for a specific routing and operation through Subcontract Routing Op PO Maint 5 11 Advanced Repetitive 209 When you create a subcontract shipper you can specify a cumulative ID The system populates subcontract shipper fields with the subcontractor data associated with the ID To be able to associate a subcontract shipper with a different subcontractor set this field to Yes Example Your company uses three different subcontractors to paint item A bicycle frames subcontract suppliers A B and C Work order 20 specifies that item A is painted red In Subcontract Routing Op PO Maint you specify the subcontract PAINT operation and routing for subcontract supplier A and B only If y
5. To scrap the quantity manually set Scrap Unreturned Material in Subcontract Shipping Control 18 22 5 24 to No Close Sub Shipper in the Subcontract Shippers frame to Yes Scrap the short amount using the scrap program of your choice FAQAD Advanced Repetitive 223 Scrapping Items through Subcontract Scrap Maintenance Use Subcontract Scrap Maintenance 18 22 5 13 to register a scrap transaction for subcontracted material against one or more subcontract shippers This program Registers a scrap transaction in Advanced Repetitive records Adjusts the scrap quantity on the subcontract shipper Removes quantities from the input and output queues of a subcontract operation To register scrap through Subcontract Scrap Maintenance use the following procedure 1 Enter selection criteria in the header including the item supplier site ship date subcontract shipper ID and cumulative ID Note If the cumulative ID you entered expired but the subcontract shipper is not complete the system may have replaced the cumulative ID on the purchase order When this happens the system finds the subcontract PO lines for the supplier you entered then matches the item number on the new cumulative ID to the item number on the expired cumulative ID to determine which shipper to display 2 Select a subcontract shipper from the display in the Subcontract Shippers frame Information about the subcontract shipper displays in th
6. Work Order Accounting Close 16 21 When you run Work Order Accounting Close the following occurs Co product costs are re averaged by taking any remaining positive or negative WIP costs and allocating them to the co products If additional costs are recorded for a work order after costs are allocated the remaining costs can be reallocated by reopening the closed work order applying the transaction and closing it again General ledger GL and current costs are updated Co products and By products 73 Some typical steps for calculating average GL costs and average current costs for co products follow 1 Define the average cost allocation methods in Average Cost Method Maintenance 15 12 5 2 Verify that the following are correct Co product by product definitions Prices for co products if allocation method involves price By product costs Base process batch size UM of the BOM Formula code for the base process equals the item UM for the base process Site setup for cost sets GL Cost Set and Current Cost Set Unit of measure conversions from base process to co products and by products Defining the Average Cost Allocation Methods Define the average cost allocation methods using Average Cost Method Maintenance 15 12 5 The system provides three methods for allocating costs from a joint order set to co products Price Receipt Quantity Receipt Quantity and Price If other methods are needed users
7. FAQAD 160 User Guide QAD Manufacturing b For more information see Milestone and Non Milestone Operations on page 167 FAQAD For example if there is a yield of less than 100 at an operation this will cause the overall cost to manufacture to increase since not all the material produced is expected to be good If No then 100 is substituted for the Yield field Zero Balance WIP This field determines how queue quantities at non milestone operations are affected when production is reported at subsequent operations This setting affects Quantities processed in Backflush Transaction 18 22 13 Subcontract shipper issues in Sub Shipper Issue 18 22 5 11 Receipts from subcontract shippers or purchase orders using PO Shipper Receipt 5 5 5 11 or Purchase Order Receipts 5 13 1 When Zero Balance WIP is Yes the system does the following after transferring the item quantity processed issued or received from the input queue of the reporting operation and when needed the queues of previous non milestone operations Moves any leftover quantities from previous non milestone operation queues to the input queue of the non milestone operation that directly follows the previous milestone operation Sets all other queue quantities to zero for previous non milestone operations up to the preceding milestone operation When Zero Balance WIP is No leftover quantities remain in non milestone operation queues
8. Forecasting Master Schedule Planning 347 In these cases it is impossible to accurately forecast all of these possible combinations for master production scheduling purposes Instead you can forecast items at the family item and planning or option item levels Multilevel master scheduling enables you to perform this type of forecasting for planning purposes Planning Bills You can establish the relationship between family level items and component items by defining planning bills in Product Structure Maintenance 13 5 or Formula Maintenance 15 5 These are identified with a structure type of P planning Usually the top level item of a multilevel master schedule product structure or planning bill represents the entire group or family of products that can be configured from a set of available models and options Family items are never manufactured or stocked You must define family items with a Pur Mfg code of Family F in Item Master Maintenance 1 4 1 Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 Components of the family item in the planning bill can be any type of item manufactured configured or another family item A planning bill also contains a forecast percentage The forecast percentage is the probability that a component of the family level or parent item will be required given the requirements for its parent Components with structure code Planning consume the forecast for their
9. 50 100 112 0 5 56 cus NR 1002 Pulp 112 30 100 112 0 3 2 33 6 MAX Method 1003 Seeds 112 10 100 112 0 1 11 2 Based on these expected quantities mix variance calculations are as shown in Table 5 14 Table 5 14 Order ID Product Mix Variance Calculation Sample Mix 1001 Orange Juice 56 56 1 50 0 1 50 0 00 efto 1002 Pulp 33 6 28 0 50 5 6 0 50 2 80 MAX Method 1003 Seeds 11 2 15 0 60 3 8 0 60 2 28 When the Maximum method is used the co product that consumed the largest quantity of the base process in proportion to the quantity ordered always has a zero mix variance This is because the base process quantity complete is derived directly from the actual quantity complete for that co product The Maximum and Minimum methods are most appropriate when a particular co product in the co by product structure is considered the primary co product for the base process A primary co product typically drives demand and determines the rate of production for the base process Examples of production processes that involve a primary co product include sheet metal stamping and injection molding Minimum If Quantity Complete Method is set to MIN in the co by product structure the system performs the same calculations for each co product in the joint order set as when Quantity Complete Method is MAX However the calculation that yields the lowest rather than the highest result is
10. A supply order was created for a quantity greater than the maximum quantity set in the item planning data Scheduled supply order receipt is past the due date Unsatisfied material requirement exists inside the planning time fence for the item MRP will not create planned orders within the time fence You should either manually schedule and expedite orders to fill this demand or delay fulfillment of the requirement that created the demand A shipment for an intersite request item is due Action should be taken at the source site to ensure that the order is received on time A shipment for an intersite request item is past due You should either delay the orders that created the requirement for the item or expedite them when the item does arrive Material Requirements Planning 375 Message Meaning No Source Of Supply A valid source network is not available for the date a DRP item is required Either the item or item site planning data does not reference a source network or the source network is not effective on that date Planned Order Count An item site combination generated the maximum number Exceeds Maximum of planned orders MRP currently cuts off the creation of orders for an item site combination at 1000 Calculation for other items continues This prevents runaway calculations caused by for example an incorrect item order quantity Planned Orders MRP generates planned orders to satisfy net requirements for items wit
11. In this case the table simply indicates one or more typical programs associated with the transaction and is not intended to be a complete list Shop Floor Control Transaction Type Description Program BACKFLSH Advanced Repetitive labor and Backflush Transaction 18 22 13 material usage CLOSE Operation closed Cumulative Order Close 18 22 10 DOWN Non productive labor reported Labor Feedback by Work Order for Shop Floor Control functions 16 20 1 DOWNTIME Downtime hours reported for Repetitive Labor Transaction 18 14 Repetitive and Advanced Down Time Transaction 18 22 20 Repetitive functions EXPENSE Expense consumed for Customer Call Activity Recording 11 1 1 13 Services functions Project Activity Recording 10 5 13 FLOORSTK _ Floor stock inventory expense Post Accumulated Usage Variance posted at order close 18 22 9 LABOR Labor hours reported for Repetitive Labor Transaction 18 14 Repetitive Advanced Repetitive Run Labor Transaction 18 22 14 and Customer Services functions Call Activity Recording 11 1 1 13 Project Activity Recording 10 5 13 MOVE Moved to next operation Labor Feedback by Work Order 16 20 1 MUV CMP Material usage variance posted Post Accumulated Usage Variance for component usage variance at 18 22 9 order close MUV WIP Material usage variance posted Post Accumulated Usage Variance for WIP material scrap usage 1
12. Processing a Subcontract Operation Processing a subcontract operation when using WIP Lot Trace and Advanced Repetitive adds a few minor steps to the subcontract procedure Note This procedure assumes that you have already backflushed all operations previous to the subcontract operation 1 Create a scheduled order in Supplier Scheduled Order Maintenance 5 5 1 13 Specify the appropriate cumulative work order ID and subcontract operation Note The system automatically populates the work order ID and operation fields when it creates a cumulative ID through any Advanced Repetitive transaction 2 Createa subcontract shipper in Sub Shipper Maintenance 18 22 5 5 a Use the parent item site as the ship from and the supplier as the ship to b Use the cumulative order ID and subcontract operation used on the scheduled order WIP Lot Trace 297 c Specify the WIP lot serials and quantity being sent to the P See page 283 subcontractor in the WLT WIP Lot Move Data frame Select Help to display a list of WIP lot serials produced at the previous operation 3 Print the subcontract shipper using Sub Shipper Print 18 22 5 9 The WIP lot serials entered in the WIP Lot Move Data frame display as Lots Shipped 4 Confirm the subcontract shipper using Sub Shipper Issue 18 22 5 11 This moves the indicated WIP lot serials from the output queue of the previous operation to the input queue of the indicated operation 5 Receive the schedule
13. Retesh gt Purchase Order hers Number C21 1Component 7 Ta GT T Comporert d i ho To Cota 7 telema Buyer Te os Lf Schedule Type 5 5 Sucgles Parning Sch AcweMet Ache vl iot Opt T 1 By Sho To Supeka em PO 2 By hens She To Sgen PO y FO Den Displaying Components Your purchased component may not display in Component Check by Item Work Order Browse When this happens it is typically because 1 The browse is driven by work order demand records where an exploded BOM exists An item record only displays when it is created by an exploded BOM record If the purchased part demand is driven directly from a sales order forecast safety stock and so on the item record does not display in the list If the item belongs to a BOM of a manufactured item but still does not display in the list it is because you need to run CRP to explode the P lanned status work order to which this item belongs Run CRP for planned orders to generate the exploded BOM Examples You can anticipate when a material shortage typically occurs in your production cycle to determine if your supply meets future demand For example if a material shortage typically occurs two to three days before a standard supplier delivery on the first of every month you can factor in this anticipated shortage and view incoming supply to determine if the demand can be met Repetitive 247 Since you can view both planned and confirmed orders f
14. 0 0000 e eae 332 Generating Reports 0 0 eee eee eee nee 335 Making Forecast Data Visible to MRP esses 336 Deleting and Archiving Forecasting Detail Records 338 Maintaining Forecasts Outside of Forecast Simulation 338 Consuming Forecasts es certesa rwr pe Wa Aa CREE DUET ES 339 Sales Order Demand ios eise rapae taa noah EESE EER eee 340 Net Forecast Calculation 0 0 0 cee eee eee 340 Forward and Backward Forecast Consumption 341 Creating Master Production Schedules 0 0 0 0 cece ee eee 343 Master Scheduled Items 0 0 0 0 0c eee eee eee 343 Approaches to Master Scheduling eel 343 Available to Promise lsseee 345 Multilevel Master Scheduling 0 0 0 ce ee eee eee 346 Maintaining Master Schedule Orders 00 004 349 Verifying Capacity for Master Schedules 0 351 Master Scheduling for Seasonality 0 00 c eee eee 351 Generating Master Schedule Reports 2 00 0 5 353 Chapter 13 Material Requirements Planning 355 Introduction 332 ates rro kad beg repa d eb dea a pesi te Re 356 MRP and Sites ei csse ee e Ee eR Rede ba ebbe 356 Sources of Demand and Supply 0 0 0 e eee eee ee 356 Setting Up MRP ia ec cea cee e See eee eee bina Pe eee s 357 MRP Control 52 t Rer ecd e x Re a ac suena 358 Item Planning D
15. FAQAD 216 User Guide QAD Manufacturing Backflushes components used in the subcontract items If you use PO Shipper Maintenance you can record the subcontract receipt and take time to compare the actual received items against the receipt quantity Use PO Shipper Receipt 5 5 5 11 and 5 13 20 to update inventory and the GL after you manually verify received subcontract items and quantities with PO Shipper Maintenance Note PO Fiscal Receiving 5 13 16 functions similarly to PO Shipper Maintenance however fiscal receipts are typically for inventory as opposed to receipts for subcontracted services Therefore subcontract shipping receipt functionality as described in this section does not apply to PO Fiscal Receiving Connecting Shippers to Received Items gt For more When receiving subcontracted items you can connect subcontract information on shippers to the receipt for more subcontract visibility connecting shippers see page 209 When you connect a subcontract shipper ID to purchase order lines you are receiving against you can also See Moving Place the items into finished goods automatically if the subcontract Finished operation is the last operation and the items are lot or serial Subcontract Items to controlled I tory page 224 T Note If WIP item components are lot serial controlled you must use the Advanced Repetitive Move Transaction 18 22 19 to record the WIP item placement into inve
16. Most user documentation is available in two formats Portable document format PDF files can be downloaded from the QAD Web site to your computer You can view and print them with the free Adobe Acrobat Reader HTML files let you view user documentation through your Web browser and use search tools for easily locating topics of interest Conventions Screen Illustrations System functions are available in a feature rich NET based graphical user interface UI a subset of functions can be used in a simplified character interface All screenshots in the documentation show the NET UL Navigation in the two UIs is not the same The user guide text follows the navigation model of the NET UI for moving from one screen to the next In the character interface the Progress status line at the bottom of a program window lists the main UI specific keyboard commands used in that program In the NET UI alternate commands are listed in the Actions menu For complete keyboard command summaries for UI navigation refer to the appropriate chapters of User Guide QAD User Interfaces Typographic This document uses the text or typographic conventions listed in the following table If you see It means monospaced text A command or file name italicized A variable name for a value you enter as part of an operating monospaced text system command for example YourCDROMDir FAQAD 4 User Guide QAD Manufactu
17. Once a formula has been defined for a particular product that product can produce a higher level product This is typical of a master batch or an oven heat which processes other items When discrete components are issued such as packaging and labels closing the process batch work order and issuing the batch to a discrete packaging work order can be useful The system offers process discrete and model option work orders or paperless repetitive scheduling in a single environment You can backflush components for any of these types of production scheduling A formula sometimes called a recipe defines the ingredients for a manufactured item Use Formula Maintenance 15 5 to define formulas The system automatically assigns the item number to the BOM Fig 4 2 Tx Formula Formula Maintenance Go To Actions Maintenance 15 5 Parent Item BRACKBCT4 None 00 Batch Size 1 EA Description Bumper Rack for BCT4 Component Item APS 1111 Component 1111 Rev Reference Effective Date Ta Quantity per Batch fy EA Scrap 0 00 m Lead Time Offset Operation Quantity Type o o Batch Percent Structure Type Sequence Number Start Effective M Forecast Percent 100 0096 End Effective v Option Group P Remarks Process P FAQAD 48 User Guide QAD Manufacturing b See page 17 FAQAD This program is very similar to Product Structure Maintenance Only additional fields are described here Bat
18. Setting Up a Co By product Structure 0 0000 62 Setting Up Structures for Recyclable By products 64 Setting Up Unit of Measure Conversion Factors 66 Setting Up Alternate Base Processes 00000 c eee ee eee 67 Setting Up Alternate Base Process Routings 67 Setting Up Definitions for Valid Substitute Items 68 Calculating Costs and Lead Times 0 00 e cee eee 69 Allocating Costs to Co products 0 0 0 0c e eee eee eee 69 Entering By product Costs 71 Freezing By product Costs 1 0 0 cece eee ee eee ee 71 Rolling Up Costs 0 0 eee III 72 Calculating Average Costs for Co products 2 0 72 Defining the Average Cost Allocation Methods 73 Average Cost Accounting 0 0 cece eee eee es 75 Rolling Up Lead Times ssseeeeeee eee 76 vi User Guide QAD Manufacturing Reviewing Product Costs 0 0 eee eee ene TI MRP for Co products By products seeeee eee TI Planning for By products 0 cece eee eens TI Planning for Co products 0 0 0 eee eee 77 Planning for Base Processes 0 0 0 e eee eee eee eens 79 Reviewing Updating and Reporting Action Messages 79 Approving Planned Work Orders lees 80 Creating Planned Order Reports llleleeeeeeeeess 80 Creating MRP Summary Reports 0 0 e eee
19. Standard Operation Work Center 100 01 Assembly Machine Description Machines per Operation 2 Milestone Operation 7 Overlap Units 0 Subcontract LT 0 Queue Time 2 0 Setup Crew 2 00 Wait Time 1 0 Run Crew 5 00 Setup Time 0 0 Yield Percent 100 0096 Run Time Batch Qty 0 0 Tool Code Move Time 0 0 Supplier Start Date Subcontract Cost 0 00 End Date Comments Batch Quantity A system maintained field recording the normal batch quantity for an item If the formula was entered in Formula Maintenance Batch Quantity defaults from the item master Otherwise it defaults from Formula Code Maintenance Use Batch Quantity Change 15 9 to change the value Ingredient quantity per and process operation run times are stated in terms of this batch quantity Run Time Batch Qty Enter the process operation run time in terms of the batch quantity for the item To save data entry time when defining processes for items that share similar operations or when creating alternates copy an existing definition record with Process Definition Copy 15 16 Then add change or delete operations as needed Formulas and Processes 51 Process Formula Maintenance Process Formula Maintenance 15 18 lets you enter formula batch process and co product by product information from a single menu program This is particularly useful when you are setting up processing for co products by products Process Formula Maintenance
20. Use it to trace component WIP material and finished goods based on parent items product structures and routings WIP Lot Trace 253 WIP Lot Trace and Regulatory Attributes The WIP Lot Trace module and the Regulatory Attributes module trace P See User Guide material at different stages in the manufacturing process gan Master With Regulatory Attributes lot control you trace inventory and the consumption of component material lots into finished material lots With WLT you trace consumption of component material lots into WIP material lots and the consumption of WIP and additional component material lots into finished material lots The two modules can work together or individually Performance is seamless when using one or both of these related but different modules Each module requires separate setup and operation When using automatic lot numbering features of Regulatory Attributes the finished item lot serial number is automatically created when the item is moved into finished item inventory Automatic lot numbering occurs even if you are using WLT If you are not using automatic lot numbering you can assign a new lot serial number to the finished item or use the WIP lot serial for the finished item Features Using the WIP Lot Trace module you can Trace lot and serial numbers of WIP material throughout the manufacturing process including WIP material processed by multiple subcontractors Create flexible registrati
21. Work Center Capacity CRP uses work center capacity when evaluating work center load It is the total number of hours the work center is available to do work Capacity varies with the work center calendar or shop calendar and the number of machines or people in the work center The formula is Work Center Capacity Calendar Hours Available Machines The work center number of machines should be at least as high as the number of machines per operation for this work center and for operations that use this work center QAD 32 User Guide QAD Manufacturing Fig 3 4 Standard Operation Maintenance 14 9 b See Lead Times on page 37 FAQAD Standard Operations Often routings share one or more operations that are essentially the same For example an automated packaging process may be the same regardless of the color of the products packaged To save work when entering new routing operations you can create template steps called standard operations When you enter a new routing operation automatically copy the standard data to the routing by referencing the standard operation code Then edit the standard information as needed Changes apply only to the new routing not to the standard operation you copied Note If you change a standard operation after referencing it on a routing the changes do not automatically apply to the existing routing Use Routing Update 14 13 7 to apply any changes you made to standard ope
22. Work Order Approval 23 10 these orders can be managed in the Work Orders module Releasing a sales order or service return material authorization RMA for a configured item to a work order in Sales Order Release to Work Order 8 13 Releasing an RMA receipt line to a work order with RMA Release to Work Order 11 7 1 5 Releasing a parent work order for an item with a routable component creates a related work order for the component Some work orders are created and managed in other modules These cannot be updated in Work Order Maintenance Work orders created by entering repetitive schedules are managed in the repetitive module Work orders created to handle customer service activities are managed with Call Activity Recording 11 1 1 13 in the Service Support Management module and Project Activity Recording 10 5 13 in the Project Realization Management module Customer services work orders are included on standard work order reports Work orders created by entering flow scheduled orders in Flow Schedule Maintenance 17 13 3 that do not include references to existing work orders are managed in the Flow Schedule module Work Orders 105 b See User Guide QAD Service Support Management for details b See User Guide QAD Lean Manufacturing QAD 106 User Guide QAD Manufacturing Fig 6 4 Work Order heit Maintenance 16 1 Work Order 1006 Go To Actions Type
23. as menu option 3 22 13 When activated additional frames display in some programs The discussion in this chapter assumes that WLT features are not active Setting Up Repetitive Setup activities for Repetitive are almost exactly the same as for Advanced Repetitive You need the same kind of base data such as items sites locations employees product structures and routings The programs used to set up production lines allocation percentages shifts and changeover times are identical in both modules Repetitive 229 Defining Control Program Settings Settings in Repetitive Control 18 24 differ from those in Advanced Repetitive Fig 9 1 zx Repetitive Control Repetitive Control Go To Actions 18 24 Next Picklist P L Prefix PL Consume Forward 0 Consume Back 0 Start of Week None Allow Zero Run Rate Next Picklist and P L Prefix Same as Repetitive Control 18 22 24 in Advanced Repetitive Consume Forward and Consume Back These fields in coordination For more with Start of Week determine how the system handles item pea see completions that exceed the quantity scheduled for a given day Completions on age 233 When Consume Back or Consume Forward is nonzero and you pag record more completions than scheduled the system consumes open quantities on past schedules then future schedules based on the number of calendar days specified in these fields Schedules with due dates before
24. conversion occurred This refers to for example any operation where a component is introduced and becomes part of the WIP material or where a rejected WIP material was reworked and assigned to a different lot serial The report shows the data recorded in these programs Purchase Order Receipts 5 13 1 Purchase Order Returns 5 13 7 Work Order Component Issue 16 10 Work Order Receipt 16 11 Work Order Operation Backflush 16 19 Labor Feedback by Work Order 16 20 1 Labor Feedback by Employee 16 20 2 Labor Feedback by Work Center 16 20 3 Repetitive Setup Transaction 18 13 Repetitive Labor Transaction 18 14 e Repetitive Rework Transaction 18 16 Repetitive Reject Transaction 18 17 Backflush Transaction 18 22 13 e Run Labor Transaction 18 22 14 Setup Labor Transaction 18 22 15 Rework Transaction 18 22 17 WIP Lot Non Convert Trans Report 3 22 13 16 Shows operation history data that references WIP lot and serial numbers but does not include records where material was converted WIP lot and serial numbers recorded during transactions in the following programs are reported e Repetitive Reject Transaction 18 17 e Reject Transaction 18 22 16 e Repetitive Rework Transaction 18 16 Rework Transaction 18 22 17 Repetitive Scrap Transaction 18 18 Scrap Transaction 18 22 18 WIP Adjust Transaction 18 22 21 Note Information recorded
25. picklists 122 receiving items 127 release date 115 releasing 120 routable 109 co product by product 84 routing 114 modifying 120 scheduling 115 scheduling operations 118 splitting 121 statuses 110 allocated 113 batch 112 closed 113 exploded 112 firm planned 112 planned 111 released 113 subcontract operations 126 tracing WIP 284 291 types cumulative 109 expense 108 final assembly 108 rework 107 scheduled 109 standard 106 user ID recorded 135 Index 403 Y yield 41 enabling operation based 359 example 42 including in repetitive schedules 159 material requirements planning MRP 364 368 MRP Control 359 work order 114 Yield field 41 FAQAD 404 User Guide QAD Manufacturing FAQAD
26. product structures 18 efficiency 151 employee 141 employee code when scrapping 222 Employee Create 36 1 7 1 141 employees efficiency 141 labor feedback 141 End Eff Days field 159 engineering change orders 23 engineering effectivity 23 exceptions BOM components 272 BOMs 272 routing 268 routing operation 270 expense work orders 108 expensed items 21 Exploded status work orders 240 exploded work orders 112 explosion advanced repetitive schedules 175 F FAS See final assembly FAS feature codes configured product 17 final assembly FAS work orders 108 finished items 224 firm category 241 firm planned work orders 112 Firm status work orders 240 first article inspections 317 fixed order quantity FOQ 363 floor stock 20 Index 393 expensed items vs 21 FOQ Fixed Order Quantity 363 Forecast Maintenance 338 Forecast Worksheet Maintenance 338 forecasting 319 342 adding methods 328 alpha factor 327 calculating forecasts 328 combining criteria templates 334 consumption 339 forward and backward 341 copying criteria templates 334 forecasts 332 results 334 creating detail records 329 creating forecasts 320 creating forecasts manually 330 criteria templates 322 329 detail records loading into summary forecast 337 loading methods 337 horizon 321 material requirements planning MRP 336 methods 325 best fit 326 classic decomposition 326 creating custom 327 double exponential smoothing 326 double movin
27. shown in Table 5 6 Co By product Order Quantity Orange Juice Co product 50 liters Pulp Co product 30 kg Seeds By product 10 kg The base process unit of measure UM is KG kilograms For the first co product orange juice the conversion factor between the base process and co product units of measure is 1 2 liters LT per 1 0 KG gt For more information on work order variances see Work Order Accounting Close on page 135 Fig 5 10 Sample Co By product Structure Table 5 6 Sample Co product and By product Order Quantities FAQAD 92 User Guide QAD Manufacturing Table 5 7 Sample Co product and By product Costs Table 5 8 Sample Co product and By product Yields FAQAD Co product and by product costs are shown in Table 5 7 Co By product Standard Cost Orange Juice 1 50 per LT Pulp 0 50 per KG Seeds 0 60 per KG For a given joint order set actual co product and by product yields are as shown in Table 5 8 Qty Qty Order ID Product Complete Rejected 1001 Orange Juice 55 liters 1 liter 1002 Pulp 25 kg 3kg 1003 Seeds 15 kg Okg Note Although a single example is used to illustrate all five quantity complete methods some methods may be more appropriate to particular process environments than others To display numeric values in the following examples these conventions are used Currency amounts are rounded to the nearest hundreth Non currency decimal value
28. under the same forecast ID as the detail record Modifying Forecast Results Forecast quantities may require modification to be more reflective of future market demand This is especially true when forecast results are based on historical data that included unprecedented sales for example sales due to a sales promotion or a natural disaster When you believe that future demand will not be similar to sales history you can adjust existing forecast detail records accordingly Note Modify forecast detail records as needed before copying forecast quantities to the summary forecasts used by MRP You can use Detail Forecast Maintenance 22 7 7 to modify forecast detail records produced by forecast calculations or loaded into the system using the CIM interface Forecasting Master Schedule Planning 331 Fig 12 5 eax Detail Forecast Detail Forecast Maintenance Go To Actions Maintenance 22 7 7 Forecast ID 2007 9 Method 00 Forecast Year 2007 Item Number 3 BB 49 UM EA Year Month Original Forecast Adjusted Forecast 2007 January 2000 2000 2007 February 2000 2000 2007 March 2000 2000 2007 April 2050 2050 2007 May 2200 2200 2007 June 2500 2500 2007 July 2700 2700 2007 August 3000 3000 2007 September 2700 2700 2007 October 2500 2500 2007 November 2050 2050 2007 December 2000 2000 Total 27 700 27 700 Select a forecast detail record to modify by specifying a forecast ID and forecast year To select a forecast de
29. 1 Forecasting Simulation Information Flow FAQAD 322 User Guide QAD Manufacturing FAQAD To produce a forecast for a given year you must specify a forecast ending year that is earlier than the forecast year To produce a 12 month rolling forecast beginning in the current month the ending year must be the same as the forecast year Note The system defines the first week of a new calendar year as the first Thursday in January in accordance with ISO standards Setting Up Forecasting Simulation Forecasting simulation programs analyze shipment history data in the customer product sales history cph_hist table For shipment history to post to cph_hist Integrate with SA must be Yes in Sales Order Control 7 1 24 Creating Criteria Templates Producing a forecast begins with defining a criteria template Criteria templates indicate which sales history to analyze and how the system should perform the forecast calculation You can define criteria templates using Simulation Criteria Maintenance 22 7 1 or use Simulated Forecast Calculation 22 7 5 to define them at the time of forecast calculation Once you use a criteria template in a forecast calculation you cannot modify it using Simulation Criteria Maintenance However you can modify previously used criteria templates when performing forecast calculations in Simulated Forecast Calculation Simulation Criteria Maintena Simulation Criteria Maintenance Forecast I
30. 100 H DOO Ste V BenNuse 2 Y QuanfyOnMand 2 Y Locaton oF Lo Semw OW Netwence 2 V Sua OY DaeOewei oY LxwDae 5 Y Total On Mand ox Component Check by Work Order Work Center Production schedulers can use Component Check by Work Order Work Center to quickly determine component availability for discrete work orders for a particular work center Checking components by work center lets production schedulers know if the production schedule is viable for the week Production schedulers for discrete work orders need the same questions answered as production schedulers who work on repetitive orders For discrete work orders they use Component Check by Work Order Work Center to View work order work center data by any combination of site center or operation item due or release dates quantity complete open or ordered and more Identify which discrete work orders have material shortages related to them dentify the components causing the shortage related to a discrete order Locate and determine the cause of material shortages View both planned and scheduled orders associated with a primary production line View in transit supply in the form of ASN receipts FAQAD Repetitive 245 Fig 9 7 PETTEE EEr Component Check Actions Print lp Add to Favores oly choi E Chan Designer Roiesh gt by Work Order pua e Work Center 10 gt date t 2D x Seach Cow AR Viessrg 1 100 of 887 Records per page 100 lt
31. 15 Subcontract Routings The way the routing is defined affects subcontracting for repetitive and advanced repetitive operations including subcontract lead time and subcontract cost Setting Up Locations The locations used to backflush inventory vary depending on the number of production lines and how items are supplied The flow of inventory to the production line usually follows one of two patterns Inventory is received from a supplier or WIP into a central storage location then transferred from storage to the production line as needed Advanced Repetitive 169 Inventory is received directly from a supplier or WIP to the production line where it is consumed In the first there is a primary stocking location and one or more locations where the item is eventually consumed In the second there may be a single stocking location on the production line Note An item s primary stocking location is defined in Item Data Maintenance 1 4 3 A production line location instead of the primary stocking location can be set up to backflush material To do this set up an inventory location for the production line and give it a location code that is the same as the work center code for the backflush operation Simulating Schedules in the Workbench You can use a single repetitive schedule for an item that is manufactured on a single production line with a known rate of production However consider using Line Schedule Workbenc
32. 17 Product Structures 15 Alternate Structures Formulas An item can use a product structure that is defined for a BOM code different from the item number After you have defined a BOM code and a product structure or formula link it to an item based on how it will be used If the structure formula should be the default for an item update the BOM code in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 The system uses this BOM code for MRP work orders repetitive manufacturing and costing If the structure formula should be the default for an item at a particular site update the BOM code in Item Site Planning Maintenance 1 4 17 The system uses this BOM code for MRP work orders repetitive manufacturing and costing for an item at a site This overrides the BOM code set up at the item level If the structure formula should be available as an alternate for an item at any site use Alternate Structure Maintenance 13 15 to link the BOM code with an item You can then change the BOM code on a work order to this alternate structure formula If the structure formula should be available as an alternate for an item at a specific site when a specific routing is used use Alternate Routing Maintenance 14 15 1 to link a BOM code and routing code to an item site You can then change the BOM code on a work order to this alternate structure formula when using the specified routing code Phantoms Sometimes enginee
33. 18 4 2 Repetitive Transaction Detail Inquiry reopiq12 p 18 13 Repetitive Setup Transaction reoptr07 p 18 14 Repetitive Labor Transaction reoptr10 p 18 16 Repetitive Rework Transaction reoptr13 p 18 17 Repetitive Reject Transaction reoptr11 p 18 18 Repetitive Scrap Transaction reoptr14 p FAQAD Advanced Repetitive WIP Lot Trace 257 Table 10 6 shows the Advanced Repetitive programs affected by enabling the WIP Lot Trace module Table 10 6 Menu Description Program Advanced 18 22 4 2 Operation Transaction Detail Inquiry reopiq02 p E Affected 18 22 4 11 WIP Status Report reworp05 p by WLT 18 22 5 4 Sub Container Maintenance rectmt p 18 22 5 5 Sub Shipper Maintenance reshmt p 18 22 5 9 Sub Shipper Print rerpll p 18 22 5 11 Sub Shipper Issue resubis p 18 22 5 13 Subcontract Scrap Maintenance resscrap p 18 22 10 Cumulative Order Close reclose p 18 22 12 WIP Status Inquiry rewoiq05 p 18 22 13 Backflush Transaction rebkfl p 18 22 14 Run Labor Transaction relbr p 18 22 15 Setup Labor Transaction reset p 18 22 16 Reject Transaction reject p 18 22 17 Rework Transaction rework p 18 22 18 Scrap Transaction rescrap p 18 22 19 Move Transaction remove p 18 22 21 WIP Adjust Transaction rewadj p QOH and Cumulative WIP Balances When the WIP Lot Trace module is active some Repetitive Advanced Repetitive and Work Orders programs maintain WIP inventory and QOH balances by lot QOH and WIP cumulative balance records are maintained for quantities sc
34. 2 Non Productive Labor Feedback Non Productive Labor Feedback x Non Productive Non productive Labor Feedback Go To Actions Labor Feedback 16 20 4 Employee BIW 2 Shift 1 Pay Code Reg Project 500 2 Effective Date 02 22 2007 Work Center WC1 Fe Machine 20 Site 10000 2 Dept 100 2 Reason P Type DOWN Time Ind Decimal Hours Start Down Elapsed Stop Down Comment 1 25 Plant Meeting Elapsed Down 0 000 You can review recorded downtime using Down Time Report 16 20 13 16 or Down Time by Reason Report 16 20 13 17 Reporting Scrap You can use Operation Scrap Transaction 16 20 7 to report scrap of partially completed finished goods items at a work order operation This program generates WO SCRAP operation history records for transactions and has no effect on GL accounts FAQAD 146 User Guide QAD Manufacturing The first frame is used to identify the work order operation Use the last frame to enter quantities scrapped and the corresponding reason codes Fig 7 3 Operation Scrap Transaction Operation Scrap Transaction 16 20 7 Work Order Item Number Operation Effective Date Employee Work Center Department Project Quantity 1 0 0 0 0 0 0 0 0 0 0 0 matioo 1 BB 10 02 22 2007 0001 100 01 100 500 Reason expired size Go To Actions 2 ID 43 Fe Work Order Status R Red Bean Bag Shift 1 Machine Assembly Dept New Assemb
35. 36 9 11 includes two settings that impact the general ledger transactions created by work orders z2 Work Order Accounting Control Go To Actions Post variances at SFC v Qty Complete Mthd SUM SUMMARIZE Post variances at SFC This field sets the default for the same field in Work Order Maintenance Yes Labor and burden variances are calculated and posted whenever shop floor labor feedback transactions are entered No Variances are suppressed and not calculated or posted until the work order is received Setting this field to No reduces the number of variance transactions posted to the general ledger particularly if there are many shop floor labor transactions processed before material receipts are recorded If you have very long run times set this field to No suppressing variance calculations until finished product is received If you have short run times set this field to Yes Quantity Complete Method The value of this field defaults to Process Formula Maintenance 15 18 and Co By Product Maintenance 15 12 1 and affects the calculation of mixed variances Creating Work Orders Work orders are created directly using Work Order Maintenance 16 1 For convenience you can also create them in Master Schedule Order Maintenance 22 13 The two programs are identical Work orders are also created as the result of executing other functions e Running MRP generates planned orders Once approved in Planned
36. 4 145 18 22 8 182 17 5 144 146 18 22 9 196 17 7 145 289 18 22 10 183 17 13 12 151 18 22 11 182 17 13 16 145 18 22 12 199 17 13 17 145 18 22 13 156 187 191 204 212 291 17 13 22 150 18 22 14 193 292 17 23 152 18 22 15 193 292 17 24 142 18 22 16 193 18 4 10 235 18 22 17 194 292 18 14 233 18 22 18 195 210 293 18 17 299 18 22 20 193 18 18 235 299 18 22 21 195 293 18 21 2 299 18 22 22 193 18 22 1 1 161 18 22 24 158 18 22 1 6 165 18 24 229 18 22 1 10 169 19 1 1 306 18 22 1 11 163 19 1 13 307 18 22 1 12 163 19 2 1 308 18 22 1 13 296 19 3 1 309 18 22 1 15 172 19 3 14 310 18 22 1 18 173 19 7 312 18 22 1 22 163 19 11 313 18 22 1 23 165 19 13 314 18 22 2 1 174 19 20 318 18 22 2 4 175 211 19 23 314 18 22 2 6 157 19 24 305 18 22 2 7 157 22 1 338 18 22 3 9 179 22 2 338 18 22 3 1 175 176 22 7 1 322 18 22 3 5 179 22 7 5 328 18 22 03 6 176 22 7 7 329 18 22 3 6 179 22 7 11 332 18 22 3 8 179 22 7 12 332 18 22 4 1 199 22 7 13 336 18 22 4 3 199 22 7 17 325 328 18 22 4 4 199 22 7 23 338 FAQAD 22 9 352 22 13 105 344 350 22 21 354 22 22 354 23 1 371 23 2 372 23 3 360 372 23 5 79 373 23 7 79 373 23 8 376 23 10 80 376 23 11 376 23 12 80 23 14 80 23 16 370 23 17 80 370 23 22 371 23 24 358 24 1 118 380 24 4 383 24 5 383 30 13 19 72 36 2 21 1 266 36 9 11 104 36 9 12 158 A accounting close joint work orders 59 work order 135 accounts department 28 Action Message Report 373 co products by products 79 Act
37. 83 Alternate Structure Maintenance 15 co products by products 67 83 alternate subcontractors 200 API See application programming interface ATP application programming interface API and Subcontractor Shippers frame 226 FAQAD 390 User Guide QAD Manufacturing updating shippers 226 user interface suppression approval MRP planned orders 376 archive delete forecast detail 338 quality orders 314 work orders 137 assigning work order and operation 156 212 asterisk in displays 237 ATP See available to promise ATP Auto Labor Report field 168 automatic completion of operations 146 labor backflush 168 available to promise ATP 345 average cost co products by products 72 75 Average Cost Method Maintenance co products by products 73 B backflush co products by products 85 86 labor automatically 168 locations 168 method co products by products 62 work order receipt 129 transactions 192 work order quantity to issue calculation 129 Backflush Transaction 156 187 191 212 291 fields 192 test results 314 tracing WIP 291 base process 56 alternate 67 alternate routings 67 BOM Formula codes 56 planning for 57 restricting inventory transactions 60 setting up item 60 batch formula quantity type 48 quantities 18 size for formula 48 work orders 112 Batch status work orders 240 bills of material See product structures BOM codes 14 as parent items 14 AQAD co products by products 61 linking to items 15
38. BOM Registration Maintenance 272 BOM See product structures bottom up view 245 browse collection tracing source record 237 burden 31 by products costs 70 definition 55 lead times 77 Material requirements planning MRP 77 recyclable 64 setting up items for 61 C calculating forecasts 329 picklists 176 calculation commitment categories 241 calculations for component check 239 Calendar Maintenance work center calendar 27 calendars shop MRP use of 375 work center 27 capacity adjusting 384 department 380 operation 33 shift 164 work center 31 380 capacity requirements planning CRP 379 385 adjusting capacity 384 adjusting load 385 defining capacities 380 department labor capacity 28 lead times 37 load reports 383 operation capacity 33 scheduling operations 381 work center capacity 31 Certificate of Analysis Print 318 changeover times 165 checking material shortage 246 closed work orders 113 close date 135 closing cumulative orders 183 closing subcontract shippers 218 Co By Product Maintenance 69 83 86 Quantity Complete Method field 90 104 Co By Product Work Order Inquiry 84 Co By Products Cost Report 72 77 combining receipt and inventory placement 200 commitment categories 241 component availability calculations 239 Component Check by Item Work Order 245 Component Check by Work Order Production Line 243 Component Check by Work Order Work Center 244 component check examples 246 Component Status field 239 co
39. Control 16 20 24 Shop Floor Control 143 Quantity Rejected The number of unacceptable units produced at this operation that cannot be moved to the next operation Quantity Reworked The number of unacceptable units requiring additional processing produced at this operation These do not all need to result in good units that can be moved to the next operation Quantities reported as completed rejected and reworked do not affect the quantity open for a work order If the reject quantity significantly reduces the expected receipt quantity for an order you should use Work Order Maintenance 16 1 to reduce the order quantity to the expected quantity so that MRP plans based on the correct order quantity Rejected and reworked quantities are independent of each other For example if you report 25 units as rejected and later report 25 units as reworked the system shows both the reject and rework quantities as 25 If you want to change the reject quantity to zero you must specify a reject quantity of 25 units Reject and rework quantities have no impact on GL since no transactions are created when they are reported They are not used to calculate variances or work center efficiency Times You can enter setup times run times and downtimes in decimal hours D or clock hours H For example an hour and 15 minutes can be entered as 1 25 decimal hours or 01 15 00 Enter elapsed setup and run times directly or let the system cal
40. Enter the site to which these by product costs apply Cost Set Enter the cost set to be frozen Item Number Enter item numbers for all by products whose costs are to be frozen Freeze Unfreeze Enter Freeze FAQAD 72 User Guide QAD Manufacturing FAQAD Rolling Up Costs Roll up lower level costs using Product Structure Cost Roll Up 13 12 13 or Simulation Structure Cost Roll Up 30 13 19 Keep in mind that the BOM Formula code associated in the item master determines the base process for a co product Note During roll up the system calculates and updates base process item costs using the unit of measure UM of the BOM Formula code for the base process This UM must be the same as the item UM for the base process Item Number To Typically this program is run for all items The system only updates base process item costs when roll up selection criteria include all items in the co by product structure Site Enter the site to which these costs apply Cost Set Enter the cost set to which these costs apply This is normally the GL or current cost set at the selected site Choose Next to begin roll up and Back when roll up is complete To see the results of the roll up use Co By Products Cost Report 13 12 7 Calculating Average Costs for Co products Cost averaging for co products happens when you close a work order using the following programs Work Order Receipt 16 11 Work Order Receipt Backflush 16 12
41. FAQAD iv User Guide QAD Manufacturing Chapter 2 Product Structures 2 00 cee eee eee 11 Introduction 2 ess edoseso ddowses Beau E E eee eae Elana 12 BOM Cod 0S sis ceii cerceii cere ee ERR he saad E ou bee ea PRG ee 14 Alternate Structures Formulas 0 0 0 cece eee eee eee 15 Phantoms zoe esc eR ido e aaa ae danas Ea reu esas 15 Simulated BOM Inquiries 0 0 cee ee eee 16 Setting Up a Product Structure eee 17 Related Topics ii scite ees eret bee RR RE cba ae eae 20 Flo ot StoCK i uror m ebbe t Re cbe 20 Relationship with Configured Products 0 008 21 Component Substitutions llle 21 Cumulative Lead Time 1 0 eee eee eee 22 Engineering Effectivity 2 0 0 0 eee eee eee 23 Chapter 3 Routings and Work Centers 25 Introduction ais etna idawds osha re ace erano ae b law cta dcn sad 26 Departments 2m eret nk kem cem e deve de e iler e ve carece 28 Work Centers ims c rere vete ee rac up aree a eee UR E 29 Work Center Capacity eseeeeeee e 31 Standard Operations 2 2 sss e ac e e e bet OR Ras e 32 Operation Capacity sedes epu e Rede xu kd RA EGUR Eae 33 Rou ngs 2eneesy crar ias DO eua Lebe eere edd Sea ese EDT EY ed 34 Alternate Routings lsseleeeee I 36 Work Center Routing Standards 00 eee eee ee eee 36 Routing Cost Roll Up 1 0 0 0 02 cece eee eee 37 Lead TIMES MORE 37 Operation Lead Time
42. If defined lot groups are used rather than the work order ID During receipt you can set the work order status to Closed Once closed no further component issues or completions can be recorded against the order The system captures the receipt and close date as well as the user ID of the person who received or closed the work order This information automatically appears on two reports Work Order Status Report 16 3 3 Work Order History Report 16 3 6 Closing a work order does not clear the balance in WIP This action is done by using Work Order Accounting Close 16 21 Receiving and Backflushing When you backflush components at work order receipt the system explodes the item product structure by the quantity of the parent item received to calculate the standard component quantities used Users can control the location and default quantity for backflushing In Work Order Receipt Backflush 16 12 specify a location in Backflush Loc The alternative is to backflush from the default location on the work order picklist Two fields in Work Order Receipt Backflush 16 12 enable you to control the default values for quantity to issue depending on the history of the work order Work Orders 129 Fig 6 8 z Work Order Work Order Receipt Backflush Go To Actions Receipt Backflush 16 12 Work Order 400033 1D 42 Effective Date 08 31 2007 Item Number 1 BB WO Stat R Receive V Red Bean Bag Backflush I7 Quantit
43. KG 1 00 30 00 30 00 30 P3 LT 0 50 40 00 20 00 20 Allocation by Receipt Quantity and Price The percentage of cost allocated to a co product is determined by the extended price of the total quantity received plus reject for that co product relative to the prices and receipt plus reject quantities for the other co products from a base process All quantities are converted to the base process unit of measure Co products and By products 75 Table 5 3 shows how costs are allocated by receipt quantity and price Table 5 3 Rept Rept Qty Price Price Price Rcpt Co product Costs Item UM Conv Qty KG Price KG Qty Allocation Allocated by Price and Receipt Pl KG 1 00 50 00 50 00 2 00 2 00 100 38 48 Quantity P2 KG 1 00 30 00 30 00 4 00 4 00 120 48 15 P3 LT 0 50 40 00 20 00 1 00 2 00 40 15 38 Average Cost Accounting WIP costs are the sum of component costs and shop floor control costs and are reduced by the cost of co products and by products received plus reject quantity These transactions do not update GL or current costs Costs are averaged by taking the costs accumulated in WIP and adjusting the costs of items in inventory received from WIP The system does this in two steps 1 Co products and by products are received from work orders into inventory using their current average costs 2 Average GL costs and average current costs are re averaged based on the costs accumulated for an item s work order when the work order is c
44. Load Last Week 2 Monthly forecast is loaded into the last Monday of the forecast month Load First Week 3 Monthly forecast is loaded into the first Monday of the forecast month Deleting and Archiving Forecasting Detail Records Use Detail Forecast Delete Archive 22 7 23 to delete forecasting detail records or archive them to file as needed You can also delete and archive criteria templates Maintaining Forecasts Outside of Forecast Simulation If you need to manually enter or modify item shipment forecasts outside of forecasting simulation functions use Forecast Maintenance 22 1 or Forecast Worksheet Maintenance 22 2 E Forecast Worksheet Maintenance Go To Actions Item Number 2 BB Site 10000 Year 2007 Week Forecast Sales Abnormal Prod Fcst Net Forecast 1 01 01 2007 2 000 0 0 0 0 2 01 08 2007 2 000 0 0 0 0 3 01 15 2007 2 000 0 0 o 0 4 01 22 2007 0 0 0 0 5 01 29 2007 0 0 0 0 0 6 02 05 2007 0 0 0 0 0 T 02 12 2007 0 0 0 0 0 8 02 19 2007 D o 0 o 0 9 02 26 2007 0 0 0 0 D 10 03 05 2007 0 0 0 0 11 03 12 2007 0 0 0 0 0 12 03 19 2007 0 0 0 o 0 13 03 26 2007 Q 0 Totals 0 0 0 Forecasting Master Schedule Planning 339 Forecast quantities entered using these functions display in weekly buckets and appear as a demand requirement for the Monday of that week To create new item forecasts for a given site and year enter expected weekly shipment quantities expressed in the item s unit of measur
45. Maintenance 36 2 5 Executing CRP Generate capacity requirements for manufacturing orders using Recalculate Capacity Plan 24 1 Note Generally you should run CRP after running MRP Capacity Requirements Planning 381 Fig 14 1 X Recalculate Recalculate Capacity Plan Go To Actions Capacity Plan 24 1 Site P To 2 Work Order Fe To P Item Number 2 To 2 Release Date To Due Date M To Mj Sales Job 2 To 2 ID P Supplier P Planned Orders Firm Planned Orders Exploded Orders Allocated Orders Released Orders S IS IS S Output Batch ID CRP determines capacities based on the available hours or machines for a work center or department It multiplies working days defined in the shop calendar by work center machine capacity to calculate capacity per CRP reporting period CRP explodes the routings and processes for the orders you select It then determines capacity requirements for selected manufacturing orders by scheduling their operations CRP determines operation start and due dates using the work center and shop calendars and a technique called back scheduling Back Scheduling When CRP back schedules orders it takes the due date of an order or repetitive schedule and schedules each of its operations from the last operation in the order routing or process backward to the first one CRP assigns each operation a start date and a due date usi
46. Next Batch when new orders are created Specify the default inspection site and location for new quality orders Items being inspected are transferred from their current site and location to the inspection site and location specified on the order FAQAD 306 User Guide QAD Manufacturing Fig 11 3 Master Specification Maintenance 19 1 1 AQAD Defining Specifications When a set of tests apply to more than one item set up the specification in Master Specification Maintenance 19 1 1 A master specification is a list of index numbers characteristics specifications and units of measure and additional information entered as transaction comments You can include tolerances or acceptable deviations from standard value These specifications are used by quality orders and in process inspection operations Master Specification Mainten MI B kaaita Master Specification Maintenance Go To Actions Document PROC 111 Expiration Date 02 28 2007 Description Standard Test Procedure Number Characteristic Specification Measure 1 Purity 299 9 96 2 Enter your name Actual Value The index numbers associated with characteristics and specifications must be unique but need not correspond to an actual test or inspection sequence Specification Values A specification can take any of the following forms A character string This is a list of elements separated by commas For example if acceptable colors for an
47. Ref Code Quantity Li Quality 2 0 Recording Labor Data Use the Labor WIP Lots frame to associate run and setup labor time with corresponding lot serials This frame appears in the following programs when the output queue of the operation being processed is WLT controlled Repetitive Setup Transaction 18 13 Run Labor Transaction 18 22 14 Setup Labor Transaction 18 22 15 Fig 10 15 Labor WIP Lots Labor WIP Lots Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial FAQAD 282 User Guide QAD Manufacturing Fig 10 16 WIP Lot Rework Data AQAD Labor time reporting is not required Any labor WIP lot serial numbers entered are not validated This frame links the labor and employee to the specified WIP lot serial numbers Labor time is reported as produced material by WLT reports Recording Rework Data Use the WIP Lot Rework Data frame to specify the WIP lot serial to rework Optionally use this frame to assign new WIP lot serials to that WIP material The WIP Lot Rework Data frame appears in the Repetitive Rework Transaction 18 16 and Rework Transaction 18 22 17 when the reject from queue is WLT controlled This frame appears immediately after the Destination Work Center and Machine frame WIP Lot Rework Data Qty to Rework 4 EA Produced By Op 20 Lot Serial JD Reference Reworked Lot Serial Referenc
48. Routing Maintenance enter the base process in the Routing Code field Setting Up Structures for Recyclable By products A recyclable by product is reused in a manufacturing process Example Ina manufacturing process dry paint is sprayed onto charged sheet metal The paint powder adheres to the metal and after baking in a kiln becomes a painted surface Upon application some of the dry paint falls to the floor where it is collected by a vacuum funnel and eventually returned to the spraying machine Although recyclable materials are technically by products the system does not treat them as part of the co product by product structure but as regular components Thus they should be defined as regular components and managed accordingly Figure 5 6 illustrates a recyclable by product process Product Recyclable By product Process Recyclable Component 1 Component 2 E NET i Co products and By products 65 You set up a structure for a recyclable by product by Entering an item number for the recyclable item Adding a recyclable item to a product structure formula Typically you enter two product structure formula records for each recyclable by product One for the component requirement a component going into the process entered as a positive quantity One for arecyclable by product a component coming out of the process entered as a negative quantity To set up a structure
49. See Defining subcontractor other than the subcontractor defined for the item s routing Singing Control and operation by setting Unassigned Suppliers to Yes in Subcontract Options on Shipping Control 18 22 5 24 page 208 Note Use Subcontract Routing Op PO Maint 5 11 to specify subcontract suppliers for a specific routing operation or use Subcontract MRP 6 Maint 5 5 1 21 to specify scheduled orders for a specific routing operation When you enter an open cumulative work order ID in the Contents Items frame the system automatically updates the following fields in the Contents Items frame with data from the cumulative work order Effective Date Site tem Number Production Line Routing BOM Code Conversely when you enter data in the fields listed above the system automatically updates the ID field with the correct cumulative work order ID Figure 8 23 shows the Sub Shipper Maintenance Contents Items frame FAQAD 214 User Guide QAD Manufacturing Fig 8 23 Sub Shipper Maintenance Contents Items Frame 18 22 5 5 AQAD Sub Shipper Maintenance vx Sub Shipper Maintenance Go To Actions Contents Items Effective Date 06 18 2007 Site 10000 P Item Number 2 Operation P Production Line P Routing P BOM Code ES ID Quantity UM UM Conv Site Location Lot Serial Reference WIP Item Multi Entry F Comments Effective Date Enter the effective date of the
50. Settings 0 0 eee eens 103 Creating Work Orders 1 1 0 0 eee een nen eee 105 Work Order Type i c qe rot ie doe es 106 Work Order Status siu ccad ata wiiaula Jea er eR eae 110 Routing Code ws 06 2 esa ce osse ee ke ehe e UR aes 114 BOM Form l dere Oe eee e eo RA Roa 114 Scheduling Work Orders sssseeeel eee 115 Manually Controlling Due Dates 000 0000 00 eee 116 Lead Time Calculations 0 0 cece eee eee 117 Scheduling Operations 0 0 0c cece eee eee 118 Modifying Work Orders 0 0 0 eect ee 119 Modifying Work Order Bills 0 0 2 ee eee eee 119 Modifying Work Order Routings 0 000000 e ee eee 120 Releasing Work Orders 0 0 eee cette ee 120 Key Items dan esser Se ed e sawed pee e seed quiate e 121 Splitting Work Orders 0 eee eee eee 121 Creating Picklists oasis ed e rere eA Rae a 122 Reprinting Picklists 0 0 eee eee eee 123 Issuing Components 0 eee eE a A E EA eens 123 Work Order Component Issue 0 0 0 0 cee eee eee 124 Issuing and Receiving Between Sites 00000008 125 Subcontract Operations 0 0 0 cee eee eens 126 Receiving Work Orders 0 cece eee teen ee 127 Receiving and Backflushing 0 0 scene 128 Managing SCtap isses sei a MR REEL eae n es 131 Generating Reports 0 0 cette hn 132 Closing Work Ordets eset etre ce ace ee res 134
51. The line allocation specifies how production is distributed among multiple lines To set up production line allocations use Line Allocation Maintenance 18 22 1 11 Set up line allocations for items that can be produced on multiple production lines within a site The line percentages must total 100 Fig 8 4 zx Line Allocation Line Allocation Maintenance Go To Actions Maintenance 18 22 1 11 Site 12000 CA Plant Item Number 1 bb Red Bean Bag Unit of Measure EA Production Line Description Percent 1001 Production Line 1001 50 00 1002 Production Line 1002 50 00 Use Line Allocation Inquiry 18 22 1 12 to view line allocations by site and item number Setting Up Shifts Use Shift Maintenance 18 22 1 22 to define the normal hours and production rate factor for each shift during a day You can also define any exceptions to that normal pattern Set up shifts for a site or for a production line at a site You can define up to four shifts for a day of the week A working day should have at least one shift with some number of hours greater than zero and a rate adjustment factor also greater than zero FAQAD 164 User Guide QAD Manufacturing Fig 8 5 Shift Maintenance 18 22 1 22 FAQAD Shift Maintenance X Shift Maintenance Go To Actions Site T100 Production Line TT Shifts Modify Sunday F Monday F Tuesday I Wednesday Thursday I Friday Saturday I Naaa0aa7 Monday Shif
52. Work Order Accounting Close 0 0 cece eee eee 135 General Ledger Period End 0 0 cece eee eee 136 Deleting Work Orders erectie siere ei n EEE EE ee 137 Chapter 7 Shop Floor Control 0000e cece eee eee 139 Introduction asian het cr e ar aloe ee Desa Rowe 140 Reporting Labor by Operation 0 0 cece eee eee 140 vii viii User Guide QAD Manufacturing Employee e FER adn heeds wate e o o o s 141 Department cuore he SERRE ee de Eder ERES N E 142 Work Center 1 d ed qne oed debuit E d debui 142 Item Quantities 2 0 een e 142 TIMES yest eke a SS ee v e eee 143 Operation Status cepe nues a Dele a ee eee aene 144 Recording Nonproductive Labor 145 Reporting Scrap usse oder me x a RE Ree eet ede ee does 145 Closing Operations sase ccs o cerne e abe Rr erg esta 146 Generating Reports 0 0 ccc eee eens 148 Transactions dees dra e coats C el ae el law ee ae 148 DOWntiMe pP 151 Input and Output sssseeeeeeeeee III 151 Utilization and Efficiency 0 0 cece ee cece eee 151 Deleting and Archiving Transactions 0 00005 152 Chapter8 Advanced Repetitive sslslsess 153 Introduction 422i dada asad Beaten PER si Pa P ra cie RR E 154 Advanced Repetitive and Repetitive 0200 00005 154 Distinctive Features of Advanced Repetitive 155 Setting Up Advanced Repetitive llle 157 Defining Control P
53. You can use a special set of features for managing processes that create more than one product Such products are referred to as co products or by products Processes that create only one product are supported by regular bills of material BOM and formulas Co product By product features support a variety of manufacturing operations including Batch processing Production of items by mixing blending and refining component ingredients such as pharmaceuticals processed foods and wine Sorting Separation of items by characteristics such as size weight or quality such as clothing computer chips and produce Disassembly Separation of items from larger items such as juice and seeds from oranges Molding Production of items using multiple cavity molds such as plastics and confections Features include support for MRP work orders shop floor control and costing as well as tools for setting up items structures and routings Great flexibility is provided in defining alternate products structures and routings As a result perhaps even more than with regular processes careful planning is critical Implementing and managing co products by products involves Setting up an operation for co products and by products Developing standard and simulation costs Implementing material requirements planning MRP Managing the work order life cycle for the related products Co products and By products 55 Overview A base p
54. a site other than the work order site and the site addresses exist in a shipping group with an inventory movement code that allows ISS WO you are prompted for shipper information This can occur in Backflush Transaction 18 22 13 and Rework Transaction 18 22 17 Shippers can also be generated when a picklist transfer occurs in Repetitive Picklist Transfer 18 22 3 6 and the addresses associated with the from and to site or location are associated with a shipping group with an inventory movement code that allows ISS TR Common Transaction Data All repetitive transactions use common information entered in the first frame Figure 8 13 shows the first frame of Backflush Transaction 18 22 13 Fig 8 13 Transaction Programs Common Information Actions Repetitive Production Li BOM Code WLT18 P1 1D 129 una Ea 5 Conversion 1 0000 Qty Rejected n n Reason Code Multi Entry M Reject To Opi 10 Modity Backflush I Move Next op I A tual Run Time DE Start Time Earning code ElspeuH ur Stop Time The Employee field is mandatory Enter a valid employee set up either in Employee Create 36 1 7 1 or Actual Pay Rate Maintenance 14 13 21 A valid effective date site item number and operation are required Shift is optional If the item number is associated with a production line you must enter a valid production line in the Line field Enter Routing and BOM only if you are not using the default ID
55. an order expected to be in usable condition If Yield is less than 100 MRP plans orders for more than needed For example if the net requirement is 100 and the item Yield is 50 then the planned order quantity will be 200 You can enter this value manually or use Routing Cost Roll Up 14 13 13 to calculate yield percent based on the yield percentages at each operation in the item routing If operation based yield is No MRP uses this yield percentage amount to calculate component requirements If operation based yield is Yes the yield percentage for components is derived from the parent item s routing data The item yield percentage is ignored If an item s yield percentage is less than 100 percent MRP may generate planned orders for fractional quantities To prevent this set Order Minimum or Order Multiple to 1 or any whole number The percentage of a component item expected to be scrapped during manufacture of the parent item This value increases the component requirements for planned orders for that component parent pair Specify scrap values for components in Product Structure Maintenance 13 5 When scrap percentage is greater than zero MRP may calculate fractional component quantities even if the component is a discrete item For example if one housing is required to build an item and the scrap factor is 5 the system will calculate a requirement for 105 2631 housings to make 100 units To prevent MRP fro
56. and all of its components to be overplanned ap percentage Depending on the manufacturing process the percentage of a lot expected is used to be of acceptable quality may also fall below 100 percent The system can calculate the total yield for an item in two ways based on the values in two item planning data fields Yield and Op Based Yield Yield Percent MRP can use the item yield percentage to plan additional supply Using this method the expected yield for an operation can be expressed as Yield Acceptable Units at Operation End 100 The total manufacturing yield for a product is determined by multiplying the yield percentages for each of its operations Manufacturing Yield Yield for Op10 Yield for Op20 Take care when setting yield to anything but 100 percent particularly when yield is used for multiple operations Example For four operations each having a yield of 90 percent the system calculates the item yield according to the following calculation 90 90 90 90 66 This equation includes an expected loss of one in three units If MRP plans this item for a demand of 100 units the system creates a scrap requirement for 51 units and a planned order for 151 units based on the following formula 100 66 QAD 42 User Guide QAD Manufacturing FAQAD With standard yield percentage all component quantities use the same 66 percent item yield when MRP derives component requiremen
57. and generate a capacity requirements plan for a department work center or machine This following topics explain how to generate and maintain a capacity requirements plan Introduction 380 Defining Capacities 380 Executing CRP 380 Generating Load Reports 383 Adjusting Capacity and Load 384 380 User Guide QAD Manufacturing b See Departments on page 28 for details b See User Guide QAD System Administration for more information about shop calendars FAQAD Introduction CRP calculates workload for a department work center or machine It does this by exploding the routings and processes for MRP planned and firm planned orders and determining start and due dates for each operation using the work center and shop calendars and a technique called back scheduling Defining Capacities The resources used to process orders on the shop floor are work centers departments and machines The capacity of a department or work center is the time available for production in that location The capacity of a department is the total number of available labor hours per day for all work centers in that department defined in Department Maintenance 14 1 The capacity for a work center is the number of machines or personnel available for that work center defined in Work Center Maintenance 14 5 multiplied by work hours defined in the shop floor calendar You can define and maintain shop floor calendars using Calendar
58. and quantities You cannot report labor hours This transaction normally has limited use since an operation can be set to have the backflush transaction and rework transaction perform this task automatically Reporting Downtime and Non productive Labor Use Down Time Transaction 18 22 20 and Non productive Labor Feedback 18 22 22 for reporting These transactions do not charge costs against WIP Both debit Cost of Production and credit Labor Down Time Transaction references the cumulative order operation item production line and site Non productive Labor Feedback lets you enter a GL project code and record comments You can enter reason codes for both transactions with type Downtime for Down Time Transaction and type Down for Non productive Labor Feedback Post Accumulated Usage Variances Post Accumulated Usage Variances 18 22 9 calculates and posts accumulated usage variances in cumulative orders according to the criteria entered You can post usage variances on demand without having to close the cumulative order Advanced Repetitive 197 For each open cumulative order selected usage variances are calculated by operation for component material WIP material labor burden and subcontract The variances calculated are for the entire life of the cumulative order The amounts to post are reduced by any amounts previously posted Additionally floor stock expense is posted Component Material Usage Variances Compone
59. are also calculated for labor For example when the standard subcontract cost is 10 and the PO cost is 12 the subcontract rate variance is 2 Reconciles the WIP account for closed work orders by calculating and posting method change variances for any residual variances WIP balances cannot be changed after the work order variances are posted Updates current labor and subcontract costs Posts floor stock amounts For Repetitive programs Cumulative Order Accounting Close 18 9 performs the same operations but only for repetitive work orders Work Order Accounting Close 16 21 closes both repetitive work orders and standard work orders General Ledger Period End Since you can enter a GL effective date on work order shop floor control and repetitive transactions a strict procedure is not required to account correctly for activity in the general ledger Some reports such as Work Order WIP Cost Report 16 3 5 are sensitive to period end procedures Use the following outline to write a procedure that fits your needs 1 All work order shop floor control and repetitive transactions should be completed and reviewed before starting the new period including the following Work Order Component Issues 16 10 Work Order Receipts 16 11 Work Orders 137 Work Order Receipt Backflush 16 12 Work Order Operation Backflush 16 19 Labor Feedback by Work Order 16 20 1 by Employee 16 20 2 by Work Center 16 2
60. available for the work order component This only includes nettable on hand inventory It does not include unconfirmed shipper receipts for example ASNs scheduled receipts for example purchase orders and planned receipts that is MRP planned work orders 4 Unconfirmed shipper receipts A PO shipper receipt was created but not confirmed for example goods may still be in transit Sufficient inventory is projected to be available for the work order component This includes nettable on hand inventory and unconfirmed shipper receipts 5 Scheduled receipts Sufficient inventory is projected to be available for the work order component This includes nettable on hand inventory unconfirmed shipper receipts and scheduled receipts 6 Planned receipts Sufficient inventory is projected to be available for the work order component This includes nettable on hand inventory unconfirmed shipper receipts scheduled receipts and planned receipts 7 Projected shortage There is insufficient inventory projected to be available for the work order component This includes nettable on hand inventory unconfirmed shipper receipts scheduled receipts and planned receipts This applies to work orders with status P lanned F irm B atch and E xploded only 8 Shortage There is insufficient inventory projected to be available for the work order component Nettable on hand inventory is not sufficient to cover requirements This applies to wor
61. b See User Guide QAD Financials B b See Operation Based Yield on page 42 FAQAD Op Enter the number identifying the operation in the routing or process where this component is used When specified operation has the following effects Determines whether this component is backflushed in repetitive manufacturing operations If you enter the operation number here this component is automatically issued when you report quantities for the parent If Op is blank or does not match a defined operation this component is not backflushed Enables component yield cost calculations Product Structure Cost Roll Up 13 12 13 and Routing Cost Roll Up 14 13 13 use this field when calculating material costs If the operation yield is less than 100 in Routing Maintenance 14 13 1 then material costs are increased to reflect yield loss If blank the system assumes components are issued at the first operation Enables operation based yield calculations If the parent item is defined with Operation Based Yield set to Yes in Item Master Maintenance and Enable Op Based Yield is Yes in MRP Control 23 24 MRP derives component yield percentages from the operations on the parent s routing The same method is used when bills of material are exploded in work orders repetitive advanced repetitive and configured products Determines whether this component prints on Repetitive Picklist Print 18 22 3 5 If you enter an operation code the
62. backflushed accordingly If you try to backflush steel lot B into WIP lot W1 the system displays an error Only one lot of steel can be consumed into WIP lot W1 This value defaults from the first frame of this program Changes you make here override the value set in the first frame for this component item in this BOM code only Working with WIP Lot Trace Before you begin using WLT you should note that some order processing procedures are slightly modified to support WLT data entry Additionally note that WIP material cannot be traced at non milestone operations WIP lot serial balances can reside only at milestone operations Some normally editable fields are not editable Instead WLT frames are used to record that information WIP quantity on hand QOH balances cannot reside in the input queue of the first milestone operation even if the first milestone operation is not the first operation Any information entered in WLT frames is used to update QOH balances and WLT tracing history records Before processing any WLT modified transactions the system checks for associated WLT routing or BOM registrations that include lot splitting combining and size restrictions If none are found the system then looks for related restrictions in WIP Lot Trace Control WIP Lot Trace 275 Using WLT Data Collection Frames Depending on your particular tracing needs and system configuration various Repetitive Advanced Repetitive Work Or
63. be promised to that order since it would be excluded from the ATP calculation MRP plans for the target inventory levels set by seasonal build requirements Specifying seasonal build requirements causes MRP to plan orders to satisfy those requirements and prevents it from issuing action messages to cancel or delay orders for seasonal build items when their demand is not yet apparent b See User Guide QAD Supply Chain Planning for more information b See Chapter 14 FAQAD 352 User Guide QAD Manufacturing Use Seasonal Build Maintenance 22 9 to create seasonal build forecasts for items by site You must define an end date by which you need items in inventory and a seasonal inventory quantity needed by that end date Fig 12 11 Seasonal Build x Maintenance 22 9 Seasonal Build Maintenance Go To Actions Site 10000 NJ Plant Item Number 2 BB Orange Bean Bag Date 03 05 2007 Reference P Seasonal Inventory 1 000 0 UM EA Example If you need 600 snowmobiles available in inventory by December 1st you may decide to build them during the previous three months at a rate of 200 per month You would then enter the following values Order Seasonal Inventory Date Period Required 09 30 05 39 200 10 31 05 44 400 11 22 05 47 600 12 1 05 48 0 P See Available Setting the seasonal inventory quantity to 0 zero for December Ist ico on indicates that the seasonal build requirement is complete This mean
64. browse is located at the top of the screen Work Order Component Browse Lists work order components for a particular work order Each component listed has a component shortage severity status associated with it The browse is located at the top of the screen Repetitive 237 Work Order Component Details Contains Supply Demand Detail and Supply Demand Summary The browses are located at the bottom of the screen Supporting Business Process Browses and Programs The default Component Check browse collections contain other supporting browses and programs For example Schedule Maintenance is provided so that you can quickly access and modify a scheduled quantity if a material shortage exists Net Change MRP is also provided so that you can view results once you change the schedule make a net change and explode a schedule Note Programs browses in Component Check by Item Work Order differ slightly Your selection in Work Order Component Browse drives the data that displays in Work Order Component Details When data displays in Work Order Component Details an asterisk displays in the row of data that relates to your selection in the Work Order Component Browse This helps you trace data back to the record upon which you are calculating component availability see Figure 9 2 QAD 238 User Guide QAD Manufacturing Fig 9 2 Component Check Data Trace b See User Guide QAD NET User Interface FAQAD Compon
65. by CRP Both are re exploded when the status is changed to Exploded Allocated or Released Approving Planned Line Orders Approving a planned line order adds the order amount to the schedule for that item s production line Orders approved for line production using Planned Repetitive Schedule Approve 23 8 are added to a schedule in a sequence according to the following hierarchy Due date Primary run sequence Secondary run sequence Item number Material Requirements Planning 377 The Sort Schedule by Run Sequence field controls the sequence in which P See Run orders are scheduled on a production line Sequences oh page 361 Yes Items are sorted and sequenced by due date primary run sequence secondary run sequence and item number No Items are sorted and sequenced by due date and item number The production schedule sequence for a given line can be viewed and See Simulating modified using Line Schedule Workbench Once a production line s Sonedules im hg Workbench on schedule is established run Repetitive Schedule Update 18 1 18 or page 169 18 22 1 18 to convert the line schedule to a repetitive schedule and remove the planned line orders from MRP FAQAD 378 User Guide QAD Manufacturing FAQAD Chapter 14 Capacity Requirements Planning The Capacity Requirements Planning CRP module uses MRP planned orders other work orders and repetitive schedules to determine work center load
66. can provide their own programs If no method is specified for a site the Receipt Quantity method is used Allocation of base process costs to co products is based on the cost of a standard batch size All allocation percentages are calculated using equivalent units of measure based on the unit of measure for the base process Where co product units of measure differ from the unit of measure for the base process the system employs conversion factors in order to express all costs in the base process unit of measure FAQAD 74 User Guide QAD Manufacturing Table 5 1 Co product Costs Allocated by Price Table 5 2 Co product Costs Allocated by Receipt Quantity FAQAD Allocation by Price The percentage of cost to allocate to a co product is determined by its price relative to the prices for the other co products from a base process Table 5 1 shows how costs are allocated by price Price Based Item UM Conv Price Price KG Allocation Pl KG 1 00 2 00 2 00 25 P2 KG 1 00 4 00 4 00 5096 P3 LT 0 50 1 00 2 00 2596 Allocation by Receipt Quantity The percentage of cost allocated to a co product is determined by the total quantity produced plus reject for the co product relative to the receipt plus reject quantities for other co products of the base process Table 5 2 shows how costs are allocated by receipt quantity Receipt Qty Receipt Based Item UM Conv Receipt Qty KG Allocation P1 KG 1 00 50 00 50 00 50 P2
67. component quantity required less the quantity produced Run MRP and have it recognize the demand and supply of the recyclable materials by product supply is negative demand Receive by products using Work Order Component Issue 16 10 Work Order Receipt Backflush 16 12 or Work Order Operation Backflush 16 19 for the operation where a by product is expected by entering a negative quantity to receive Setting Up Unit of Measure Conversion Factors When the base process unit of measure UM differs from the UM for a co product or by product UM conversion factors must be defined Conversions are from the base process UM to the co product or by product UM Example If the base process UM is liters and the co product UM is kilograms a UM conversion is required where the UM is liters and the alternate UM is kilograms Set up UM conversion factors in Unit of Measure Maintenance 1 13 Unit of Measure Enter the base process unit of measure Alternate UM Enter the co product or by product unit of measure Item Number Enter the base process item number or leave blank UM Conversion Enter the conversion factor converting quantities from Alternate UM to Unit of Measure Co products and By products 67 Setting Up Alternate Base Processes An item can be a co product or by product of more than one base process The base process for that item is its BOM Formula code defined in Item Master Maintenance 1 4 1 or Item Site Plann
68. corresponding QOH balance for the WIP lot serial specified in the WIP Lot Output Queue Issue Data frame The system checks QOH balances against settings in WIP Lot Trace Control QOH balances are recorded to tracing history WIP Lot Trace 289 Work Order Operation Backflush Work Order Operation Backflush 16 19 combines P See Chapter 6 Work Orders The issuing functions of Work Order Component Issue 16 10 on pase 99 i The labor reporting functions of Labor Feedback by Work Order 16 20 1 The receipt functions of Work Order Receipts 16 11 Three WLT frames are used to collect WIP tracing information WIP Lot Input Queue Issue Data b See page 277 Destination Work Center and Machine P See page 275 WIP Lot Output Queue Receipt Data P See page 278 Managing Scrap Scrap refers to unusable materials In the manufacturing process there can be two kinds of scrap Component materials issued to the work order that are unusable known as component item scrap tem materials built by the work order that are unusable known as finished item scrap When additional component material is required for a work order because item material was lost or unusable the replacement component materials should be issued to the work order with Work Order Component Issue 16 10 This correctly results in an unfavorable material usage variance for the order Reporting Scrap in Work Orders Record finished materi
69. create them automatically for routable components when changing the order status to Allocated or Released Use Multiple WO Status Change 16 8 to change order status at the appropriate time You cannot record inventory transactions or labor feedback against a batch order Exploded Exploding a work order recalculates the work order bill and freezes the bill along with the routing The bill and routing can only be changed manually until the order is released Note When the explosion takes place any requirements for phantom items are not exploded into requirements for their lower level components Work Orders 113 You cannot record inventory transactions or labor feedback against work orders with status Exploded Allocated Allocated orders are extensions of exploded orders and are used for inventory transactions You cannot record labor feedback against orders with status Allocated Allocated orders differ from exploded orders in the following ways Inventory allocations are made for all of the required components When the work order bill is created the system explodes through the requirements for phantoms if needed using up quantities of phantom items already in inventory before creating requirements for their components Work orders are automatically created for components with Pur Mfg codes set to Routable in Item Planning Maintenance 1 4 7 These orders normally have a status of Batch Released A released o
70. dates Wait and move times follow the stop date When an order quantity differs significantly from the average order quantity the system may allow too little or too much time to complete the order The greater the difference between the actual quantity ordered and the average order quantity the less likely it is that these dates will be realistic or reasonable QAD 118 User Guide QAD Manufacturing Table 6 7 Operation Lead Time with Multiple Components b See Executing CRP on page 380 for more details FAQAD Scheduling Operations The distinction between setup and run time is important when more than one machine is used to perform an operation Example Each machine takes four hours to perform an operation on 100 units and each requires an hour of setup time Setup Run Packaging Inspection One Machine hour 8 hours 16 hours 8 hours Two Machines hour 4 hours 16 hours 8 hours hour 4 hours In Table 6 7 if you decide to make 200 units with one machine it takes nine hours setup plus run If you then decide to use two machines it takes five hours for each machine because the setup time is the same for each but the run time is halved Some adjustments may be necessary when operations overlap This occurs when some units proceed from one operation to the next before all units for that operation are complete This reduces the aggregate lead time for completing multiple operations Specify the number of
71. description of their purpose Report Description WIP Status Inquiry 18 22 12 Displays quantities in the input output and reject queues for an operation WIP Status Report 18 22 4 11 Generates a report of WIP queue quantities for all operations in selected cumulative orders The report also shows the cumulative activities affecting each of the queue quantities such as cumulative completed scrapped adjusted rejected reworked and moved to next operation Operation Transaction Inquiry 18 22 4 1 Displays repetitive operation history records Scrap Analysis Report 18 22 4 3 Displays percentages scrapped by reason code over an interval of time compared to the quantity completed in that interval Reject Analysis Report 18 22 4 4 Displays percentages rejected by reason code over an interval of time compared to the quantity completed in that interval Rework Analysis Report 18 22 4 5 Displays percentages reworked by reason code over an interval of time compared to the quantity completed in that interval WIP Adjustments Analysis Reports 18 22 4 6 Displays WIP adjustments over an interval of time Cumulative Order Cost Report 18 22 4 10 Displays all data related to costing captured in the cumulative order when it is created It reports by operation the product structure and component costs labor hours per operation labor cost per hour burden factors yield
72. eee eee 80 Identifying the Source of Demand for a Co product 80 Managing Joint Work Order Sets 20 0 0 81 Joint Work Order Sets 2 0 eee 81 Accessing and Modifying Joint Order Sets 00 82 Creating a Joint Order Set from an Alternate Base Process 84 Reviewing Printing and Releasing Joint Orders 84 Receiving Scrapping and Backflushing 0 85 Receiving Unplanned Items 0 0 0c eee eee ee eee 88 Processing Shop Floor Control Transactions 04 88 Processing Joint Orders at Work Order Close 88 Deleting and Archiving Joint Orders 0 0 0 00000005 88 Tracing Lots oii essei siad nn Reed eh oe ee ee a 88 Accounting for Joint Orders 0 0 eee eee 89 Restrictions 22 2203 dvdowsd aue Seas ees dean ete daw eed area Codd d 97 lindo DT 97 Purchasing iius eb cer Ue Pune tun thee tae ea 97 Repetitive and Advanced Repetitive 0 0 e ce eee eee 98 Chapter6 Work Orders 200 cece eee eee eee 99 Introduction 2 3 5522 ia andes Siew Hie waa sea a end diate aed 100 Work Order Life Cycle 2 0 0 0 cee cee eee 100 Manufacturing Environments 0 0 eee eee eee eee 101 Work Order by Site Control llle 102 Restricted Transactions 0 eee eee ee eee 102 Effects of Optional Modules 0 0 0 0 eee ee eee 103 AQAD Contents Defining Control
73. every operation performed on a product The manufacturing lead time the length and number of operations and capacity planning at work center operations must all be considered Tracking measuring and accounting for labor by work center and operation are also factors to consider when specifying a routing In some cases it is appropriate to set up a routing with a single operation used for backflushing and receiving material Product lead times are short less than two or three days Capacity is planned by production line Labor is collected and reported in aggregates such as by department or production line The routing operations for an item must be integrated with the item s product structure for components to be backflushed All components backflushed from inventory must reference a routing operation However all components do not have to refer to the same operation number With long lead times different components can be backflushed when different operations are completed A number of fields in Routing Maintenance have special significance for repetitive processing Advanced Repetitive 167 Routing Maintenance vx Routing Maintenance Go To Actions Routing Code 1001 Operation 0 Start Date End Date Standard Operation Work Center 100 01 Assembly Machine Description Machines per Operation 2 Milestone Operation Iv Overlap Units 0 Subcontract LT 0 Queue Time 2 0 Setup Crew 2 00 Wait T
74. factor subcontract cost and the group of costs Operations Numbering Report 18 22 4 12 Displays operation transaction history by number or date range Transaction sequence numbers apply to the database as a whole as a result transactions within a domain may appear to have gaps This report lets you see transactions created in all domains and verify that numbering is sequential 199 Table 8 3 Repetitive Reports FAQAD 200 User Guide QAD Manufacturing FAQAD Report Description WIP Valuation Report 18 22 4 13 Reports the value of the WIP queues at the operation costs contained in the selected cumulative orders Either the cumulative order operation standard costs the cumulative order average costs or the current GL standard operation costs can be used for valuation You have the option to display cost elements Scrap and WIP Adjustments Valuation Reports the value of material Reports 18 22 4 14 and 18 22 4 15 scrapped adjusted within an interval of time The data can be sorted by either site and item or by descending value Either the cumulative order operation standard costs the cumulative order average costs or the current GL standard operation costs can be used for valuation You have the option to display cost elements Managing Subcontracting Use Advanced Repetitive with other programs to manage subcontract operations You can Track item quantities sent to
75. for a recyclable by product complete the following steps 1 In Item Master Maintenance 1 4 1 enter Item Number Enter an item number for each recyclable by product Use a single item number even if the item requires reprocessing after it is received as a by product and before it is reintroduced as an ingredient of a process In Product Structure Maintenance 13 5 or Formula Maintenance 15 5 enter Component Item Enter the item number of the recyclable material Reference Enter a code to differentiate between a component requirement and a recyclable by product Typically component requirements have blank reference codes Recyclable by product codes are user defined Qty Per Enter a quantity for this product structure or formula For a recyclable by product enter a negative number to indicate the quantity expected to be recovered from the process For a component requirement enter a positive number to indicate the full amount required LT Offset Enter the number of days to be added to the work order start date to determine when the by product is available for supply Op Enter the operation for which the by product is available or the operation for which the component is required QAD 66 User Guide QAD Manufacturing FAQAD Once these steps are complete you can Print work order picklists with component requirements summarized by operation Roll up costs using the net material requirement for the
76. inventory directly with Work Order Component Issue 16 10 Receipt A A Backflush see Issue inventory as completed products are received with Work Order Subcontract Receipt Backflush 16 12 Operations on page 126 ssue inventory report labor and receive items with Work Order Operation Backflush 16 19 Inventory transactions occur at different points depending on which method you use Component QOH is reduced at a later time using the backflush method Work Order Receipt Backflush combines the functions of Work Order Component Issue and Work Order Receipt You can also backflush quantities different from those received Either method keeps track of the inventory transactions used to issue components to a work order and excludes floor stock which is issued using an unplanned issue transaction FAQAD 124 User Guide QAD Manufacturing Fig 6 7 Work Order Component Issue 16 10 AQAD Work Order Component Issue If all components were picked from the locations printed on the work order picklist they can be issued automatically by setting Issue Picked to Yes This reduces manual entry because it sets the default sites locations lot serial numbers references and quantities from the detail allocations on the picklist Work Order Component Issue vx Work Order Component Issue Go To Actions Work Order 400033 ID 42 Op Effective 02 22 2007 Item Number 1 BB WO Stat R Issue Alloc J R
77. is a system generated cumulative order ID and cannot be modified The system uses the values entered in the Effective Site Item Number Operation Production Line BOM and Routing fields to locate the appropriate cumulative order FAQAD 188 User Guide QAD Manufacturing Table 8 2 How a Cumulative Order is Selected b See Phantoms on page 15 AQAD The selected cumulative order has start and end effective dates that include the transaction effective date Table 8 2 describes the way a cumulative order is selected based on the effective date entered If Then A cumulative order has a blank start effective date indicating that its effective interval is from the end effective date into the indefinite past A cumulative order has a blank end effective date A cumulative order has blank start and end effective dates No cumulative order is found matching the above criteria The dates in the new order overlap with the dates in some other cumulative order it will always be selected if the transaction effective date is on or before the end effective date its effective interval is from its start effective date into the indefinite future and will always be selected if the transaction effective date is on or after the start effective date the cumulative order will always be selected one is immediately created The start and end effective dates are set according to the parameters defined
78. is calculated from the receipt quantities processed for all the co products and by products Unit of measure conversion factors are used to express all item quantities in base process units Co products and By products 87 Use Method 1 when the quantity for a batch is directly related to the sum of its output For example for a process that sorts fruit into different sizes and grades the batch quantity can be calculated from the total amount of fruit processed for all sizes and grades This method is generally used when there is greater variability in output percentages for products Backflush Method 2 The default backflush base process quantity is the order quantity for the base process work order You can change the backflush quantity to reflect the actual quantity processed for a batch Use Method 2 when the batch quantity is closely related to the expected output of a particular co product For example for a process that makes ice cream the batch quantity can be calculated from the amount of ice cream processed Any by products such as waste water are not necessary for the calculation of the batch quantity Receiving Unexpected Items Occasionally an item produced from a joint order has a different grade or quality than expected When this is the case and the item assumes a different item number than the expected item it can be received even without a joint order in the set for the unexpected item These items are received a
79. item are gray and black the specification is gray black Anumeric value with a tolerance This is stated as a range with minimum and maximum values separated by the pipe I character Shift For example if the idle speed of an engine is 1000 150 rpm the specification is 8501 1150 You can also designate a range within a range In the previous example a range of 50 rpm together with a tolerance of 150 is designated by the string 85019501 10501 1150 The system looks only at minimum and maximum values but this format allows you to see the optimal range within a tolerance Quality Management 307 e A comparative symbol lt gt lt or gt and a numeric value This type of specification provides a value against which a measurement is seen as less than more than less than or equal to or more than or equal to For example if the acceptable weight for an item is less than 25 grams the specification is entered as lt 25 e An asterisk indicating a wildcard value This allows any value to be recorded and accepted a useful feature for collecting data for failure analysis Note You can record the name of a tester by calling the first test Name and defining its specification as the wildcard The first required test result is then the tester s name Defining Item Specifications Use Item Specification Maintenance 19 1 13 to attach a set of specifications to a routing or quality control operat
80. item is lot or serial controlled enter the lot serial number for the items received on this purchase order line if items are tracked by lot or serial number Reference Enter the optional lot reference number for the items received on this purchase order line Receipt Quantity Enter the quantity of items you received from the subcontractor The system tracks the receipt quantity for the subcontract shipper you specified This information displays as received quantities in the subcontract shipping programs If you enter a positive quantity the system considers this a received P See Returning quantity if you are in a receipt program or a returned quantity if you D NE tors are in areturn program The system updates the shipper you selected on page 219 with the quantity If you select a subcontract shipper that has an expired cumulative order associated with it the system uses the current cumulative ID on the scheduled order If you enter a negative quantity the system considers this as a return quantity if you are in a receipt program The system updates the shipper you selected with the quantity When entering a quantity note the following The quantity you receive cannot exceed the quantity on the subcontract shipper FAQAD 218 User Guide QAD Manufacturing b See Scrapping Subcontract Items on page 220 FAQAD The total quantity for all specified subcontract shippers cannot exceed the total purchase orde
81. more accurate calculations and prevents overplanning of components This is especially true in a mature process where yield percentages are highly predictable Use AppServer Specify whether your system uses a Progress P See Improving application server to enhance MRP performance ide m Bh AppServer Name When Use AppServer is Yes enter the name of the pagk aaa application server that is configured to run the MRP programs The value you enter must already be defined in AppServer Service Maintenance 36 19 1 Default Number of Threads When your system uses an AppServer for MRP processing enter the default number of processing threads or agents that the AppServer can create This can be any integer up to 99 This value defaults to the Number of AppServer Threads field in the MRP programs You can update it based on the overall load on your system when you run MRP As a general rule set this field to twice the number of processors your computer has For example if you have a dual processor machine set the field to 4 You can adjust it based on how well your system and MRP perform FAQAD 360 User Guide QAD Manufacturing Fig 13 2 Item Planning Maintenance 1 4 7 b See Creating Master Production Schedules on page 343 FAQAD Item Planning Data MRP uses item planning data to plan items Define this data in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 If an item is used at mult
82. not considered by MRP or other planning functions until you copy them to repetitive schedules using Repetitive Schedule Update 18 22 1 18 To create a simulated schedule specify the production line site and start date Set the Multiple field to a positive number to limit the quantity for each line sequence record to multiples of that number Then enter production quantities and dates into the workbench or review and modify existing sequence records as needed Each entry has a sequence priority number By manipulating the sequence number you can change the order in which items will be manufactured Use Insert to create a new line sequence record in the workbench Line Schedule Workbench vx Line Schedule Workbench Go To Actions Production Line 1000 Repetitive Production Li Start Date 02 23 2007 Site 10000 NJ Plant Multiple 1 00 Available Sequence Records Sequence Item Number Quantity Due Date New Seq No Delete 1 00 WLT18 P1 115 00 02 23 2007 2 00 WLT18 PSUB 50 00 02 23 2007 Determining Order Multiples The Multiple field controls the minimum divisible schedule quantity for a workbench session The default setting of 1 00 lets you create schedules with whole integer quantities only When set to zero Line Schedule Workbench attempts to use all available time to manufacture scheduled quantities As a result it will schedule decimal quantities if necessary You can set Multiple to any other quantity as needed This i
83. parent Example The sale of a specific type of computer entered in the planning bill with a structure code of Planning consumes the computer family forecast but the sale of an extended keyboard an option does not Option Bills Structure type O option also affects forecasting and master scheduling Options are typically used with configured products to indicate one of a set of choices FAQAD 348 User Guide QAD Manufacturing FAQAD Option bills are treated in the same way as planning bills by master scheduling The forecast percentage and quantity per for the option determines the production forecast However unlike components in a planning bill independent demand can often exist for an option For example a Zip drive is an option for a computer model You enter a forecast percentage indicating how frequently a Zip drive is included when a computer is purchased Zip drives can also be sold as a separate item When you sell a Zip drive separately it does not consume production forecast If however you have an independent forecast for the zip drive not derived from upper level requirements it will be consumed If you know that an option will be sold both by itself and as part of another item you can plan production by either increasing the forecast percentage associated with the product structure or entering independent forecast in Forecast Maintenance Production Forecasts Production Forecasts When you establ
84. performed by an outside supplier or subcontractor rather than by a work center This requires some special setup particularly if you want to include subcontracted operations in supplier load and capacity reports Set up at least one department for outside processing and a separate work center for each type of subcontract operation Each supplier or type of subcontract operation should have at least one work center defined for it This lets you specify the work center on dispatch reports which provide visibility of upcoming operations Set the work center labor and burden rates to zero to prevent GL transactions from being created You can express work center lead times in subcontract days if load reporting is not a requirement Otherwise use queue setup run wait and move times in conjunction with a work center calendar You can also add one or more departments for specific suppliers for whom capacity is a major concern Review capacity for these departments by printing the department load reports in the CRP module Routings and Work Centers 41 Vield Operation and item yield are different than the component scrap See Scrap on percentage in product structures Component scrap results in additional pe hee led requirements for individual components of a parent item When an item s description of yield is less than 100 percent MRP creates additional scrap requirements how the componen for the item causing the item
85. policies to determine planned order quantities Table 13 3 Order Modifier Description Order Modifiers Order Quantity The quantity for which all MRP planned orders are created for an item with an order policy of FOQ Safety Stock The quantity of this item maintained in inventory as protection Minimum Order Quantity against fluctuations in demand or supply MRP processing considers safety stock a requirement and schedules planned orders to cover this requirement You should not designate safety stock levels for non master scheduled items because it may cause MRP to overplan inventory The minimum quantity allowed for a planned order If the net requirement is below this amount MRP creates an order for this minimum quantity To ensure that items that have decimal demand values due to yield or scrap calculations are ordered in whole number quantities set this value to 1 or to any whole number FAQAD 364 User Guide QAD Manufacturing FAQAD Order Modifier Description Maximum Order Quantity Order Multiple Yield Scrap Lead Times When a net requirement exceeds this amount MRP generates the action message Order Exceeds Maximum for the order created to fill this requirement When order policy is POQ or LFL planned orders are created in multiples of this quantity For example if the order multiple is 100 planned orders are only created for quantities of 100 200 300 and so on The percentage of
86. recalculates the net forecast based on the changes Figure 12 9 shows an example for which the Consume Forward and Consume Back values in Sales Order Control are both 2 weeks Excess sales in week 2 consume the forecast in week 1 Excess sales in week 3 consume the forecast in week 4 then week 1 Excess sales in week 5 consume the forecast in week 4 then week 7 Excess sales in week 6 consume the forecast in week 7 FAQAD 342 User Guide QAD Manufacturing Fig 12 9 Forecast Consumption 2 S l S a F e ED I r1 sssiu l Forecast Actual Sales MRP and Prior Period Forecasts When you set up the system to consume forecast in previous periods MRP recognizes prior period unconsumed forecast as additional demand in the current period When this occurs you can Delete the forecast for prior periods This assumes that if the forecast was not fully consumed for a prior period it was faulty and should not be considered additional demand for the current period Use this approach to avoid manufacturing excess inventory for items for which demand will not be generated in the near future Make no changes to the prior period forecast This assumes that unsold inventory will be shipped to fulfill future demand exceeding the current and possibly future forecast Update the forecast for future periods When prior period forecasts are
87. routing registration record Start Date Enter the date when this routing registration record is effective When a start date is not specified this registration record becomes effective immediately When multiple registration records have overlapping effective dates the registration with the start date closest to the transaction effective date is used Lot Trace Start Op Enter the operation where WIP lot tracing should begin for the specified routing code The default is 0 zero Leave this value to begin WIP lot tracing at the first operation in this routing Any component material consumed at operations prior to the operation specified here is not traced The system does not prompt for input WIP lots at this operation It prompts for input and output WIP lots at the operations that follow Serialized WIP Start Op Enter the operation at which serial tracing should begin WIP serial tracing cannot begin before WIP lot tracing begins It must begin on or after the operation specified in Lot Trace Start Op FAQAD 270 User Guide QAD Manufacturing Fig 10 4 Routing Registration Operation Frame FAQAD Leave the default value of 99999 to indicate that serial tracing should not occur For WIP lots to be serial traced transaction quantities can only be 1 0 or 1 and WIP lot quantity on hand QOH balances must be 0 or 1 Example For a manufacturer of a pharmaceutical serial tracing begins at the bottling operation
88. shipper 4 Specify Yes when prompted to continue Continue processing the receipt or return When you are ready to complete the transaction the Scrap Details frame displays Note The Scrap Details frame displays in Purchase Order Receipts 5 13 1 and Purchase Order Returns 5 13 7 see Figure 8 26 5 Enter the employee code of the person reporting this labor in the Employee field 6 Enter a code identifying the work shift associated with this operation in the Shift field 7 Enter Input or Output in the Queue field to indicate the subcontract operation queue from which the items are scrapped Note Ifthe subcontract operation is the first operation and WIP Lot Trace is enabled you cannot update the queue and reason code Input Enter Input if you want the system to adjust the scrapped material at the input queue of the subcontract operation The system does not include subcontract labor and materials for the scrapped items when calculating the value of the scrapped material Output Enter Output if you want the system to adjust scrapped material at the output queue of the subcontract operation The system includes subcontract consumed labor and materials for the scrapped items Note To scrap at the subcontract output queue you must set Move Next Op to No in Purchase Order Receipts 8 Enter a code for the reason items are scrapped Note You must create reason codes with a reason type of Scrap in Reason Codes Maintenance 36 2 17
89. sources of demand and supply to Calculate gross item requirements and projected on hand inventory Schedule and plan orders Produce action messages The following topics explains how to create and maintain a material requirements plan Introduction 356 Setting Up MRP 357 Executing MRP 367 Reviewing MRP Output 373 Approving Planned Orders 376 356 User Guide QAD Manufacturing b See User Guide QAD Supply Chain Planning b See Chapter 12 Forecasting Mas ter Schedule Planning for more detail FAQAD Introduction Material requirements planning MRP balances supply and demand for purchased and manufactured items Given a set of demands or requirements MRP automatically calculates a time phased schedule of planned supply orders or replenishments to satisfy those demands MRP looks at demand for finished items and uses product structure information to calculate demand for component items For each item MRP looks at the ordering information the amount currently on hand and lead times and generates planned orders suggesting how many of that item to buy or make and when to do so MRP and Sites MRP s planning activity is performed by site Each site s material plan is completely independent from inventory demand and supply at other sites You can run MRP for several sites in succession but it does not plan for these sites as a group For organizations with multiple sites MRP can be used
90. the Summarize Co products method may be appropriate in environments where completed by products cannot always be traced to particular base process orders For example in some business environments completed by product quantities are reported in bulk at the end of each shift instead of in conjunction with work order operations Maximum If Quantity Complete Method is set to MAX in the co by product structure the system considers the quantity complete for each co product and determines the quantity of the base process typically required to generate that co product quantity The following calculation is performed for each co product with a nonzero order quantity Co product Quantity Complete Scrap Base Process Quantity Ordered Co product Quantity Ordered The co product that yields the highest result determines the base process quantity complete for the joint order set For the sample joint order set calculations are as follows Co prod1 Quantity 55 1 100 50 56 2 112 Co prod2 Quantity 25 3 100 30 28 3 3333 93 3324 Since the calculation for co product 1 orange juice yields the highest result 112 is used as the base process quantity complete for the joint order set Co products and By products 95 Expected co product and by product receipt quantities are calculated as shown in Table 5 13 Table 5 13 Order ID Product Expected Receipt Calculation Sample Expected 1001 Orange Juice 112
91. the quantity required or the quantity open whichever is less Components issued to a work order are posted to WIP at GL cost Issuing and Receiving Between Sites You can receive or issue items at a site other than the order creation site There are two basic scenarios Receive completed items at a site other than the order ssue items to a site other than the order site In the first scenario you receive at Site 2 a work order created at Site 1 First a receipt transaction is created at Site 1 the order site Then an issue transfer transaction is created at Site 1 subtracting the received quantity A balancing receipt transfer transaction is then created at the receiving site Site 2 Table 6 8 shows this transaction for a quantity of 100 Table 6 8 Site 1 Site 2 Scenario One RCT WO 100 0 ISS TR 100 0 RCT TR 100 0 In the second scenario if you issue components from Site 2 for an order created at Site 1 an issue transfer is first created at Site 2 the issuing site Then a receipt transfer is created at the order site Site 1 and then the issue work order transaction is created again at Site 1 Table 6 9 Site 1 Site 2 Scenario Two ISS TR 100 0 RCT TR 100 0 ISS WO 100 0 You can specify the issue or receipt location and site on any of these transactions However if the order site is defined with automatic locations set to No the item s default location must exist at the order site For QAD 126 U
92. the subcontractor Note If WIP item components are lot serial controlled you must use the Advanced Repetitive Move Transaction 18 22 19 to record the WIP item placement into inventory If only the WIP item is lot serial controlled then the placement of inventory occurs during receipt Subcontract processing requires the use of several modules Although most of the processing occurs in the Advanced Repetitive module you must complete setup steps in other modules as well as Advanced Repetitive All setup tasks are described here b See Chapter 10 WIP Lot Trace on page 251 QAD 202 User Guide QAD Manufacturing Fig 8 15 Preliminary Subcontract Setup b See User Guide QAD Master Data AQAD Setting Up Preliminary Subcontract Data This section describes tasks you complete before you can begin shipping items to and receiving items from subcontractors Setting up this data saves you time and extra steps once you begin Advanced Repetitive operations Set up items and suppliers Set up routings Create subcontract scheduled orders Create subcontract discrete purchase orders Specify subcontractors for Specify subcontractors for discrete purchase orders scheduled orders Data setup varies depending on whether you are using discrete purchase orders or scheduled orders Setting Up Subcontract Items and Suppliers Using WIP items helps ensure consistent pricing for sub
93. those shifts for the affected date range If overtime is planned for shift 4 then specify additional hours for that shift Unlike with the shop calendar you can add shifts that do not fall on normal working days Use Shift Report 18 22 1 23 to see active shift status exception dates and shift hours Setting Up Changeover Times Define changeover times for a production line in Line Changeover Maintenance 18 22 1 6 For the system to work correctly you should define changeover times between each pair of items For instance on a line where red green and gray items are manufactured the changeover time can vary depending on whether red is being switched to green or to gray Example If a line manufactures three items A B and C define changeover times for each of the following From To A B B A A C C A B C C A A large number of changeover times might be more effectively managed P See User Guide outside of the system using spreadsheet software Use the CIM interface rou i um programs to load the data into Line Changeover Maintenance for details on CIM QAD 166 User Guide QAD Manufacturing See Routings on page 34 for more details FAQAD Setting Up Routings and Operations Items on a repetitive schedule must have a routing The operations of a routing are used to backflush components and receive completed products into inventory When you define a routing you do not have to specify
94. transaction The system searches open cumulative orders that pertain to the effective date Site Enter the site from which the subcontract material will be shipped Item Number Enter the item to be shipped to the subcontractor Operation Enter the number of the subcontract operation on the routing for this item Production Line Enter the production line on which the item is manufactured Routing Enter the routing code for the items being shipped BOM Code Enter the BOM code for the items being shipped ID Enter the ID of the work order associated with the items being shipped Quantity Enter the quantity of the items being shipped to the subcontractor UM Conv Enter the unit of measure conversion for the item Location Enter the location of the items to be shipped Lot Serial Optional Enter the lot serial number for the items shipped on this subcontract shipper if items are tracked by lot or serial number Reference Enter the optional lot reference number for the items shipped on this subcontract shipper Advanced Repetitive 215 WIP Item The system displays the WIP item number indicated in the routing operation Multi Entry Indicate whether this transaction references multiple sites locations lot number serial numbers or lot reference numbers No This transaction is processed using values you enter on this screen Yes Another entry screen displays letting you enter multiple lines for this transac
95. transfers the WIP queue quantities from the old cumulative order operations to the output queues in the receiving order operations 3 The system records the transfer by creating an operation history record of type Transfer 4 The system generates the appropriate GL transactions to transfer the WIP value to the new cumulative order 5 When the cost of the WIP queue inventory for an old cumulative order operation differs from the cost at the receiving operation the system posts the difference to Method Variance After these calculations are complete a residual value may remain in WIP This is because when the system debits WIP during repetitive reporting transactions fractional values may remain in WIP due to rounding differences These residual values accumulate in WIP until the cumulative order is closed Cumulative Order Close posts the residual WIP value from each closed cumulative order to Method Variance You can run Cumulative Order Close in report only mode as needed FAQAD 186 User Guide QAD Manufacturing b See the Shipping chapter in User Guide QAD Sales for details FAQAD Cumulative Order Maintenance Use Cumulative Order Maintenance 18 22 6 to create new cumulative orders manually or maintain the start and end effective dates on an existing order You cannot change effective dates so that they overlap those on another cumulative order for the same profile You can also delete closed cumulative orders E
96. two programs are known as global phantoms If an item is a phantom only when assembled as a component of a specific parent item use a structure type of X within the product structure or formula Such a phantom is known as a local phantom since its use as a phantom depends on a particular bill of material When Material Requirements Planning MRP plans requirements it always ignores a local phantom and creates planned orders for its components This process of driving requirements from the components is sometimes referred to as blowing through a phantom If there is a quantity on hand of a global phantom MRP uses it to fill requirements before creating additional requirements for the components Simulated BOM Inquiries Quantities on hand of local phantoms do not impact the Simulated Picklist Item Check 13 8 17 or the Simulated Batch Ingredient Check 15 7 17 Use up logic is typically not applied to local phantoms This is one reason to define them as local rather than global Quantities on hand of global phantoms still decrement quantity requirements when you select use up logic by setting the Use up PH field to Yes on these two inquiries Product Structures 17 Setting Up a Product Structure Define product structures in Product Structure Maintenance 13 5 Fig 2 2 x Product Structure Product Structure Maintenance Go To Actions Maintenance 13 5 Parent Item 1 BB Description Red Bean Bag Component Item 100
97. undersold you can revise forecasts for future periods to reflect the difference Master schedulers typically use a combination of these techniques For example past due forecasts may be maintained for four weeks and then deleted whereas forecasts for future periods may be reviewed and updated once a month AQAD Forecasting Master Schedule Planning 343 Creating Master Production Schedules Master schedulers use detailed forecasts to determine what to produce when to produce it and in what quantities These three things define a statement of production that becomes the master production schedule MPS Master Scheduled Items Master schedule items are typically end items critical subassemblies spares service items critical components or key resources To define an item as master scheduled set Master Schedule to Yes for that item in Item Master Maintenance 1 4 1 Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 for multisite environments Approaches to Master Scheduling There are several possible approaches to creating and managing master production schedules each allowing a different amount of control by the system Fully automatic Fully manual Computer assisted Fully Automatic Scheduling The master schedule can be generated entirely by MRP This means that See Chapter 13 the system has complete control over master scheduled items with no none E distinction between m
98. until they are moved to subsequent operation queues or manually deleted using WIP Adjust Transaction 18 22 21 Reason Code Criticality Specify the system response when an invalid reason code is entered while recording repetitive backflush transactions W Warning The system displays a warning message and pauses the system accepts the value when you press any key This is the default value C Critical The system displays an error message and prompts you to continue If you choose No the system returns to the Reason field so you can modify it If you choose Yes the system accepts the value Advanced Repetitive 161 Allow Zero Run Rate Specify whether item level records defined in Production Line Maintenance can include a 0 zero value in the Units Hour field No default The item Units Hour defaults from the production line run rate The system always uses the item run rate when calculating schedules for the item Although you can change the default you cannot set it to 0 Yes The item Units Hour defaults to 0 Unless you change it the system uses the production line run rate when scheduling the item Otherwise it uses the specified non zero item level value Set the field to Yes to define a global run rate for all items on each production line In Production Line Maintenance you can then specify a Units Hour value at the production line level and leave all or most item level fields set to 0 If individual items are
99. used to determine the base process quantity complete QAD 96 User Guide QAD Manufacturing Table 5 15 Sample Expected Receipt Calculations for MIN Method Table 5 16 Sample Mix Variance Calculations for MIN Method b For more information on when to use this method see Maximum on page 94 FAQAD For the sample joint order set calculations are as follows Co prod1 Quantity 55 1 100 50 56 2 112 Co prod2 Quantity 25 3 100 30 28 3 3333 93 3324 Since the calculation for co product 2 pulp yields the lowest result 93 3324 is used as the base process quantity complete for the joint order set Expected co product and by product receipt quantities are calculated as shown in Table 5 15 Order ID Product Expected Receipt Calculation 1001 Orange Juice 93 3324 50 100 93 3324 0 5 46 6662 1002 Pulp 93 3324 30 100 93 3324 0 3 27 9997 1003 Seeds 93 3324 10 100 93 3324 0 1 9 3332 Based on these expected quantities mix variance calculations are as shown in Table 5 16 Order ID Product Mix Variance Calculation 1001 Orange Juice 46 6662 56 1 50 9 3338 1 50 14 00 1002 Pulp 27 9997 28 0 50 0 0003 0 50 0 00 1003 Seeds 9 3332 15 0 60 2 5 6668 0 60 2 3 40 When the Minimum method is used the co product that consumed the smallest quantity of the base process in proportion to the quantity order
100. when you confirm the shipper using Sub Shipper Issue 18 22 5 11 This frame also appears in Operation Move Transaction 16 20 6 immediately after the Source Destination Work Center and Machine frame The WIP lot serials you specify in the WIP Lot Move Data frame are moved from the source location to the destination location you specify in the Source Destination Work Center and Machine frame Current Work Center and Machine Use this frame to specify the work center and machine location from which input WIP lot serials will be consumed by the operation For example using Work Order Component Issue 16 10 this frame appears after you indicate the work order number ID and operation from where the components or WIP material will be issued The Current Work Center and Machine frame appears in Work Order Receipt 16 11 and Work Order Component Issue 16 10 when the operation being processed is WLT controlled Current Work Center and Machine Work Center 100 01 2 Machine Fe Using WLT with Work Orders When using WIP Lot Trace WLT in a Work Orders manufacturing environment you should be aware of the following points Work Order Receipt Backflush 16 12 is disabled because it does not let you report production on an operation per operation basis You must specify an operation when processing a receipt issue or labor transaction for a WLT controlled work order The following sections describe the programs
101. will show a shortage of 100 of Item A at OPS and detail allocates 100 at the inventory location When the picklist is printed the 100 will be shown as picked and 100 will be moved to location OPS when the transfer is run The inventory will not be issued until labor is reported for each operation Note To use picklists you must set up a location with the same ID as the work center Calculate the Picklist Calculate the picklist and create detail allocations using Repetitive Picklist Calculation 18 22 3 1 The calculation considers component requirements from the exploded repetitive schedules that match the sites items work centers and production dates specified Advanced Repetitive 177 Fig 8 11 zx Repetitive Picklist Repetitive Picklist Calculation Go To Actions Calculation 18 22 3 1 Site 10000 To 10000 Parent Item To Component Item To work Center 100 01 To 100 01 Production Date 02 23 2007 To 02 27 2007 Release Date To Use Work Center Inventory 7 Use Order Multiple Detail Requirements Picklist Number PL1 Delete When Done Output 2 Batch ID P For a new schedule creating requirements at a work center with no shortages Repetitive Picklist Calculation uses the following equation Shortage at Work Center New Requirements Net Available Where net available equals Actual OH Qty Alloc Qty Req by Other Scheds Untransferred Picked The Net Available is the material available fo
102. 0 Issued To WIP Lots Frame b See page 275 and page 278 b See Chapter 7 Shop Floor Control on page 139 FAQAD 288 User Guide QAD Manufacturing Fig 10 21 WIP Lot Output Queue Issue Data Frame AQAD Receiving Finished Goods Use Work Order Receipt 16 11 to receive finished goods manufactured with WLT controlled routings Use the detail fields to specify the lot serial reference and other details of the WIP material being received This program consumes the WIP lot serials being received into finished goods inventory Then it updates WLT tracing history WIP QOH balances and receipt and issue information Use the Current Work Center and Machine frame to specify the work center and machine from where the WIP lot serial inventory should be consumed The WIP Lot Output Queue Issue Data frame is used to enter a list of the WIP lot serials that should be consumed from the previous operation s output queue in the specified work center and machine The WIP Lot Output Queue Issue Data frame appears only in Work Order Receipt Open WIP Lot Output Queue Issue Data UOM EA Lot Serial Ref Quantity WO183 95 0 Co T coq senma Scrapped Qty Reference UM Multi Entry UM Co Lot Serial Ref Quantity WO183 95 0 The system calculates and records WIP QOH balances for standard work orders in three steps Each finished material lot serial quantity moved into inventory is deducted from the
103. 0 phantoms 15 reference codes 17 repetitive 174 scrap 18 substitutions 21 type codes 19 used for multiple items 14 Production Line Maintenance 161 production lines 161 changeover time 165 schedules 169 shifts 163 production schedules repetitive 243 productivity 151 profit margin forecasting 336 Pur Mfg code MRP use of 361 Purchase Order Maintenance 204 co products by products 97 using to trace WIP 294 Purchase Order Percents Frame 206 Purchase Order Receipts 209 215 co products by products 98 tracing WIP receipts 295 Purchase Order Returns 209 tracing WIP 296 Q quality management 303 318 Certificate of Analysis Print 318 destructive testing 317 first article inspections 317 inspection 311 inspection site 305 inventory audits 316 inventory sampling 309 item specification 307 master specifications 306 procedures 308 FAQAD 398 User Guide QAD Manufacturing process inspection 314 process validation 317 quality orders 310 quarantine 304 specifications 305 values for 306 test results 315 Test Results Maintenance 314 Quality Management Control 305 Quality Order Delete Archive 314 Quality Order Maintenance 312 Quality Order Results Entry 313 destructive testing 317 quality orders creating 312 deleting 314 entering results 313 inspection 311 quarantine 304 queues lead time component 37 operation input 186 output 186 reject 186 operation status 144 R rate variance advanced repetitive 189 Reason Cod
104. 0 10 0 You can define other collections of related browse and maintenance programs within the QAD NET UI that let you browse and maintain related item site schedule and order data that you can then save under Favorites Use the Browse Collection Maintenance program to do this Decimal Places In Component Check browses numbers display only a single digit after the decimal point unlike typical system screens and reports that can display up to eight places after the point for example in Component Check browses the system displays 1 1 not 1 111399 To expand the decimal places modify the format of the field in Browse Collection Maintenance Changing the format does not impact calculations Repetitive 239 System Security System security can be set for any program or browse that has a menu entry If the program or browse exists within one of the Component Check browse collections the following security issues can exist If you do not have access to either a program or the menu within which the program resides you cannot access the program in a Component Check browse collection Example If you do not have access to Repetitive Schedule Maintenance in the Schedule Menu 18 2 but have access to it in the Advanced Repetitive Menu 18 22 2 the program is not be available to you in the Component Check browse collection Of the browse components in the Component Check browse collections only the top level browses ha
105. 0 110 90 Decrease Multiplier February 150 165 135 March 120 132 108 Scale The percentage by which a forecast quantity is multiplied or scaled This value cannot be negative Table 12 7 Month Units 10 10 Scale Multiplier January 100 10 n a February 150 15 n a March 120 12 n a Trend The percentage by which a forecast quantity increases each month A negative percentage decreases the quantity over time Table 12 8 Month Units 10 10 Trend Multiplier January 100 110 90 100 100 10 February 150 180 120 150 150 20 March 120 156 84 120 120 30 You can use more than one multiplier at a time The effect of multiple factors is cumulative Base Increase Decrease is applied first Scale second and Trend third When you are replacing an existing detail record and apply multipliers to the source quantities the results overwrite the quantities in the target detail record QAD 334 User Guide QAD Manufacturing See Multipliers on page 332 for details FAQAD When you are combining records and use a multiplier the multiplier is applied to the source quantity and the result added to the target quantity The factor is not applied to the combined source and target quantity Simulation To Simulation Copy Use Simulation to Simulation Copy 22 7 11 to copy an existing forecast detail record to another forecast ID or to combine several forecast detail records into a single detai
106. 0 3 Operation Complete Transaction 16 20 5 Repetitive Setup Transaction 18 13 Repetitive Labor Transaction 18 14 Non Productive Labor Feedback 16 20 4 2 The status of all closed work orders should be changed to Closed 3 All open cumulative work orders in the Repetitive module should be changed to Closed 4 Run WIP Material Cost Revaluation 16 22 to update allocated released and closed work orders 5 Run Work Order Accounting Close 16 21 and Cumulative Order Accounting Close 18 9 6 Print Work Order WIP Cost Report 16 3 5 and any other time sensitive reports required 7 After reviewing these reports proceed with the new period Deleting Work Orders You can delete work orders using Work Order Maintenance under two conditions They have a status of P Planned B Batch Input Firm Planned or F Firm Planned with a WIP total of zero They have a status of C Closed a WIP total of zero and a valid accounting close record Obsolete work orders can also be deleted and or archived with Work Order Delete Archive 16 23 Only orders closed with Work Order Accounting Close can be deleted FAQAD 138 User Guide QAD Manufacturing FAQAD Clo Generating Re E 140 User Guide QAD Manufacturing gt For details see Chapter 10 WIP Lot Trace on page 251 FAQAD Introduction Use Shop Floor Control to report setup time hours worked material scrapped and
107. 0 571 76 Sep 1984 30 474 24 49 600 00 19 125 76 Oct 1781 27 356 16 44 525 00 17 168 84 Nov 1634 25 098 24 40 850 00 15 751 76 Dec 1457 22 379 52 36 425 00 14 045 48 Total 21883 336 122 88 547 075 00 210 952 12 Making Forecast Data Visible to MRP Forecasts generated using forecast simulation functions or loaded into forecasting simulation functions using the CIM interface are stored in forecast detail records whereas MRP uses summary forecast records to drive its demand calculations Use Simulation to Summarized Forecast 22 7 13 to load forecast quantities into the summary forecast records used by MRP This program uses the forecast detail records to create new summary forecast records replace old summary records or combine with existing summary forecasts Simulation To Summarized F Forecasting Master Schedule Planning 337 Simulation To Summarized Fest Forecast ID 2007 Forecast Year 2007 Item Number Line P Group P Type D Summarized Site 10000 Loading Method J Start 03 05 2007 Replace Combine Replace Update Forecast detail records are identified by forecast ID year and item whereas summary forecast records are identified by item site and year Since MRP is site specific you must specify a summary site to update This site may be different from the order line site specified on the criteria template When a forecast is for a group of items you can genera
108. 1 WIP Lot Reject Data frame 278 WIP Lot Reject Scrap Data frame 280 WIP Lot Rework Data frame 282 WIP Lot Scrap Data frame 279 WIP Lot Trace and Regulatory Attributes 253 data collection frames 275 284 overview 252 pre setup issues 264 reports 299 302 setup 264 subcontract process 204 298 WIP Lot Trace Control 265 WIP Lot Trace module 103 WIP Lot Where Used Report 302 WIP Status Inquiry 199 WIP Status Report 199 WIP Valuation Report 200 WLT controlled BOMs and routings 275 Work Center Maintenance 29 co products by products 60 labor rate 141 FAQAD 402 User Guide QAD Manufacturing work center specifying 203 Work Center Routing Standards Maintenance alternate work centers 36 work centers 29 31 alternate standards 36 calendars 27 capacity 31 380 co products by products 60 department accounts 28 departments 28 labor feedback 142 routing standards 36 Work Order Accounting Close 113 co products by products 59 72 76 88 effects on GL 135 operation status 144 148 Work Order Accounting Control 104 Work Order Attribute Maintenance co products by products 88 Work Order Backflush 289 Work Order Bill Maintenance 119 Work Order Bill Shortage by Item Report 121 Work Order Bill Shortage Report 121 Work Order Browse features 236 Work Order by Item Report 132 Work Order by Order Report 132 Work Order Component Browse features 236 Work Order Component Check 121 Work Order Component Issue 124 issued to WIP Lot
109. 1 to make adjustments Scheduling Work Orders MRP uses a combination of work order due date release date and manufacturing lead time to schedule work orders Work Order Maintenance Work Order 1006 Go To Work Order 1006 Item Number 1 BB Type Site 10000 Quantity Ordered 1 0 Quantity Completed 0 0 Qty Rejected 0 0 Work Order Status F Sales Job Supplier Yield Percent 100 0096 Remarks Comments Actions ID 41 Red Bean Bag Order Date Release Date Due Date Site P Routing Code 9 BOM Formula Code Post variances at SFC M 02 22 2007 02 22 2007 02 22 2007 ioo 1001 P 1001 D Release and Due Date are used in scheduling The due date determines the date when inventory is needed and an order should be complete MRP uses order due dates to determine when quantities will be available to replenish inventory The release date 1s the date when an order is scheduled for release to the shop floor MRP uses the release date to determine when components are required When an order is released the scheduled release date is changed to the date actually released The release and due dates for an order are offset by the lead time for the item produced For example if it takes an average of five working days to manufacture an item the release and due dates are separated by one week This ensures that an order for that item w
110. 10 10 lists the programs where this frame appears Menu Program 5 13 1 Purchase Order Receipts 5 13 14 PO Shipper Maintenance 5 13 20 PO Shipper Receipt 16 10 Work Order Component Issue 16 19 Work Order Operation Backflush 18 14 Repetitive Labor Transaction WIP Lot Trace 277 Menu Program 18 17 Repetitive Reject Transaction 18 22 13 Backflush Transaction If the current operation s output queue is WLT controlled these WIP lot serials default to the WIP Lot Output Queue Receipt Data frame Figure 10 9 That output frame appears immediately after this input frame Fig 10 8 WIP Lot Input Queue Issue Data Qty Processed 15 EA WIP Lot Input Lot Serial Ref Quantity Queue Issue Data Li 2 0 Lot Serial Ref Quantity L1 2 0 The current operation s WIP QOH balances are updated to reflect the issue or receipt of this WIP material The WIP lot serials entered are recorded in tracing history as being consumed from the input queue of the current operation and produced into the output queue WIP lot serials entered in the WIP Lot Output Queue Receipt Data frame WIP Lot Output Queue Receipt Data Use the WIP Lot Output Queue Receipt Data frame to report the WIP lot serial numbers references and quantities of the WIP material produced by an operation This frame appears in e Purchase Order Receipts 5 13 1 when the output queue of the current operation is WLT controlled e Repetitive Labor Transaction 18 14 when
111. 153 i Maintenance Instead you must change the routing and roll up the cost again Releasing Work Orders Inventory can only be issued or received against a released work order Release orders one at a time using Work Order Release Print 16 6 Release multiple orders at the same time using Multiple Work Order Release Print 16 7 Release orders in Work Order Maintenance 16 1 by changing their status to Released This method does not let you print a picklist or routing but it still explodes phantom components and creates work orders for routable components Releasing a work order has the following effects tems not previously allocated are detail allocated The system uses the default picking logic defined in Inventory Control 3 24 The picklist is printed showing the location and quantity of the material in Picked status for this order See page 104 The first operation is moved to the queue status if Move First Operation is Yes in Work Order Control 16 24 FAQAD Work Orders 121 It is possible to prevent work orders for specified items from being released to the shop floor For example you might want to restrict from release any items that are going to be phased out or obsoleted in the near future To use this feature use Item Status Code Maintenance 1 1 5 to identify one or more status codes that you want to associate with items that cannot have work orders released Assign REL WO to these c
112. 3 22 3 89 3 22 4 89 3 22 13 1 268 3 22 13 13 298 300 3 22 13 14 272 300 3 22 13 15 292 301 3 22 13 17 302 3 22 13 18 302 3 22 13 19 302 3 22 13 20 302 3 22 13 24 265 5 5 1 13 204 5 5 1 17 206 5 5 3 1 206 211 5 5 3 8 211 5 5 5 5 209 5 5 5 11 216 5 7 204 294 5 10 295 5 13 1 209 215 5 13 7 209 296 5 13 14 209 5 13 20 216 13 1 14 13 1 2 4 77 13 5 63 13 12 7 72 TT Index 13 12 13 72 13 12 14 23 13 15 15 67 83 13 19 21 68 14 1 29 14 5 29 60 14 9 32 202 14 13 1 64 203 14 13 7 32 14 13 13 37 14 13 17 235 14 13 18 235 14 13 19 235 14 15 1 15 67 83 14 17 1 36 15 1 14 48 15 5 47 15 8 49 15 12 1 69 83 86 90 104 15 12 5 73 15 13 50 64 15 16 50 15 18 51 62 69 90 104 16 1 83 105 16 3 132 16 3 1 132 16 3 2 132 16 3 3 132 135 16 3 4 85 133 16 3 5 85 133 16 3 6 85 134 135 16 3 13 84 16 5 121 16 6 84 109 123 16 7 84 109 16 8 111 16 9 122 16 10 124 286 QAD 388 User Guide QAD Manufacturing 16 11 72 85 127 288 18 22 4 5 199 16 12 66 72 85 128 18 22 4 6 199 16 13 1 119 18 22 4 10 199 16 13 13 120 144 18 22 4 11 199 16 16 121 18 22 4 12 199 16 17 121 18 22 4 13 200 16 18 127 134 18 22 4 14 200 16 11 289 18 22 4 15 200 16 19 100 286 289 18 22 5 5 213 16 21 59 72 88 135 144 148 18 22 5 11 204 215 16 23 88 137 18 22 5 13 210 220 16 24 103 18 22 5 17 218 17 1 140 287 18 22 5 24 213 17 2 140 287 18 22 6 186 17 3 140 287 18 22 7 182 17
113. 30 the system moves it into the input queue of operation 20 and the quantity at operation 30 is set to 0 zero Fig 8 6 Routing Maintenance 14 13 1 b See Zero Balance WIP on page 160 FAQAD 168 User Guide QAD Manufacturing b See Managing Subcontracting on page 200 for more details AQAD When Zero Balance WIP is No the system does not automatically move quantities out of non milestone operation queues when you report at subsequent operations Rather leftover quantities remain at these operations until you move them out or delete them manually using WIP Adjust Transaction 18 22 21 Automatic Labor Reporting The Auto Labor Report field determines if standard labor is reported automatically by Backflush Transaction 18 22 13 When Yes Backflush Transaction automatically reports the standard number of run hours for the quantity processed Any hours specified directly are considered as additional to the standard Negative numbers are subtracted from the standard Backflush Transaction also automatically reports standard hours for each prior non milestone operation that also has this field set to Yes Set this field to No if you do not want to generate labor reporting automatically In this case you should report labor explicitly in either the Backflush Transaction or the Run Labor Transaction 18 22 14 In either case all setup labor must be reported using the Setup Labor Transaction 18 22
114. 3000 O a Nem tiunber Wok Onder Component Status Component Sista Quantity Ordeerd Quantity Completed QuarttyOpen RoomaDao Dun Cote Wok Order Status Woh Corim Opmaton al E w x Proche Shortage 100 00 100 ONUA 01 1000 F wee w xm Projected Shortage 100 00 100 mavam 0 0207 F wont E 10 donot Prowcimd Shortage 100 oo 1600 01 10 2000 01 10 2007 F wong 40 15 eD No Component 1 30 10 20 11082007 1108200 e w w T6 2500 No Component 1 10 no 20 1 20 2007 NAV e 1090 ste Propis Sale 1 100 00 1000 TAEZ2007 110600 e E oa I WO Component Avolabilty Werk Order Mowtenance Work Order FieleaiePret Work Order Component Issue Recalculate Copocity Pion Amane SY Pren da 1O Ohan Designer Veg 15 a5 Recorts per page 100 6G MenNunbm a V Component Status SY Promoted Net Anaie Y GipRiegaed Y Quartty Abocsted CY Quantity Picked gt V Quarttylssund Y QuanttyOpen CY Deco gt Y os 2010 Actis s50 wo 00 00 no 100 SA20101 0 WO Como Availabilty SuppiyDemaest Summary WO Component fumlabiity Calculation Details m Imentor Detwi try Ste amoni i5 Prnt ds Chae I9 Chan Designer New g Ede Vom dud Recents pe page 100 900 Sis T benMunbm 2 V Quantity OnHand 2 Y Location 2 Y Lateral 2 V Neleence V Status 2 V Date Crested V Dore Daie Y Total On Hand ar Component Check by Item Work Order Materials planners can use Component Chec
115. 305 Defining Specifications 0 0 eee ee eee 306 Setting Up Procedures 0 0 eee eens 308 Defining Sampling Patterns 0 0 eee eee eee eee 309 Executing Stand Alone Tests 0 0 0 2c eee eee eee 310 Creating Quality Orders 0 eee ee eee 312 Entering Quality Order Results 0 0 0 0 0 cee eee eee 313 Deleting Quality Orders 0 eee ee eee 314 Conducting Process Inspections 00 eee eee ee eee 314 Conducting Other Tests seas ea bPRa eli EE ed rg aa 316 Inventory Audits leseeeeeeee e 316 First Article Inspection 0 0 0 cece eee eee eee eee 317 Process Validation 0 0 cece cece eee 317 Destructive Testing 2 04 icu eee ee ee ee ee 317 Printing Test Results iude seals ere beds ERE RD end 318 Chapter 12 Forecasting Master Schedule Planning 319 Introduction 4 cob eR elated s be eere VI PER a 320 xii User Guide QAD Manufacturing Creating Forecasts resuelven LEER PENES 320 Forecast Creation Workflow 00 0 0 e cece eee eee 320 Forecasting Simulation 0 0 0 cee eee eee eee 321 Setting Up Forecasting Simulation 000008 322 Creating Criteria Templates 0 0 0 0 eee eee eee eee 322 Calculating Forecasts 0 0 cece eee eens 328 Manually Creating Forecasts lees 330 Modifying Forecast Results 0 0 eee eee ee eee 330 Copying and Combining Forecasts
116. 4 programs such as Backflush Transaction Reject Transaction and Rework Transaction FAQAD 266 User Guide QAD Manufacturing FAQAD Trace Parents Enter Yes to trace all parent items otherwise enter No You cannot trace components or references unless Trace Parents is Yes in the control program or for the routing This value defaults to Trace Parents in Routing Registration Maintenance Max Lot Size Enter the maximum size for WIP lots produced at any operation A warning message displays when the cumulative WIP lot size exceeds this quantity Enter 0 zero to indicate that lot size is not restricted and to prevent warning messages from displaying This value defaults to Max Lot Size in Routing Registration Maintenance WIP Lot Number Sequence ID Enter an optional sequence ID defined with Number Range Maintenance 36 2 21 1 The system uses this sequence to generate output WIP lot serial numbers automatically NRM generated WIP lot serial numbers cannot exceed 18 characters This value defaults to WIP Lot Number Sequence ID in Routing Registration Maintenance If an NRM sequence is not specified you must manually enter output WIP lot serial numbers However when an NRM sequence ID is specified in WIP Lot Trace Control or in the routing registration record you can leave the fields blank The system automatically generates a lot serial number based on this sequence ID Split WIP Lots Enter Yes if an input WI
117. 4 Finished Good Rev Reference Start Effective End Effective Quantity Per Rl EA Scrap 0 0096 Lead Time Offset Operation Sequence Number Structure Type Forecast Percent 100 0096 Start Effective 2 21 2007 Option Group P End Effective 2 21 2008 v Process 2 Remarks Important fields include the following Reference On a complex assembly that contains many components an item may appear several times on the same drawing and product structure Use Reference to identify a component that appears multiple times on the same parts list The reference code can be a drawing reference number that helps to relate a component to a specific position on a drawing or a code associated with an engineering change order or an engineering change notice The system uses parent component reference and start date to define a unique product structure record A component can have the same parent and same reference as long as the start dates are different Note If you use the Product Change Control PCC module b See User Guide engineering change notice functions in Product Structures are ied aed disabled information on f PCC Since the system uses product structures to store configuration bills you can also enter the feature code for configured products in Reference FAQAD 18 User Guide QAD Manufacturing b See Engineering Effectivity on page 23 FAQAD Start and End Effective The way an it
118. 8 22 9 variance at operation close RBUV Run labor burden usage variance Post Accumulated Usage Variance posted at operation close 18 22 9 REWORK Quantity reworked and labor Rework Transaction 18 22 17 hours posted RLUV Run labor usage variance posted Post Accumulated Usage Variance at operation close 18 22 9 SBUV Setup labor burden usage Post Accumulated Usage Variances variance posted 18 22 9 SCRAP Quantity scrapped at an Operation Scrap Transaction operation 16 20 7 SETUP Setup hours recorded Setup Labor Transaction 18 22 15 Table 7 1 Operation History Transaction Types Page of 2 149 Table 7 1 Operation History Transaction Types QAD 150 User Guide QAD Manufacturing FAQAD Transaction Type Description Program SLUV Setup labor usage variance Post Accumulated Usage Variances posted 18 22 9 SUBCNT Subcontract quantity received or Purchase Order Receipts 5 13 1 returned at an operation Purchase Order Returns 5 13 7 SUBSHIP Quantity of WIP shipped to a Sub Shipper Issue 18 22 5 11 subcontractor SUV Subcontract processing usage Post Accumulated Usage Variance variance posted at operation 18 22 9 close TRANSFER Quantity of WIP transferred to Cumulative Order Close 18 22 10 another cumulative order at operation close VAR POST Labor variance posted at work Work Order Receipt Backflush order receipt 16 12 WIPADJ I Q
119. A Bumper Rack for BCT4 Item Number APS 1117 EA Component 1117 Substitute Item APS 1118 EA Component 1118 Substitute Qty pm Remarks Comments Cumulative Lead Time When a product is planned it is sometimes necessary to know its cumulative lead time the longest time required to produce it The cumulative lead time determines the minimum planning horizon for the master schedule and material requirements planning Cumulative lead time is calculated by first determining the composite lead times between the product and each of the lowest level components The longest of these composite lead times determines the critical path and sets the cumulative lead time When a product structure contains a BOM code in a lower level the cumulative lead time of the end item includes lead times for components of the BOM code Example Sunglasses are manufactured from a purchased frame assembly Table 2 3 shows the lead time for each item Table 2 3 Manufacturing Sunglasses with Coated Lenses 1 Lead Times Frame assembly 28 Leftlens 2 Right lens 2 Blank 7 Blank 7 AQAD Product Structures 23 Sunglasses with Coated Lenses 1 Tint 28 Tint 28 Coating 35 Coating 35 The composite lead times for the sunglasses are calculated for each of the component lead time paths starting from the top level assembly and going down to the component as illustrated in Table 2 4 Table 2 4 Assembly or Component L
120. AD Manufacturing FAQAD About This 2 User Guide QAD Manufacturing FAQAD This guide covers features of the core QAD manufacturing modules See User Guide QAD Lean Manufacturing for information on manufacturing modules based on lean techniques such as kanban and flow scheduling Other QAD Documentation For an overview of new features and software updates see the Release Bulletin For software installation instructions refer to the appropriate installation guide for your system For conversion information refer to the Conversion Guide For an overview of system features and instructions on navigating the user interface see User Guide QAD User Interfaces For detailed information on using system features refer to the relevant user guide For technical details refer to Entity Diagrams and Database Definitions For a complete list of QAD Documentation visit the QAD Support site at http support qad com QAD Web Site The QAD Web site provides a wide variety of information about the company and its products You can access the Web site at http www qad com For users with a QAD Web account product documentation is available for viewing or downloading from the QAD Online Support Center at http support qad com You can register for a QAD Web account by accessing the Web site Your customer ID number is required Access to certain areas is dependent on the type of agreement you have with QAD
121. Approval 376 Planned Repetitive Sched Approve 376 Planned status work orders 240 Planned Work Order Approval 376 co products by products 80 planned work orders 111 375 planning bills for 347 capacity requirements 379 master production schedule MPS 343 material requirements 355 shipment performance monitoring 201 PO Shipper Maintenance 209 PO Shipper Receipt 216 POQ 363 Post Accumulated Usage Variances 196 PQOH column Demand Supply Detail Browse 241 primary run sequence 361 printing picklists 179 Procedure Maintenance 308 Process Definition Copy 50 Process Definition Maintenance 50 co products by products 64 run time 37 process inspection 315 Process Formula Maintenance 51 co products by products 62 69 86 Quantity Complete Method field 90 104 processes 50 51 batch quantity 50 copying 50 defining 50 manufacturing 18 product definition 5 Product Line Maintenance co products by products 60 product lines co products by products 60 Product Structure Code Maintenance 14 Product Structure Cost Report co products by products 77 Product Structure Cost Roll Up co products by products 72 product structure Op field 20 Product Structure Maintenance co products by products 63 Index 397 lead time offset 122 planning bills 347 work order BOM 114 product structures 11 24 alternate 15 alternate routings 15 BOM codes 14 component quantities 18 configured products 17 21 effective dates in 18 MRP use of 366 operation codes 2
122. D 2007 Forecast Year 2007 Forecast Method 00 Item Number Prod Line 2 Group P Item Type Fe Order Line Site P Use Ship To Sold To Sold To v Customer n Region P Years of History Specify the number of years of shipment history to analyze up to five years The system reduces this number if there are no sales data for a given year Use Ship To Sold To Indicate whether the system selects sales history to analyze based on the customer s ship to or sold to address Customer Region List Type Use these fields to identify subsets of customers for which the system selects sales data to analyze Forecasting Master Schedule Planning 323 Go To Actions Description Next Year Forecast Years of History 5 Alpha factor 40 User factor 1 00 P To To 2 To P To P To 2 List Type To P To 2 Forecast Year For a rolling forecast starting this month this year must be identical to the ending year Ending Ending year must be the same as or earlier than the forecast year Forecast Method Specify either a predefined forecast method 01 06 or your own forecast method Alpha factor Trend User factor 1 and 2 Specify weighting factors used by the forecast method Item Number Product Line Group Item Type Use these fields to identify a single item or range of items for which to forecast Order Line Site Specify the order line site on sales orders or ship from site on a customer sc
123. D to update WIP lot serial QOH balances When WIP Lot Trace WLT is active all of the inventory related fields in the purchase order receipt detail are disabled including Site Location Lot Serial Ref Supplier Lot Multi Entry and Change Attributes All lot serial information should be specified using the WLT frames that display Note If Move to Next Op is Yes then the WIP lot serials specified in the WIP Lot Output Queue Receipt Data frame are moved to the input queue of the next milestone operation QAD 296 User Guide QAD Manufacturing FAQAD Returning Purchased Materials Purchase Order Returns 5 13 7 updates QOH balances cumulative totals and WLT tracing history to reflect the return of materials at a subcontract operation The WIP Lot Input Queue Issue Data and WIP Lot Output Queue Receipt Data frames appear when processing WLT controlled material Any material being returned is reverse backflushed For example instead of receiving material to WIP material is removed from WIP The system basically processes a PO receipt with all negative quantities If Move To Next Operation is Yes the system removes WIP lot serials from WIP inventory at the input queue of the first milestone operation following the subcontract operation When this value is No or a milestone operation does not exist after the subcontract operation then the system removes the WIP lot serials from the output queue of the subcontract operation
124. Enable WIP Lot Trace to Yes in WIP Lot Trace Control 3 22 13 24 Fig 10 2 SC WIP Lot Trace WIP Lot Trace Control Go To Actions Control 3 22 13 24 Enable WIP Lot Trace v Trace Parents v Max Lot Size 0 0 WIP Lot Number Sequence ID C INC 2 Split WIP Lots Combine WIP Lots WIP Lot Overissue Trace Components Trace Reference Combine Component Lots LSI IS S S Control program settings apply to all routings and BOMs used throughout See page 268 and your manufacturing environment Specify the most common BOM and page 272 routing settings in the control program These values depend greatly on the information you collected when planning how you will use WLT You can create exception records to override these settings for specific routings and BOMs For example in an environment where most parent items are traced the Trace Parents value is set to Yes To disable tracing for specific parent items that do not need it use Routing Registration Maintenance to create a record for each of those parent items Set the Trace Parents value to No for those records Use the following field descriptions and any data you collected as discussed in the planning section to guide you through the control program setup Enable WIP Lot Trace Enter Yes to activate the WIP Lot Trace module When WIP Lot Trace is active new fields and frames display in See page 25
125. FAYQAD QAD Enterprise Applications 2009 Enterprise Edition User Guide QAD Manufacturing Product Structures Routings and Work Centers Formulas and Processes Co products and By products Work Orders Shop Floor Control Advanced Repetitive Repetitive WIP Lot Trace Quality Management Forecasting Master Schedule Planning Material Requirements Planning Capacity Requirements Planning 78 0697C QAD 2009 Enterprise Edition April 2009 This document contains proprietary information that is protected by copyright and other intellectual property laws No part of this document may be reproduced translated or modified without the prior written consent of QAD Inc The information contained in this document is subject to change without notice QAD Inc provides this material as is and makes no warranty of any kind expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose QAD Inc shall not be liable for errors contained herein or for incidental or consequential damages including lost profits in connection with the furnishing performance or use of this material whether based on warranty contract or other legal theory QAD and MFG PRO are registered trademarks of QAD Inc The QAD logo is a trademark of QAD Inc Designations used by other companies to distinguish their products are often claimed as trademarks In this document the product names appear in init
126. If Co By Type is B an allocation percentage cannot be entered Costs for co products and by products are calculated using the same P See Allocating programs that calculate regular costs Once costs are rolled up for a m cde d base process yielding gross cost by product costs are subtracted to page 69 arrive at the base process net cost The entire net cost is then allocated to co products of the base process Allocation percentages for all co products of a base process should add up to 100 percent Structure Type This field is display only and always set to J Joint Set up formulas or product structures used to define the ingredients or components required for a base process You can use Process Formula Maintenance 15 18 or Formula Maintenance 15 5 To enter a product structure use Product Structure Maintenance 13 5 Parent Item Enter the base process item number Component Item Enter components of the base process item When adding a formula you can enter a batch size Use Batch Quantity Change 15 9 to modify a formula s batch size QAD 64 User Guide QAD Manufacturing Fig 5 6 A Recyclable By product Process FAQAD 4 Set up routings for the base process using Process Formula Maintenance 15 18 Process Definition Maintenance 15 13 or Routing Maintenance 14 13 1 In Process Formula Maintenance enter the base process in the BOM Formula Code field In Process Definition Maintenance or
127. Increase Decrease Scale or Trend factor on page 332 During a combine or replace the original target forecast record and criteria template are overwritten The source record is not altered Generating Reports The system does not generate forecasts in currency values However Detail Forecast Report 22 7 9 lets you review forecast quantities along with the production cost and sales price by month You must specify the cost set site price list and currency in which to display the monetary amounts FAQAD 336 User Guide QAD Manufacturing Table 12 9 Sample Forecast Report b See Chapter 13 Material Requirements Planning on page 355 FAQAD If both the cost and price are in the same currency the report displays the profit margin calculated as price minus cost The number of units the extended cost value and the extended price value are also totaled for the entire 12 month reporting period Table 12 9 illustrates a sample forecast report assuming the forecasted item has a unit cost of 15 36 and a unit price of 25 00 Forecast Item Ext Ext ID Year No Mo Units Cost Price Margin j205095 2002 j2050 Jan 1336 20 520 96 33 400 00 12 879 04 Feb 1568 24 084 48 39 200 00 15 115 52 Mar 1839 28 247 04 45 975 00 17 727 96 Apr 1970 30 259 20 49 250 00 18 990 80 May 2182 33 515 52 54 625 00 21 109 48 Jun 1995 30 643 20 49 875 00 19 231 80 Jul 2003 30 766 08 50 075 00 19 308 92 Aug 2134 32 778 24 53 350 00 2
128. Input Queue Scrap Data Use the WIP Lot Input Queue Scrap Data frame to record the WLT controlled material being scrapped from an operation s input queue It displays in Backflush Transaction 18 22 13 Fig 10 13 WIP Lot Input WIP Lot Input Queue Scrap Data Qty Scrapped 2 EA Queue Scrap Data Roul Lot Serial Ref Code Quantity ID 100 Li Quality 2 0 Work Center 12000 Machine General 2 Department 10 General To Queue EA Conversion 1 0000 In Queue 2 0 From Queue Multi Entry F Out Queue 2 0 Reason Code Multi Entry F Reject Queue 2 0 Reason Code Multi Entry Lot Serial Code Quantity Lil P Quality 20 FAQAD WIP Lot Trace 281 The quantity scrapped is deducted from the WIP QOH balance for the current operation s input queue It is added to the cumulative scrapped quantity WIP Lot Output Queue Scrap Data Use the WIP Lot Output Queue Scrap Data frame to record the WLT controlled material being scrapped from an operation s output queue It displays in Scrap Transaction 18 22 18 Fig 10 14 WIP Lot Output Queue Scrap Data WIP Lot Output Queue Scrap Data Qty Scrapped 2 EA RoulLot Serial Ref Code Quantity ID 100 Li 2 Quality 2 0 work Center 12000 Machine General 2 Department 10 General To Queue EA Conversion 1 0000 In Queue 2 0 From Queue Multi Entry Out Queue 2 0 Reason Code Multi Entry Reject Queue 2 0 Reason Code Multi Entry Lot Serial
129. Net Change MRP 371 non milestone backflushing 156 nonproductive labor 145 Non Productive Labor Feedback 145 193 Number Range Maintenance 266 number range management NRM WIP lot serial numbers 263 e one time only OTO 363 Operation Complete Transaction 146 operation status 144 Operation Cost Calculation 235 Operation Cost Inquiry 235 Operation Cost Report 235 Operation Move Transaction FAQAD queue status 144 Operation Scrap Transaction 145 tracing WIP scrap 289 Operation Transaction Inquiry 199 Operation Transaction Numbering Report 150 operation specifying code 205 operations automatic completion 146 capacity 33 changes to 32 lead time 38 lead time calculation 38 load 383 milestone 33 167 product structure 20 scheduling 118 380 standard 32 status 144 complete 144 hold 144 queue 144 running 144 setup 144 subcontract 40 yield 41 Operations History Delete Archive 152 Operations Numbering Report 199 order modifiers 363 order pegging 370 order policies MRP use of 362 OTO 363 P parent items product structures 12 performance efficiency 151 productivity 151 utilization 151 period order quantity POQ 363 phantom use up logic 24 phantoms 15 global 16 identifying 16 local 16 use up logic 16 picklists processing flow 176 repetitive 175 reprinting 123 work order 122 plan category 241 plan orders parameter 361 Planned Order Reports co products by products 80 Planned Purchase Order
130. Note In all cases the order quantity is used in calculating run time Example Figure 6 6 illustrates two schedules created based on the data listed in Table 6 6 The schedule is generated for 100 items assuming six hour shop days Queue Setup Run Subcontract Operation 10 6 1 05 Operation 20 1 day Operation 30 5 01 Work Orders 117 Fig 6 6 Operation Times Forward Scheduling Wed Thu Fri Sat Sun Mon Tue Evrd cca eee Queue 6 0 Setup 1 0 Subcontract x Queue 5 0 Run 5 0 1 day Run 1 0 Backward Scheduling Wed Thu Fri Sat Sun Mon Tue So re Queue 6 0 Setup 1 0 x Subcontract Queue 5 0 Run 5 0 1 day Run 1 0 Different release and due dates are possible using forward versus backward scheduling This is because some lead time components are scheduled in shop days and some in calendar days A shop day lead time component may be in effect over a weekend in one direction whereas in the opposite direction a calendar day component may be in effect Lead Time Calculations The system uses an average manufacturing lead time calculated from See Lead averages of queue setup run subcontract wait and move times for re routings The calculation assumes the average order quantity for the item details site or item The operation start and stop dates indicate when an order will occupy a work center Queue time precedes the start date Setup run and subcontract times fall between the start and stop
131. Order Close on page 183 FAQAD Method Change Variances Method change variance MCV when calculated is posted by the following transactions Cumulative Order Close 18 22 10 Backflush Transaction 18 22 13 Run Labor Transaction 18 22 14 Setup Labor Transaction 18 22 15 Rework Transaction 18 22 17 Move Transaction 18 22 19 MCV is calculated as the difference between the final operation cost recorded in the cumulative order and the GL standard cost of the finished material extended by the quantity being reported In the backflush and move transactions MCV can be posted when moving from the output queue of the last operation to finished material inventory In the transactions where labor is reported MCV is also generated when reporting at a work center other than the cumulative order operation work center MCV is calculated as the difference between the standard labor and burden rates of the work center being reported and the standard labor and burden rates of the cumulative order operation work center extended by the number of hours reported This prevents unexpected rate variances from being applied to work centers In Cumulative Order Close MCV can be posted when transferring WIP quantities to new cumulative orders MCV is calculated as the difference between the operation cost in the former cumulative order operation and the operation cost of the new cumulative order operation extended by the quan
132. P lot can be divided into multiple output WIP lots Example One WIP lot of blank bolt studs goes into a threading machine The lot being consumed should not be split into separate output WIP lots such as one lot of metric thread bolts and one lot of standard thread bolts To prevent lot splitting enter No This value defaults to Split WIP Lots in Routing Registration Maintenance WIP Lot Trace 267 Combine WIP Lots Enter Yes if multiple input WIP lots can be combined into a single output WIP lot Example At operation 20 input WIP lot L1 is consumed into output WIP lot M1 using the backflush transaction On the next backflush you try to consume input WIP lot L2 into output WIP lot M1 If Combine WIP Lots 1s No the second backflush transaction cannot proceed This value defaults to Combine WIP Lots in Routing Registration Maintenance WIP Lot Overissue Enter Yes if a quantity can be issued for a WIP lot even when that issue results in a negative WIP lot quantity on hand QOH Example With a WIP lot serial QOH of 5 the system lets you issue a quantity of 7 when WIP Lot Overissue is Yes A warning tells you that this issue will result in a negative QOH balance of 2 If WIP Lot Overissue is No the system displays an error message This situation can occur when a later operation is reported before an earlier one This value defaults to WIP Lot Overissue in Routing Registration Maintenance Trace Components Enter Yes to trace c
133. Process Formula Maintenance Go To Actions Formula BOM Formula Code BRACKBCT4 None 00 Batch Size 1 0 Description Bumper Rack for BCT4 Formula V Use this frame Backflush Method 1 Quantity Complete Method MAX to specify which Entry Options screens Operation Detail v Co By Products display There are four main screens in addition to a transactions comments Screen The Formula BOM Code screen records the code for the parent item Components Comments It is the same as Formula Code Maintenance 15 1 The Process Operation Detail screen records information about the operations associated with the formula s process definition It is the same as Process Definition Maintenance 15 13 The Formula Components screen records information about the components used at each operation It is the same as Formula Maintenance 15 5 The Co By Products screen records information about co products and by products This is the same as Co By Product Maintenance 15 121 b See Chapter 5 Co products and By products on page 53 Fig 4 5 Process Formula Maintenance 15 18 P See Setting Up a Co By product Structure on page 62 FAQAD 52 User Guide QAD Manufacturing FAQAD duct Operation 58 ead Times 69 MRP for Co p ts By products 77 der Sets 81 estrictions A 54 User Guide QAD Manufacturing FAQAD Introduction
134. RP Control Calculations are based on this weekly period MRP calculates net requirements for items using three variables Gross item requirements are the sum of an item s requirements from forecasts higher level products customer orders service items and intersite orders They do not take into account inventory on hand or scheduled receipts Scheduled receipts for that item including open purchase orders open work orders with a quantity open and a status of R and intersite requests for DRP items Quantity on hand from the previous period MRP uses these three variables in the following calculation Net Requirements Gross Requirements Quantity on Hand for the previous period Scheduled Receipts MRP schedules planned purchase orders and work orders to fill these net requirements Planned work orders generated by MRP are exploded into gross requirements for their components This process continues until there are no more planned work orders to explode Note MRP does not explode product structures for purchased and distribution items or components with structure code Document FAQAD 368 User Guide QAD Manufacturing b See Yield on page 41 b See Phantoms on page 15 for more information on global phantoms b See Chapter 5 Co products and By products for more details FAQAD Yield Calculations When MRP plans orders for a parent item it also determines if orders are requir
135. RP does not consider blanket purchase orders or non nettable inventory as sources of supply Setting Up MRP Before running MRP set up the following data in your system Control program parameters in MRP Control tem planning parameters nventory status codes Product structures and formulas FAQAD 358 User Guide QAD Manufacturing Fig 13 1 MRP Control 23 24 b See User Guide QAD Supply Chain Planning FAQAD MRP Control Enter appropriate values in MRP Control 23 24 MRP Control wx MRP Control Go To Actions MRP Horizon 365 MRP DRP Combined Summary Default Today 4 Order Release Horizon Enable Op Based Yield Use AppServer AppServer Name m Default Number of Threads 0 MRP Planning Horizon Enter the period of time in calendar days which MRP should plan MRP calculations ignore data outside this time period The horizon should be at least one day longer than the longest item cumulative lead time in the database If you change the MRP planning horizon impacted items are not automatically replanned when you run net change MRP Ensure that all items are replanned by running MRP in regenerative mode MRP DRP Combined Enter Yes to indicate that MRP planned items can be planned using DRP functions Enter No if they can only be planned using MRP functions Summary Default Specify the day of the week used by all MRP summary reports and inquiri
136. RP use of 360 phantoms 16 Pur Mfg code 109 routing code 36 Item Specification Maintenance 307 FAQAD Item Status Code Maintenance co products by products 60 Item Substitution Maintenance 21 co products by products 68 87 items expensed 21 key 121 master scheduled 343 360 planning parameters 360 specifications for 307 Item Site Cost Maintenance co products by products 71 Item Site Planning Maintenance 174 BOM code 14 co products by products 60 61 MRP use of 360 phantoms 16 routing code 36 J joint order sets 81 printing 84 releasing 84 reviewing 84 K key items work orders 121 L labor 31 advanced repetitive transactions 193 backflushing automatically 168 nonproductive 145 reporting feedback 140 reports 148 down time 151 input output 151 transactions 148 utilization and efficiency 151 labor feedback departments 142 employees 141 item quantities 142 test results 314 work centers 142 Labor Feedback By Employee 287 Labor Feedback by Employee 140 Labor Feedback By Work Center 287 Labor Feedback by Work Center 140 Labor Feedback By Work Order 287 Labor Feedback by Work Order 140 test results 315 Labor WIP Lots frame 281 labor reporting feedback using WIP Lot Trace 287 lead times 364 changing 39 composite 23 co products by products 76 77 cumulative 22 manufacturing 40 move 38 operation 38 queue 37 run 37 scheduling production lines 172 setup 37 subcontract 38 wait 38 Line Allocation Inquiry 163 L
137. Receipts Total scheduled receipts for an item from work orders repetitive schedules purchase orders and distribution orders Projected QOH Projected item quantity on hand calculated by the system This is a projection by period of an item s on hand balance plus scheduled receipts minus gross requirements Available to Promise The uncommitted portion of inventory or planned production calculated by deducting real demand from real supply Cumulative ATP A running total based on available to promise quantities Note To prevent the program from consuming ATP from other periods set Negative ATP to Yes This allows the system to display negative ATP in any column of the report Seasonal Build Seasonal build quantity in inventory for that period not included in the ATP quantity b See page 346 b See page 340 b See Chapter 13 b See page 345 b See page 351 FAQAD 354 User Guide QAD Manufacturing FAQAD The Master Schedule Detail Inquiry and Report functions 22 21 and 22 22 display the same information as the Master Schedule Summary Inquiry and Report sequenced by due date They also include source to demand pegging details allowing you to identify the actual work order or sales order generating a particular item requirement Chapter 13 Material Requirements Planning Material Requirements Planning MRP is a key manufacturing planning process that uses a site s master schedule and all other
138. S it is easy to identify them on Work Order Dispatch Report 16 18 and other reports Departments and work centers can be defined more specifically for individual suppliers depending on whether operations are performed by a single supplier Subcontract Life Cycle When the Work Orders Shop Floor Control and Purchasing modules are used together the subcontract cycle includes the following steps Work Order Maintenance 16 1 or Planned Work Order Approval 23 10 Work Order Component Check 16 5 Work Order Release Print 16 6 Work Order Component Issue 16 10 Work Orders 127 Work Order Dispatch Report 16 18 Purchase Order Maintenance 5 7 Purchase Order Receipts 5 13 1 Labor Feedback by Work Center 16 20 1 optional Work Order Receipt 16 11 Work Order Accounting Close 16 21 Requirements for Subcontract Purchase Orders Use Work Order Dispatch Report 16 18 and Work Center Dispatch Report 18 4 8 to determine when purchase orders for subcontract operations should be released The Work Order Dispatch Report displays the operations scheduled at a work center sorted by start date The report includes the item being built the work order that authorizes the work standard setup and run times and the open quantity on the order at that work center Use this report to provide work visibility for a specified number of days determined by the Window Days field Also use it as a measurement too
139. Schedule Maintenance 17 13 3 and do not include a reference to an existing work order the system automatically creates a type W Flow work order for the due date and required quantity entered on the flow scheduled order The status of the order is set to exploded and MRP uses it when planning requirements Note You cannot update system maintained type W work orders using Master Schedule Order Maintenance or Work Order Maintenance Repetitive Schedules If you use the Advanced Repetitive or Repetitive module to manage your manufacturing processes rather than the Work Orders module you can enter your master schedule as a repetitive schedule Do this using Schedule Maintenance 18 2 1 or 18 22 2 1 Then explode the repetitive schedule to create scheduled orders by running Net Change MRP 23 1 Regenerative MRP 23 2 and Schedule Explosion 18 2 4 or 18 22 2 4 Exploding the repetitive schedule creates new scheduled orders and revises existing orders to support the repetitive schedule Note You can modify the master production schedule by modifying the repetitive schedule and then re exploding it Scheduled orders are work orders with a type code of Scheduled and a status of Exploded They have their own bills of material To produce the master scheduled items you can use the programs in the Advanced Repetitive or Repetitive module or convert the scheduled orders to regular work orders if required Forecasting Master Schedule P
140. Schedule Delete 18 22 2 7 enables easy deletion of repetitive schedules and their planned work orders Limit schedule consumption in the past by deleting schedules left open that fall before a specific date In Schedule Delete the date defaults to Monday s date Use this to establish the earliest open schedule Many activities in the two modules are exactly the same or similar This P See Repetitive chapter describes how to use Advanced Repetitive Chapter 9 describes on page 227 the features of basic Repetitive that differ Setting Up Advanced Repetitive Repetitive activities assume that base data is already set up Much of this is the same data that is required by work orders Define master data such as items sites and locations Also set up each employee who will be reporting labor Define bills of material and product structures in the Product P See page 11 Structures module for each item to be scheduled Also associate each component in the product structure with a routing operation Define departments and work centers routings and operations in the P See page 25 Routings Work Centers module Each work center must have a corresponding location with the same ID as the work center FAQAD 158 User Guide QAD Manufacturing Fig 8 1 Repetitive Control 18 22 24 AQAD Within the Advanced Repetitive module you must complete additional setup activities Set up values in Repetitive Control and Advanc
141. Shipper Maintenance 213 WIP Lot Move Data frame 296 subcontract tracing WIP 290 subcontract cost specifying 203 subcontract fields in Routing Maintenance 203 Subcontract Item Status Inquiry 218 subcontract items connecting shippers to received items 216 receipt 200 receiving 215 reports 224 returning 219 scrapping 200 scrapping during receipt 218 scrapping unreturned material 210 setting up 202 specifying in an order 204 specifying received quantities 217 viewing subcontractors during receipt 209 subcontract lead time specifying 203 subcontract operation during backflush 156 subcontract operation assigned during backflush 212 Subcontract Order MRP Maint 206 subcontract orders creating 204 Subcontract Routing Op PO Maint 206 subcontract shipper closing during receipt 218 reopening during return 219 tracking 217 tracking through return 219 Subcontract Shippers frame 209 Subcontract Shipping Control 208 213 subcontract visibility 224 Subcontractor Scrap Maintenance 220 Subcontractor Scrap Transaction 210 subcontracts advanced repetitive 200 advanced repetitive processing 156 labor and burden rates 40 life cycle 126 operations 40 126 routings for 168 scheduled orders 204 substitute items co products by products 68 product structures 21 Supplier Lot Transaction Report 302 Supplier Scheduled Order Maintenance 204 suppliers unassigned 208 supply sources for MRP 357 supply and demand MRP totals 242 Sup
142. This also occurs when the system runs out of open schedule quantities to consume Completed planned orders are not considered by MRP Repetitive Scrap Transaction An item scrapped in the first operation may have a lower cost than one scrapped on receipt It will not have the accumulated labor burden and additional material costs that accrue during subsequent operations Repetitive Scrap Transaction 18 18 reports scrap at the item s accumulated cost through the operation where it is scrapped The system uses the standard cost created by the most recent use of Operation Cost Calculation 14 13 17 However if no operation costs exist for the item routing cost set Repetitive Scrap Transaction automatically rolls up and totals the material labor burden and subcontract costs by operation It also does this for scrap reported for alternate BOMs routings not included in Operation Cost Calculation The item cost by operation can be reviewed using the Operation Cost Browse 14 13 18 or the Operation Cost Report 14 13 19 After the scrap transaction is recorded the scrap cost can be verified using the Repetitive Operations Accounting Report 18 4 10 Repetitive Scrap Transaction debits scrap and credits WIP for the operation cost multiplied by the quantity scrapped QAD 236 User Guide QAD Manufacturing FAQAD Checking Component Availability You can use the following Component Check browse collections for real time retr
143. Trace Reports FAQAD Some existing reports and inquiries also display WLT data When using WLT you should use the WLT reports to report any WLT controlled WIP and item component material WLT does not trace WIP at non milestone operations even if those operations belong to a WLT controlled routing If you use Advanced Repetitive reports to view QOH balances for WLT controlled routings or BOMs the report may show that there is WIP material in the input queue of non milestone operations If you report for the same routing or BOM using WLT reports these reports will show that the WIP lot serial QOHs are in the input queue of the following milestone operation Table 10 12 summarizes WIP Lot Trace reports Report Menu Number Description WIP Lot 3 22 13 13 Displays the WIP lot inventory associated with each Inventory discrete work order or repetitive cumulative work Status Report order Item Lot Ship 3 22 13 14 Shows ISS SO transaction history tr_hist records Transaction created by Sales Order Shipments 7 9 15 or Pre Report Shipper Shipper Confirm 7 9 5 for a selected finished material lot Lets you easily identify the customer or ship to where the finished material lot was shipped WIP Lot Trace 301 Report Menu Number Description WIP Lot Convert Transaction Report 3 22 13 15 Shows operation history op_hist data and tracing information for transactions where material
144. U IU Work Center 12000 Machine General 2 Department 10 General Qty Processed 15 0 UM EA Conversion 1 0000 Qty Scrapped 3 0 Reason Code Multi Entry Oty Beiected n n Beasnn Code Multi Entry T Lot Serial Ref Code Quantity LS Quality P 3 0 The quantity scrapped is deducted from the lot quantity entered in the WIP Lot Output Queue Receipt Data frame It is added to the cumulative scrapped quantity 279 FAQAD 280 User Guide QAD Manufacturing WIP Lot Reject Queue Scrap Data Use the WIP Lot Reject Queue Scrap Data frame to record WIP material being scrapped from an operation s reject queue This frame displays in Scrap Transaction 18 22 18 when a reject quantity is entered in Rjct Queue and the reject queue is WLT controlled It also displays in Repetitive Scrap Transaction 18 18 Fig 10 12 WIP Lot Reject WIP Lot Reject Queue Scrap Data Qty Scrapped 3 EA Queue Scrap Data Prod Op _Lot Serial Ref Code Quantity 20 Ls Quality 3 0 Work Center 12000 Machine General 2 Department 10 General To Queue EA Conversion 1 0000 In Queue 0 0 From Queue Multi Entry Out Queue 0 0 Reason Code Multi Entry Reject Queue 3 0 Reason Cade Multi Entry Prod Op Lot Serial Ref Code Quantity L5 P Quality 2 3 0 The quantity scrapped is deducted from the WIP QOH balance for the current operation s reject queue It is added to the cumulative scrapped quantity WIP Lot
145. WIP material will be moved This frame appears only when Move to Next Op is Yes WLT frames added to Backflush Transaction appear in this order when the corresponding queue is WLT controlled WIP Lot Input Queue Issue Data Destination Work Center and Machine WIP Lot Output Queue Receipt Data WIP Lot Reject Data WIP Lot Scrap Data Reporting Run and Setup Labor WLT adds the Labor WIP Lots frame to Run Labor Transaction 18 22 14 and Setup Labor Transaction 18 22 15 Any run or setup labor you report for WLT controlled operations is associated with the WIP lot serials you indicate in this frame Use WIP Lot Convert Trans Report 3 22 13 15 or Operation Trans Detail Inquiry 18 22 4 2 to review the labor associated with any WIP lot serial Reworking Rejected Material Use Rework Transaction 18 22 17 to move previously rejected WLT controlled material back into production Use the WIP Lot Rework Data frame to indicate which lot serials were reworked The reworked WIP material is moved to the location you indicate in To Operation and To Queue in the work center and packing list you specify in the Destination Work Center and Machine frame WIP Lot Trace 293 Scrapping Reject Material Use Scrap Transaction 18 22 18 to scrap or remove WIP quantities from any queue of an operation without backflushing If you scrap quantities from a WLT controlled queue use the WLT frames to specify the lot serials of the WIP material
146. able or blank FAQAD 78 User Guide QAD Manufacturing Its BOM Formula code is a base process that has the item as a co product If these conditions are not met the item is planned like a regular item MRP evaluates the beginning inventory demand supply and safety stock for a co product and when there is unsatisfied demand creates a demand record for its base process This demand record reflects the amount of the base process required to meet the unsatisfied demand for the co product As shown in Figure 5 8 MRP passes demand records directly from the co product to the base process without using the co product s order policy or related planning parameters Fig 5 8 MRP Processing of When MRP Co products _ Planned processes a When MRP Orders processes a Co product Regular Action Item Messages Planned Base Process Orders for Demand Base Process Ly Action z Messages i Co P By P Action Messages for Base Process Co product Base Process A co product is like a parent of its base process MRP plans all items in a site by low level code then by item number Low level codes are determined by parent component relationships FAQAD Co products and By products 79 Planning for Base Processes MRP plans for a base process by determining the unsatisfied co product demand for all co products that reference the base
147. al scrap using Work Order Receipt 16 11 Use See page 280 Operation Scrap Transaction 16 20 7 to remove scrap WIP material from a work order operation Use the WIP Lot Input Queue Scrap Data and WIP Lot Output Queue Scrap Data frame to record scrap lot serials for material at WLT controlled work order operations QAD 290 User Guide QAD Manufacturing b See Purchase Order Maintenance on page 294 for details FAQAD The program generates WO SCRAP operation history records for transactions It reduces QOH balances for the operation input and output queues for the lot serial quantities specified in the WLT frames The scrapped quantities are also added to the cumulative scrapped quantities for the lot serials The cumulative scrapped quantity for each queue is also increased by the lot serial quantity scrapped You can report reject materials at the operation level using Shop Floor Control However only units recorded as scrap during work order receipt affect the general ledger GL debiting Scrap and crediting WIP Rejects recorded in Shop Floor Control are for reporting only and have no GL effect Processing a Subcontract WO Operation Processing a subcontract work order operation when using WLT adds a few minor steps to the normal procedure 1 Create a subcontract purchase order for the work order operation using Purchase Order Maintenance 5 7 a Set Type to S for subcontract b Use the work order subcont
148. alculate work center capacity This value displays as the default when you reference this work center as part of a standard routing or process Setup and Run Crew Optionally enter the number of people required to set up and run this work center These fields are for reference only Machines Enter the number of machines or people in this work center CRP calculates the total capacity for a work center by multiplying the number of working hours defined in the shop calendar by the number of machines AQAD Routings and Work Centers 31 Setup and Labor Rate Enter the average labor rates paid per labor hour to set up and run this work center These values are used by item cost calculations and by labor feedback functions to calculate and post actual costs and variances Note Rates apply to all operations carried out at this work center You cannot change them for individual operations Mach and Labor Burden Rate Enter the burden rates per hour applicable to machine and labor run time and setup at this work center These values are used by item cost calculations and by labor feedback functions to calculate and post actual costs and variances Labor Burden Enter the labor burden percentage applicable to the total labor cost at this work center Important Changes to work center labor and burden fields affect how transaction amounts and product costs are calculated They should be authorized by your cost accounting department
149. ales Order Demand Sales order demand is the quantity of an item sold as recorded on confirmed sales orders or required ship schedules The system recognizes item quantities ordered as demand when a sales order has been confirmed that is Confirmed is Yes in Sales Order Maintenance 7 1 1 or a customer planning or shipping schedule has been changed to a required ship schedule using Required Ship Schedule Update 7 5 5 or Selective Required Ship Schedule Update 7 5 6 Note Confirmed issue lines on service return material authorizations RMAs and material order lines MOs in the Customer Services module are treated like sales order lines Sales order demand consumes shipment forecasts based on the item number site quantity and due date recorded on the sales order or customer schedule Abnormal Sales Demand Sales order demand is considered abnormal if the quantity or source of demand is not characteristic of quantities anticipated by the current forecast and it should not be used to plan forecasts in the future You can designate sales order demand as abnormal by setting the Consume Forecast option to No for that sales order or customer schedule line Abnormal sales demand is added to the net forecast rather than being subtracted from the shipment forecast Net Forecast Calculation Master production scheduling and MRP use the net forecast and abnormal sales order demand to calculate total demand The net forecast is calculated
150. all related work orders are received by default QAD 86 User Guide QAD Manufacturing FAQAD Use Work Order Receipt Backflush 16 12 and Work Order Operation Backflush 16 19 to Modify the backflush quantity and method Initiate transactions to receive co products and by products Backflush issue base process components When components are backflushed the receipt and scrapped quantities are used to calculate default issue quantities for the components Backflush Calculation Methods Specify one of two backflush methods for the base process in Co By Product Maintenance 15 12 1 or Process Formula Maintenance 15 18 The backflush quantity for the base process is used to calculate backflush issue quantities for the components of a joint order set In Work Order Receipt Backflush 16 12 Work Order Enter any work order number in the joint order set ID Enter the specific ID desired or leave blank to retrieve the first ID in the joint order set Receive All Co By Products Enter Yes if all co products and by products are to be received Enter No if only the items on this particular order are to be received Backflush Method Enter 1 or 2 Method 1 backflushes based on the co product and by product quantities received Method 2 backflushes based on the order quantity of the base process The following two sections describe each method in more detail Backflush Method 1 The backflush base process quantity
151. ame WIP Lot Trace 271 Combine WIP Lots Enter Yes if multiple input WIP lots for this operation can be combined into a single WIP output lot before being processed by the next operation This value only affects WIP material produced by this operation Example Because Combine WIP Lots is No for operation 30 WIP lots produced by operation 30 cannot be combined at operation 40 Two WIP lots of blank bolt studs produced by operation 30 go into a threading machine at operation 40 The lots to be consumed at operation 40 cannot be combined into a single WIP lot To allow lot combining set this field to Yes This value defaults from the first frame WIP Lot Overissue Enter Yes if a quantity can be issued for a WIP lot even when that issue results in a negative WIP lot quantity on hand QOH at this operation This value defaults from the first frame This value only affects WIP material produced by this operation This value affects the output queue of this operation and the input queue of the following operation When the output queue of the current operation is driven negative by a backflush at the following operation the system must also allow for the input queue of the following operation to be driven negative Example A routing has 10 operations In this manufacturing environment the output of operation 5 must be allowed to have negative WIP lot balances A backflush at the next operation consumes from its input queue as well as
152. and balances for WIP material sent to multiple subcontractors Print WIP lot numbers in subcontract shippers Move WIP lots to subcontract operations during shipper confirm Print WIP lot numbers on subcontract POs Backflush subcontracted WIP lots as part of the PO receipts process Changes to Other Modules When activated the WLT module adds a number of similar data collection frames and fields to the programs in the following modules Inventory Control Purchasing Work Orders Shop Floor Control Repetitive WIP Lot Trace 255 Advanced Repetitive WLT also modifies some reports and inquiries to include WLT gt See Working information Most frames function identically whenever they are used M EP page 274 Inventory Control Table 10 1 shows the Inventory Control programs affected by enabling by the WIP Lot Trace module Table 10 1 Menu Description Program Inventory Control Programs Affected 3 4 3 Transfer With Lot Serial Change iclotr03 p by WLT 3 4 4 Batchload Transfer With Lot Serial Change iclotr04 p 3 21 1 Transaction Detail Inquiry ictriq p Purchasing Table 10 2 shows the Purchasing programs affected by enabling the WIP Lot Trace module Table 10 2 Menu Description Program Purchasing Programs Affected 5 7 Purchase Order Maintenance popomt p by WLT 5 10 Purchase Order Print poporp03 p 5 13 1 Purchase Order Receipts poporc p 5 13 7 Purchase Order Returns porvis p 5 13 13 PO Conta
153. and received from subcontractors by updating subcontract shippers with receipt return and scrapped quantities Save processing steps by combining receipt and inventory placement of the finished item from the subcontractor Define multiple subcontractors for a single routing and operation Optionally use subcontractors other than those defined for the subcontract operation Scrap subcontract materials during receipt or using a separate program also using the receipt function View subcontractor activity and history through inquiries and status reports Receive lot serial controlled items into inventory Advanced Repetitive 201 Overview Subcontract operations vary depending on whether your company subcontracts WIP lot or serial controlled items how many subcontractors you use to perform the same operation on the same item site routing combination and where in the routing you use subcontract services If your company uses WIP Lot Trace WLT to control items setup and transactions for subcontract operations may involve additional WLT related steps If you typically use more than one subcontractor in your WIP operations you can optionally activate features that improve visibility and efficiency in managing multiple subcontract operations If your subcontract services are the last operation in a WIP item s routing you can save processing steps by combining receipt and inventory placement of the finished item from
154. anning work orders and cost roll up An item can be a by product and have a normal BOM Formula code Note For items that are always by products BOM Formula codes are optional Entering the base process item number as the BOM Formula code for by products and co products enables you to sort MRP Summary and Detail Reports by BOM Formula code QAD 62 User Guide QAD Manufacturing b See page 86 FAQAD Routing Code This should be left blank in most cases If a co product has a preferred routing different from the base process routing enter that preferred routing This routing must be set up as an alternate routing for the base process Phantom Enter No A co product can be a component in a regular product structure but the structure type cannot be X phantom Setting Up a Co By product Structure A co product by product structure defines the items that result from a base process and specifies whether they are co products or by products These product structures can be set up in several ways The easiest way is through Process Formula Maintenance 15 18 which combines the features of the following programs Master Comment Maintenance 14 12 e Routing Maintenance 14 13 1 Formula Code Maintenance 15 1 Formula Maintenance 15 5 Co By Product Maintenance 15 12 1 1 Setup BOM formula codes using Process Formula Maintenance 15 18 or Formula Code Maintenance 15 1 Note You can have the system create BOM f
155. anufacturing Environments FAQAD 102 User Guide QAD Manufacturing b See User Guide QAD Security and Controls for details FAQAD Work Order by Site Control When two or more manufacturing sites exist within one physical database they are often managed by different production controllers or planners Many work order programs let users select a range of orders to process When a database has multiple sites it is important that planners update only the orders for which they are responsible In most cases this means restricting order update to a single site Most work order update programs and reports include either a site selection or a site range selection Site security defined in the System Security menu 36 3 is checked for all programs that update the database If the site selection is blank the user must have access to all sites Users with access to only specific sites must run the programs by limiting the site selection appropriately Restricted Transactions In some cases the work order release mechanism needs to be controlled for an item because engineering changes must be completed before the order can be released into the manufacturing process You can prevent such an item from inadvertently reaching the shop floor on a work order by setting up a status code in Item Status Code Maintenance 1 1 5 that is restricted for the ADD WO transaction Then enter that code in the Status field in Item Master Maintenan
156. ard If the system cannot find enough open balances the operation is posted with the transaction quantity However the repetitive schedule and work order record are posted with the open quantity available You can modify repetitive schedule completions using Cumulative Completed Maintenance 18 22 2 6 You can view the repetitive schedule completions using either Schedule Inquiry 18 22 2 2 or Operation Schedule Report 18 22 2 5 You can view work order completions using Work Order Browse 16 2 QAD 192 User Guide QAD Manufacturing Fig 8 14 Backflush 7x Transaction Backflush Transaction Go To Actions 18 22 13 Employee MFS01 Effective 06 18 2007 Shift Site 10000 Item Number WLT18 P1 WIP Lot Std Rep Operation 10 Line 1000 Repetitive Production Li Routing WLT18 P1 BOM Code WLT18 P1 ID 129 Work Center 10000 Machine General 1 Department 10 FS General Qty Processed 0 0 UM EA 2 Conversion 1 0000 Qty Scrapped 0 0 Reason Code D Multi Entry Qty Rejected 0 0 Reason Code FS Multi Entry Reject To Op 10 Modify Backflush Move Next op Actual Run Time 0 0 Start Time Earning Code Elapsed or Stop Time The following are fields in the second frame of Backflush Transaction 18 22 13 Work Center Machine and Department default from the routing operation and can be overridden Qty Processed Shows the quantity processed through the operation This value includes any quantity entered
157. arent s operation records to determine component quantities Operation 10 has an effective yield of 90 percent It is anticipated that 10 percent of the parent items are scrapped at this operation FAQAD 44 User Guide QAD Manufacturing FAQAD As a result only 135 151 90 parent items are input to operation 20 and only 135 COMP 2 items are needed 135 1 Operation 20 also has a 90 percent yield As a result only 90 percent of the 135 parent items 122 units survive to operation 30 This means only 122 COMP 3 items are required and so on As this example indicates operation based yield calculation can have a dramatic effect on the requirement for the components associated with the final operations in a manufacturing process Important Operation based yield modifies only the quantity planned for production It does not modify the quantity of components consumed by work orders 46 User Guide QAD Manufacturing b See Chapter 3 Routings and Work Centers on page 25 Fig 4 1 Formula Process Module b See Chapter 5 Co products and By products on page 53 FAQAD Introduction A formula or recipe is another way to define a product structure A process definition is identical to a routing In fact there is no difference to the system between defining a set of operations in Routing Maintenance 14 13 1 or Process Definition Maintenance 15 13 Before you set up a process definition you must s
158. as follows Net Forecast Forecast Sales Order Demand Note When the shipment forecast is oversold that is the quantity sold exceeds the forecast amount the net forecast will not go below zero Forecasting Master Schedule Planning 341 Forward and Backward Forecast Consumption Typically shipment forecasts are more accurate over a month than over a week You can lessen the effects of inaccurate forecasts using forward and backward consumption Confirmed sales order and required ship schedule quantities automatically consume forecast in the week they are due However if there is no remaining unconsumed forecast for that week the system can be set to consume remaining forecast quantities for a number of weeks before or after that week You can specify the number of forward and backward weeks over which to consume using the Consume Forward and Consume Back fields in Sales Order Control 7 1 24 The system consumes forecast first by going back then forward one period from the original forecast period Consumption continues alternately backward and forward until the specified number of previous and future periods is exhausted If there are sales quantities still left over MRP recognizes them as additional demand MRP and master schedule planning recognize prior period unconsumed forecast as demand for the number of weeks specified in Consume Back If the Consume Back and Consume Forward values change the system automatically
159. ase process as the BOM Formula Reviewing Printing and Releasing Joint Orders To review joint work orders use Joint Work Order Inquiry 16 3 13 Orders can be specified by item number work order number work order ID BOM Formula code due date site or any combination of these To print a joint order set use Work Order Release Print 16 6 or Multiple Work Order Release Print 16 7 Both programs release the joint order set provided one order in the set is selected for processing In addition to standard work order picklists and routings you can also print documents listing the co products and by products expected for a base process You can print the list of co products and by products before the picklist or after the routing operations When a joint order s status changes to Released and the associated base process has a component that is routable the Pur Mfg Code for the component item is R a routable work order is automatically created When created the routable work order s status 1s Batch Co products and By products 85 Routable work orders created from a joint order set use the joint set work order number but are given a unique suffix For example a joint order set with work order number 1234 can create routable work orders 1234 1 and 1234 2 When a routable work order is created from a regular work order the routable work order uses the work order number of the parent but has a unique work order ID To se
160. aster scheduled and MRP items Planning on page 355 Note When this approach is used material plans may change dramatically each time MRP is run For example a master schedule order may be expedited one day and canceled the next FAQAD 344 User Guide QAD Manufacturing b See Chapter 13 Material Requirements Planning on page 355 b See Chapter 13 Material Requirements Planning on page 355 AQAD To use the fully automatic approach to master scheduling items set the following values for each master scheduled item in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 Master Schedule Yes Plan Orders Yes Order Policy Any option other than blank Fully Manual Scheduling The master schedule can be created and maintained entirely by a master scheduler who enters firm planned orders using Master Schedule Order Maintenance 22 13 or Work Order Maintenance 16 1 MRP can be set up to generate action messages to assist the master scheduler in creating orders for master scheduled items To have MRP review master scheduled items and produce action messages but not plan orders for those items set the following values for each master scheduled item in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 Master Schedule Yes Plan Orders No Order Policy Any option other than blank Note If an item s Order Policy is blank MRP does not generate action message
161. ata selle III 360 FAQAD Contents xiii Inventory Status Codes 0 0 eee cee eee 366 Product Structures and Formulas e eee 366 Bxecuting MRP osassa beret utet edo aioe dG da ea eros e 367 MRP Processing oa uta tens assed wlan esce E a eed 367 MRP Scheduling 0 0 cece eee eee 369 MRP Pegged Requirements 00 0 cee e eee eee eee 370 MRP Planning Modes 00 cece eee eee eee 371 Reviewing MRP Output 0 0 cece ee 373 Action Messages ssns cesi eee Reb Ohad ERR CR es 373 Planned Orders 0 cece eee ees 375 Approving Planned Orders 0 0 0 cece ee eee eens 376 Approving Planned Purchase Orders 200 00 ee eee 376 Approving Planned Work Orders 00 0002 less 376 Approving Planned Line Orders 0 0 0 ee eee eee 376 Chapter 14 Capacity Requirements Planning 379 Introduction eisi ote celer d Aeg nts ae Roe Rea Ce oae ut 380 Defining Capacities sips csrroos eitie ni anea nen nes 380 Executing CRP hcslerlddesocaerdaes euer re eee Arr ae cad 380 Back Scheduling 415 5 v eR EE RR Wedd ad 381 Generating Load Reports 0 0 cece een ee 383 Reviewing Input and Output 0 0 eee eee 383 Adjusting Capacity and Load 0 0 eee ee eee 384 Adjusting Capacity 0 0 eee ee eee eee 384 Adjusting Load ies eue pia gerne tbe aes eod in ee 385 Jie es ee eo 387 FAQAD Xiv User Guide Q
162. ate forecasts Different programs employ different statistical methods FAQAD 328 User Guide QAD Manufacturing FAQAD You can create specialized forecast methods for the system to use in producing forecast quantities User Forecast Method Maintenance 22 7 17 lets you add your forecast methods in the form of Progress programs you supply to the existing forecast methods The criteria template includes two variables that can be set to interact with your own forecast method User factor and User factor2 These are reserved for your forecast methods and do not operate with any of the predefined methods For user defined forecast methods The name of the program must be ffcalcxx p where XX isa forecast method number between 51 and 99 The Progress program must be written and accessible to the system before you can define the method number in User Forecast Method Maintenance e Your Progress program must use an array named calc 1 60 for the historical data input and an array named cast 1 12 for the calculated output Your Progress program must include the following files at the beginning of the program fcalvar iand ffvar i Compare your forecast method program to the existing programs ffcalc 02 06 p as needed Calculating Forecasts Run forecast calculations using Simulated Forecast Calculation 22 7 5 Forecasting Master Schedule Planning 329 Simulated Forecast Calculation vx Simulated Forecast Cal
163. aterial out of inspection and issues supplies required by inspection Fig 11 8 Quality Order Results Entry vx Quality Order Quality Order Results Entry Go To Actions Results Entry 19 11 Quality Order Inr10 Batch 2 Effective 03 07 2007 Item Number 10074 Master Status Procedure test Consignment III template Test Steps Item Number Op Qty Pending Qty Accepted Qty Rejected 10074 Master 10 0 0 0 0 0 0 Operation Qty Pending Qty Accepted Op Time Work Center Qty Rejected Act Op Machine Status You can record results for an order for each operation on an order or for each specification for an operation For an order you can record total quantity accepted and rejected For an operation you can record quantity accepted and rejected actual time required for testing and comments For each specification you can enter results and comments You can also change the quantity pending for an operation You might do this if the quantity rejected at a previous operation results in units being scrapped and thereby made unavailable for inspection at the current operation FAQAD 314 User Guide QAD Manufacturing FAQAD Deleting Quality Orders If no results are entered for an order you can change the quantity pending to zero and delete the order in Quality Order Maintenance If dispositions or results have been entered you can close the order and delete it with Quality Order Delete Archive 19 23 Conducting Proc
164. but WIP lot tracing begins at the first operation where lot controlled ingredients are consumed For a manufacturer of specialized components for medical equipment serial tracing begins at the first operation that consumes a serial controlled component End Date Enter the last date that this routing registration record is effective Leave blank to indicate that this registration should be effective indefinitely Once routing defaults are set you can further define whether to allow lot splitting combining and overissuing per operation in the defined routing This is done in the second frame of this program Operation Fe Split WIP Lots I Combine WIP Lots WIP Lot Overissue Operation Enter the operation for which you are creating a routing operation registration record Split WIP Lots Enter Yes if WIP lots produced by this operation can be divided into multiple lots by the next operation This value only affects WIP material produced by this operation Example Because Split WIP Lots is No for operation 30 WIP lots produced by operation 30 cannot be split at operation 40 One WIP lot of blank bolt studs produced by operation 30 goes into a threading machine at operation 40 The lot to be consumed at operation 40 cannot be split into separate WIP lots such as one WIP lot of metric thread bolts and one WIP lot of standard thread bolts To allow lot splitting set this field to Yes This value defaults from the first fr
165. can use one NRM sequence ID to generate all lot serial numbers for WIP Lot Trace Optionally you can designate specific NRM IDs for individual routing codes Note WLT requires that NRM generated numbers be no longer that 18 characters Generated lot serial numbers are not checked against existing manually entered or NRM generated lot serial numbers Maintaining Accurate System Configuration Information In environments where strict tracing records are kept such as manufacturing of pharmaceuticals you should maintain detailed and dated records of control program settings routing registration records and BOM registration records These records are important for product recall and for quality assurance You should also set up procedures like the following to help you record and regulate any changes to these WLT control settings Consider defining designated roles with permissions to WLT control programs b See User Guide QAD System Administration FAQAD 264 User Guide QAD Manufacturing Maintain an external system where you can record any control changes This might be a simple spreadsheet or an automated data mining utility that records any control changes automatically Avoid making manual changes to routing or BOM registrations Instead you should use the registration start and end dates to manage changes Example When lot serial number formats change create a WLT routing registration with the new NRM ID Se
166. ce 1 4 1 or Item Data Maintenance 1 4 3 In Work Order Maintenance 16 1 you cannot enter an order or change the work order status of an MRP planned order for an item with a restricted item status code Additionally the following programs display an error message if you attempt to release or update the status on a work order for such an item Work Order Release Print 16 6 Multiple WO Release Print 16 7 Multiple WO Status Change 16 8 Work Orders 103 Effects of Optional Modules Some features of work orders are affected if you are using the Regulatory P See User Guide Attributes module When this module is active you can assign batch Dd dci ils numbers restrict items issued to an order restrict items received and on the Regulatory enforce stricter lot serial control rules These features are described in Attributes detail in the discussion of the Regulatory Attributes module The US description of work orders in this chapter assumes that Regulatory Attributes features are not active The WIP Lot Trace module WLT affects some work order functions P See Chapter 10 When WIP Lot Trace is active you can WIP Lot Trace on page 251 e Monitor and trace work in process WIP inventory Track WIP material lot serials processed by multiple subcontractors e Maintain detailed historical records including which components produced a finished item and which finished items went to a customer WIP Lot Trace i
167. ce 1 4 17 Reviewing Product Costs To verify that costs are correct for base process items and their lower level components review costs using one of the following Product Structure Cost Report 13 12 4 This report identifies an item as a co product or a base process Co By Products Cost Report 13 12 7 This report shows you how co product costs were calculated from a base process and its by products MRP for Co products By products Because planned orders for co products and by products can be from more than one base process overplanning of some items can result This is because MRP plans each base process individually based on unsatisfied demand for its co products rather than evaluating multiple base processes and delivering an optimum plan Careful planning and setup of these operations by the manufacturer is therefore essential Planning for By products MRP plans orders for a by product as a result of creating planned orders for a base process By product demand is not considered when planning a base process but unsatisfied demand for a by product can result in a normal planned order if the item is purchased distributed or has a BOM Formula code for a regular formula or product structure Planning for Co products MRP creates base process demand records from the unsatisfied demand for a co product An item is a co product if two conditions are met Itis manufactured its Pur Mfg code is Manufactured Rout
168. ce 13 5 and Formula Maintenance 15 5 Component Quantity To calculate component requirements for planned orders MRP multiplies each component s quantity per assembly value by the planned order release quantity Component Lead Time MRP determines a component s due or required date using the scheduled release date of the parent item and the component lead time offset specified in the product structure Example When a component s lead time offset is 10 days its due date will be 10 manufacturing days after the planned release date of the assembly When it is 5 days the due date is 5 manufacturing days before the planned release date of the assembly If no lead time offset is specified for a component the component release date will be the same as the release date for the parent item Material Requirements Planning 367 Component Effective Dates MRP uses component effective dates to determine which components are gt See Engineering required for a given order due date Components are active beginning on Effeotivity on spb Us page 23 for more the start date specified in the product structure and remain active through information on the stop date the last day a component will be used E component effective dates Executing MRP MRP Processing MRP reports and inquiries can optionally display item requirements summarized by week The beginning day of the week is specified in the Summary Default field of M
169. cess types and receipt scenarios To determine the mix variance amount for a co product or by product work order the system first calculates the expected receipt quantity for the order by multiplying the following two factors The ratio between the co product or by product quantity ordered and the base process quantity ordered expressed as a decimal value The base process quantity complete which is variable and calculated based on the quantity complete method specified in the co by product structure The base process quantity complete can be based on any one of the following depending on the setting of Quantity Complete Method in Process Formula Maintenance 15 18 or Co By Product Maintenance 15 12 1 The total quantity complete for all co products and by products in the joint order set SUM The total quantity complete for co products only SUMC The base process quantity required to complete the co product that consumed the greatest amount of the base process in proportion to the quantity ordered MAX The base process quantity required to complete the co product that consumed the least amount of the base process in proportion to the quantity ordered MIN The quantity ordered on the base process order ORD Note When method SUM or SUMC is used the system converts co product or by product quantities to the base process unit of measure before adding them together The following equation is used to calculate t
170. ch Size A system maintained field recording the normal batch size for an item If a formula code has been defined for the item in Formula Code Maintenance 15 1 or Process Formula Maintenance 15 18 the batch size displays from that record Otherwise the system displays the value from Item Master Maintenance 1 4 1 Quantity Type Specify how the component or co product by product quantity is used for this formula or base process Blank parent unit of measure Defines quantity in terms of a single unit of the parent in the parent s unit of measure For example if the unit of measure of ink is liters and the quantity per of ink concentrate is 10g 10 grams of concentrate are needed for each liter of ink B standard batch size Defines quantity in terms of the parent s batch quantity For example if the batch size of ink is 50 liters and the quantity per of ink concentrate is 10g 10 grams of concentrate are needed for each batch P percentage of batch Defines quantity as a percentage of batch specified in Batch Percent field For example if batch size of ink is 50 liters and water makes up 90 of the batch 45 liters of water are needed for each batch Note If the batch and component quantities are not in the same unit of measure set up a UM conversion Batch Percent Enter the quantity of the component ingredient required to manufacture a batch of the parent item expressed as a percentage of the batch Use this field onl
171. ch the original quantity shipped RQAD 210 User Guide QAD Manufacturing b See Viewing Subcontracted WIP Materials on page 224 b See Chapter 10 WIP Lot Trace on page 251 FAQAD Scrap unreturned material Enter comments about the receipt Scrap Unreturned Material Indicate 1f you want to be able to scrap the quantity short from the subcontractor when you receive or return subcontract items You cannot set this field to Yes unless Manual Shipper Update is Yes No the default You cannot specify a scrap quantity when you receive or return items The system does not register a scrap transaction for the quantity short If No and you have subcontract items to scrap you should manually enter the scrap quantity through Advanced Repetitive Scrap Transaction 18 22 18 or Subcontract Scrap Transaction 18 22 5 13 Yes You can enter the quantity scrapped when you receive or return items using Purchase Order Receipts 5 13 1 and Purchase Order Returns 5 13 7 The system updates the subcontract shipper you select and registers a scrap transaction for the quantity you specify in the Subcontract Shippers frame To scrap unreturned subcontracted items the quantity received must be less than the quantity indicated on the subcontract shipper minus the quantity already received Processing Subcontract Shipments If you are processing WLT controlled items for subcontract shipping additional processing occur
172. chedule controls the same activities as a work order However because it is used for continuous process manufacturing it issues components from inventory by backflushing This method deducts the required quantities from inventory when order quantities are reported as complete If you used Line Schedule Workbench 18 22 1 10 or Planned Repetitive P See Simulating Sched Approve 23 8 to create a line schedule use Repetitive Schedule e erama me Update 18 22 1 18 to turn the line schedule into a repetitive schedule page 169 Otherwise create repetitive schedules using Schedule Maintenance 18 22 2 1 Updating a Repetitive Schedule from a Line Schedule Once you are satisfied with a line schedule in the workbench use Repetitive Schedule Update 18 22 1 18 to generate the repetitive schedule or update an existing one Fig 8 8 us Repetitive Schedule Repetitive Schedule Update Go To Actions Update 18 22 1 18 Site 10000 To 10000 Production Line 1000 To 1000 Item Number 1004 To Due Date 02 23 2007 To Update Delete Line Schedule Output 2 Batch ID P You can delete the line schedule as you update or retain it Typically you retain the line schedule since you can continuously maintain it by adding new MRP orders However you can use this function to delete an unneeded simulation by setting Update Repetitive to No and Delete Line Schedule to Yes FAQAD 174 User Guide QAD Manufacturin
173. ck to regular inventory D Destructive The quantity to inspect is transferred to the inspection location but both accepted and rejected quantities are issued and expensed to cost of production Site This site defaults from the inspection site defined in Quality Management Control Auto Issue Enter Yes to have supplies required for an inspection automatically issued The quantity issued is the Quantity Per for the supply item specified in the associated procedure multiplied by the change in the quantity pending inspection Enter No to have supplies issued during Quality Order Results Entry 19 11 Quantity Pending This is the quantity to be transferred to inspection If the quantity pending is changed on a quality order the difference is calculated and transferred either to inspection or to inventory Quality Management 313 Quantity Accepted Quantity Rejected These quantities default from Quality Order Results Entry Effective Date Enter the date the system should use for GL transactions The system verifies that the date is in an open GL period Status The status of a quality order Values are either blank Open or Closed An order remains open until quantity pending is zero Procedure A quality order can reference a procedure the same way a work order can reference a routing Entering Quality Order Results Enter results of a test or inspection in Quality Order Results Entry 19 11 This program also moves m
174. completed at each previous operation is also incremented up to the amount required to make the scheduled amount of the finished item If the quantity open at the last operation is still nonzero indicating the y See Chapter 13 quantity completed is less than the quantity scheduled the quantity B m open is treated as supply by MRP and shown as the current amount of Planning on the planned order in MRP Detail Inquiry 23 16 page 355 FAQAD 234 User Guide QAD Manufacturing b See Defining Control Program Settings on page 229 FAQAD The Consume Forward Consume Back and Start of Week settings in Repetitive Control 18 24 determine how the system handles item completions that exceed the quantity scheduled on a given day For example you may complete some items ahead of schedule or scrap fewer items than expected When this occurs the system follows these steps to record the excess completions against other exploded schedules 1 The system searches for a scheduled order routing with a start and due date range that includes the effective date of the repetitive labor transaction If the system finds scheduled order routings that meet this criterion it applies the excess completions to their corresponding schedules starting with the schedule that has a due date closest to the reporting transaction effective date If excess quantities still remain after the previous step has executed the system subtracts the numbe
175. component can be picked Related Topics This section discusses a number of topics related to product structures and how they are used in the system Floor Stock Continuing the example of the sunglasses most items such as frame pieces and lenses are issued from an inventory location based on a formal document such as a work order picklist However some inexpensive easily replenished components such as the screws may be held on the factory floor and used as needed Such items are called floor stock Product Structures 21 Use Issues Unplanned 3 7 to record floor stock issued from stores to a work in process expense account To prevent these items from being picked they should have an issue policy of No in the item master and item site planning data Do not confuse floor stock with expensed items Expensed items do not appear in the item master or product structure and are expensed immediately when they are received from the supplier Enter expensed items on a purchase order as non inventory memo purchases with type code M Relationship with Configured Products Product structure records are also used to store information on product P See User Guide configurations A configured product is defined in Item Master ee deu ond Maintenance with a purchase manufacture code of C configured The configured system uses the Reference field to store the option s feature group and products the Structure Code field defaults to Optio
176. components to the first operation of a routing After components are issued and the operation is complete use Labor Feedback by Work Order 16 20 1 to report labor for the operation Use the Destination Work Center and Machine and WIP Lot Output Queue Receipt Data frames to collect WIP lot serial tracing information Issue components and report labor for the remaining operations After all operations are complete receive the finished goods into inventory using Work Order Receipts 16 11 Use the Current Work Center and Machine frame to indicate where the WIP lots or serials being received currently reside You can use Work Order Operation Backflush 16 19 as an alternative to following separate steps It incorporates the functions of the three programs previously described The WLT frames that display in the three separate programs also appear in Work Order Operation Backflush Issuing Component and WIP Material Use Work Order Component Issue 16 10 to issue component and WIP material to WLT controlled work orders This program performs the following WLT functions Prompt for WIP lot serials to issue Prompt for WIP lot serials to be produced from the issued lot serials Consume WIP lot serials from WIP lot inventory balances Update and record WIP lot serial QOH balances for all affected operation queues This program issues the WIP and component material you specify to the WIP lots you also specify It updates WIP QOH ba
177. contract services Use WIP items to represent services being purchased from subcontractors For example you can use HEAT TREAT SERVICE as a WIP item for a subcontractor Set up WIP items in Item Master Maintenance 1 4 1 before entering them on supplier schedules Enter the routing code in the Routing Code field in the Item Planning Data frame The routing code you enter here defaults to Advanced Repetitive operations Use Standard Operation Maintenance 14 9 to set up subcontractors as suppliers in your standard operations Enter a code for the subcontractor in the Supplier field Advanced Repetitive 203 Setting Up Subcontract Routings There are a few subcontract related fields that you can set when defining the routing for an item in Routing Maintenance 14 13 1 x Routing Maintenance Go To Actions Routing Code A100 Fe Operation 10 Start Date v End Date Standard Operation Work Center INVY Machine Description m Milestone Operation 7 Subcontract LT 0 Setup Crew 0 00 Machines per Operation Overlap Units 0 Queue Time 0 0 Wait Time 0 0 Run Crew 1 00 Setup Time 0 0 Tool Code Run Time 1 0 Supplier Inventory Value 0 00 Subcontract Cost 0 00 Comments Move Time 0 0 Start Date End Date Yield Percent 100 0096 WIP Item D Move Next Operation v Auto Labor Report Set these fields for Subcontract operations Work Center Set u
178. crap amount If scrap is always posted regardless of yield then Include Yield in See Include Repetitive Control should be No This sets the cumulative order yields to bed 59 100 Usage variances are posted only if GL standard costing is in effect for the finished item Usage variances are not posted if GL average costing is in effect FAQAD 198 User Guide QAD Manufacturing FAQAD Labor and Burden Usage Variances Labor and burden usage variances are calculated as the difference between actual and expected labor hours extended by the cumulative order operation labor or burden rate The expected labor hours equal the cumulative order operation standard labor hours per unit multiplied by the quantity processed at the operation Usage Variance Transaction Records The system records each usage variance posting by creating an operation history record with one of the following types MUV CMP material usage variance component MUV WIP material usage variance work in process FLOORSTK floor stock expense RLUV run labor usage variance RBUV run labor burden usage variance SLUV setup labor usage variance SBUV setup labor burden usage variance SUV subcontract usage variance You can run this program in a non update mode In this case the report is generated but no database updates occur Advanced Repetitive Generating Repetitive Reports Table 8 3 lists reports on the Reports Menu with a brief
179. ction in that it examines a sample by comparing it to most if not all of the engineering specifications appropriate for a specific level of processing First article inspection and process validation can use either quality orders or in process inspection The selection depends on whether or not the units evaluated are obtained from a supplier or from an internal manufacturing process Process Validation Process validation an extension of first article inspection is used to qualify a manufacturing process Rather than use a single sample or unique lot process validation requires one or more large batches each of them a typical manufacturing lot Samples from the beginning middle and end of production can be examined to determine the stability of a manufacturing process and its ability to consistently produce quality material Quality orders can handle process validations since they record inventory transactions and allow unplanned issue of testing supplies Destructive Testing On a regular quality order the quantity subjected to destructive testing should be reported in Quality Order Results Entry 19 11 as rejected regardless of whether it passed or failed This causes the quantity to be issued from inspection and expensed to scrap FAQAD 318 User Guide QAD Manufacturing FAQAD The lot quantity subjected to destructive testing can have its own quality order with a type code of D When results are entered quantiti
180. cts Y and Z Since there is greater demand for Y than for Z base process X is planned to produce the desired quantity of Y The quantity of Z produced will therefore exceed demand A co product can be a component of another process or product structure For instance for Company Q nonvintage wine may be a co product of the wine manufacturing process and a component of the wine cooler manufacturing process as shown in Figure 5 3 Components CCS Co products Bang Fig 5 3 A Co product Used as a Component in Another Structure Vintage wine Wine in r 1 year old barrels Base Process Nonvintage d Blend me Wine in wine from a 2 year old barrels barrels Wine coolers separate base process Wine in 3 year old barrels By definition demand for by products is not expected If demand for a by product is generated MRP treats it as demand for a normal item MRP does not plan work orders to satisfy by product demand FAQAD 58 User Guide QAD Manufacturing Fig 5 4 General Workflow for Co products By products Fig 5 5 Setting up for Co products By products FAQAD Co product By product Workflow Figure 5 4 shows steps for setting up and managing a typical operation involving a base process with co products and by products Set up co product by product operation pe Make shop floor control entries Enter co product deman
181. cturing where lead times are one day or less where WIP is complete at the end of each day where WIP costs are tracked and batches do not overlap or where WIP costs are insignificant or fairly constant Work in Process Lot Trace The WIP Lot Trace WLT module lets you monitor and trace work in process WIP inventory at each operation in the manufacturing process easily and accurately It facilitates tracking of WIP material lot serials processed by multiple subcontractors and supports serial tracking of WIP material as needed This module maintains detailed historical records including which components produced a finished item and which finished items went to a customer Introduction to Manufacturing 9 Quality Management The Quality Management module defines standard testing procedures applies tests to work orders and repetitive schedules records quality test results and manages inventory sampling and quality work orders Forecasting Master Schedule Planning The Forecast Master Schedule Planning module lets you create and maintain shipment forecasts and master production schedules Using this module you can analyze sales shipment history calculate forecasts and update demand for material requirements planning MRP creating a closed loop system Material Requirements Planning MRP MRP is a key manufacturing planning function It assesses supply and demand and generates planned order and action messages For organizatio
182. culate them from the start and stop times For example for a start time of 08 00 00 and a stop time of 14 45 00 the system calculates an elapsed time of 6 75 decimal hours QAD 144 User Guide QAD Manufacturing b For more information see Closing Operations on page 146 AQAD Operation Status Operation status codes indicate the detailed status of individual operations The system automatically assigns status codes to operations as transactions are processed Queue An operation s status is automatically set to Queue when material is moved to that operation either by releasing a work order entering labor feedback for that operation or using Operation Move Transaction 16 20 6 to manually move material When Move Next Operation is Yes in a labor feedback transaction the next operation is automatically set to status Queue and quantities reported complete are moved to that operation Setup An operation s status changes to Setup when you report setup time for that operation Running An operation s status changes to Running when you report run time for that operation This is not affected by the number of units reported as completed rejected or reworked Complete An operation s status changes to Complete when you Report it as completed using one of the labor feedback transactions or Work Order Operation Backflush 16 19 Close it using Operation Complete Transaction 16 20 5 e Run Work Ord
183. culation Go To Actions Forecast ID 2007 Forecast Year 2007 Years of History 5 Ending 2006 Forecast Method 01 Alpha factor 40 Trend 10 User factor 1 00 2 00 Item Number ERE 2 To P Product Line 2 To Fe Group D To 2 Item Type 2 To FS Order Line Site Fe To D Use Ship To Sold To Sold Tov List Type Customer P To 2 Region P To P Output Batch ID Simulated Forecast Calculation analyzes an item s shipment history data and produces a forecast detail record that predicts what quantity of the item will be sold in the future This calculation requires a criteria template You can either specify a criteria template defined in Simulation Criteria Maintenance 22 7 1 in the Forecast ID field or define a new criteria template at this time When insufficient shipment history exists to generate a valid forecast for an item the detailed forecast record for that item is created for a quantity of zero Negative results also display as zero quantities Note Atleast one sales record is required to produce a nonzero forecast quantity Running Simulated Forecast Calculation generates sales predictions for each specified item for a one year period If you specify an entire product line product type or product group for which to forecast each individual item is forecasted separately Also included in the report are the number of items calculated and insufficient items that is items that lack enough
184. culation Method field when rounding or truncation errors may occur during backflush as a result of a component having a small or non evenly divisible quantity relative to the bill If you are completing a partial receipt and want to use up global phantoms before issuing components for the phantom enter Phantoms First in the Quantity Calculation Method field Example Ten phantoms are in stock If you complete a partial receipt backflush for 10 items and the phantom and its components have a quantity per of 1 the phantom quantity to issue is 10 Otherwise the phantom and its components are calculated proportionally each with a quantity to issue of 5 Since phantoms are not defined as phantoms in the work order bill the Phantoms First option uses the current product structure to identify phantom items Work Orders 131 When you use Work Order Backflush Receipt to receive or close work P See Closing orders the system records the system date as the receipt or close date and area es your user ID These items appear on two work order reports Managing Scrap Scrap refers to unusable items In the manufacturing process there can be two kinds of scrap Components issued to the work order tems built by the work order that are unusable Component Loss When additional components are required for a work order because items were lost or unusable the replacement components should be issued to the work order This results in an unfavo
185. cumulated material labor burden and subcontract costs and the cost of receipts and rejects to arrive at the cost currently in WIP for each order and each WIP account Activities affecting these costs include component issues labor feedback operation completions purchase order receipts for subcontract orders and work order receipts QAD 134 User Guide QAD Manufacturing Menu Report Description 16 3 6 Work Order History Designed for managers and accountants who need Report to see closed work orders with their bills routings date of closure and user ID of the person who closed them Components are reported with the quantities required and issued Operations are reported with the number of units completed and the expected and actual hours for setup and run time 16 18 Work Order Dispatch In a job shop it is important to know which work Report orders will arrive at a work center and which orders are already there This information helps you determine priorities and anticipate work load This report groups this type of information by work center The Window field lets you control and filter incoming orders based on the start date of the operation and today s date For example when the window is three days the report includes open work order operations that should be started within three days of today Note Most of the reports in the Work Orders and Shop Floor Control modules can als
186. cumulative order performs the same processing as the Post Accumulated Usage Variances transaction Variances are calculated posted and reported When Transfer WIP is Yes WIP queue balances are transferred from the closed cumulative orders to new cumulative orders To close a cumulative order before its end effective date use Cumulative Order Maintenance to set the end effective date to yesterday s date The system creates a new cumulative order for the balance of the period if the End Eff Default Method is set to 1 or 2 in Repetitive Control 18 22 24 b See Managing Subcontracting on page 200 FAQAD 184 User Guide QAD Manufacturing Table 8 1 Transferring WIP AQAD Transferring WIP To transfer WIP values and quantities from closed orders to new cumulative orders set Transfer WIP to Yes in Cumulative Order Close The system searches for a cumulative order with the same profile site item number production line routing and product structure code and a start effective date equal to the day after the end effective date specified in the selection criteria If Then An open cumulative order exists the system receives the WIP quantities of the cumulative order being closed A closed cumulative order exists WIP quantities do not transfer There is no cumulative order the system creates a new one to which WIP is transferred Processing Steps Cumulative Order Close does the following for each operation
187. d Receive products Run MRP Perform work order accounting close Generate joint order set Setting Up a Co By product Operation Figure 5 5 shows steps for setting up a typical operation for co products and by products Each step is discussed in detail in the following sections Set up mix variance accounts n Set up UM conversion factors Set up sites locations and work centers for the base process Set up alternate base processes and their routings Set up product lines Set up definitions for valid substitute items Set up item status codes and items for base process co products and by products Set up costs and lead times Set up product structures for co products by products and recyclable by products Co products and By products 59 Setting Up Mix Variance Accounts If the quantity of a co product or by product received to stock differs For more from the quantity expected a variance occurs To record such variances i i properly called mix variances a Mix Variance account must be see Calculating established Even if you do not plan to use the co product by product Mix Variances for Joint Orders on features a Mix Variance account must be established before any work page 89 orders can be generated 1 Set up Mix Variance accounts and optionally sub accounts and cost cen
188. d Exploding Repetitive Schedules 0004 231 Using Repetitive Picklists 0 0 cee cece eee 231 Managing Cumulative Orders 0 0 2 cece eee eee 231 Executing Repetitive Transactions 0 0 ce eee eee eee eee 231 Operation Reporting 0 2 eee eee 231 Repetitive Completions 0 0 0 cece cece ee eee 232 Reporting Completions 0 0 0 arauren ereraa 233 Repetitive Scrap Transaction 0 0 0 c eee eee eee eee 235 Checking Component Availability 0 0 0 ee eee ee 236 Using Browse Collections 0 0 0 c eee eee eee eee 236 Component Check Calculations 0 0 0 e ee eee ee eee 239 Component Check by Work Order Production Line 243 Component Check by Work Order Work Center 244 Component Check by Item Work Order 0 0 245 Examples 2 repe er Conte one E bee E E ETE 246 Chapter 10 WIP Lot Trace esseeeeeeeseeeenre 251 Overview of WIP Lot Trace sseseleee eee eee 252 WIP Lot Trace and Regulatory Attributes 0 4 253 Features ED ape eat ea aha Rnd ion abd sass aan tees 253 Subcontract Processing Features 0 0 00 c eee eee eee ee 254 Changes to Other Modules 00 000 eee cece ee eee 254 WIP Lot Trace Programs 0 0 0c cee eee eee 258 Planning for WIP Lot Trace 0 eee eee eee 259 Deciding Which Material to Trace
189. d actual statistics on what happens during production This might include how long it takes to produce items what quantities are produced and by whom whether there was downtime or some other interruption to production and so on These statistics are always recorded against a routing operation Routings are required if you use the Repetitive module In addition to providing manufacturing instructions routings contain data used as a standard for evaluating production operation times yield percentages the number of machines normally needed and so on The department and work center codes associated with routing operations link actual production results with capacity planning cost accounting and other programs Specifically routings can be used to Calculate the cost of producing an item Calculate the time it takes to manufacture an item Schedule operations for work orders and repetitive schedules Backflush components in the Repetitive module Calculate work center and department load Print routings for work orders Obtain operation feedback using programs in Shop Floor Control Repetitive and Advanced Repetitive Routings and Work Centers 27 Some of these capabilities are especially important when there is a combination of medium to long operation lead times a significant labor component of cost many operations and bottleneck operations Routing operations may not be necessary when Item lead times are ve
190. d into WIP lot Wi This value defaults to Combine Component Lots in BOM Registration Maintenance Registering Routing Exceptions Use Routing Registration Maintenance 3 22 13 1 to define exceptions to the control program settings by creating new settings for parent item routings and routing operations that need different values than those defined in the control program Example In WIP Lot Trace Control you indicate that the maximum WIP lot size is 150 because in general lot sizes must stay below this quantity in your manufacturing operations However for routing 007 you do not want the WIP lot size to exceed 50 Use Routing Registration Maintenance to specify this maximum lot size for routing 007 WIP Lot Trace 269 Fig 10 3 x Routing Routing Registration Maintenance Go To Actions Registration Maintenance 3 22 13 1 Routing Code 1002 Start Date 02 26 2007 Trace Parents v Max Lot Size 50 0 WIP Lot Number Sequence ID 2 Split WIP Lots M Combine WIP Lots v WIP Lot Overissue v Lot Trace Start Op 0 Serialized WIP Start Op 99999 End Date i Some field values default from the control program Additional fields are described below Use these descriptions and any data you collected as discussed in the planning section to register control program exception records for specific routings and routing operations Routing Code Enter the routing code for which you are creating a
191. d order in Purchase Order Receipts 5 13 1 PO Shipper Maintenance 5 13 14 or PO Shipper Receipts 5 13 20 a Use the WIP Lot Input Queue Issue Data frame to specify the P See page 276 WIP lot serials that were sent to the subcontractor Select Help to display a list of WIP lot serials as they appeared on the subcontract shipper b Use the WIP Lot Output Queue Receipt Data frame to specify the P See page 277 WIP lot serials being received from the subcontractor The lot serial you entered in the input queue frame defaults to the output queue frame Processing a Subcontract Operation for Multiple Subcontractors Follow the procedure outline above with the following additional steps Create a separate subcontract scheduled order for each subcontractor being used at the work order operation Create confirm and print separate subcontract shippers for each subcontractor When you backflush the next operation the subcontract WIP lot serials you received in the Purchase Order Receipts Output Queue Receipt Data frame appear on the WIP Lot Input Queue Issue Data frame browse QAD 298 User Guide QAD Manufacturing b See page 291 b See page 291 FAQAD Use the WIP Lot Inventory Status Report 3 22 13 13 to display the operation and queue where specific WIP and item material is located during manufacturing Using WLT with Repetitive The following sections describe the Repetitive programs affected by WLT chang
192. ded in available to promise MRP inquiries and reports show all planned orders these are not seen as supply FAQAD 376 User Guide QAD Manufacturing P See Creating Work Orders on page 105 FAQAD Approving Planned Orders To approve planned purchase work and line orders use Planned Purchase Order Approval 23 11 Planned Work Order Approval 23 10 or Planned Repetitive Schedule Approve 23 8 Once approved planned orders become either purchase requisitions firm planned work orders or are added to production line schedules After a planned order is approved MRP does not change the quantity or due date on the order the next time it is run Instead it generates action messages suggesting changes to the order You can modify firm planned order due dates and quantities as needed in Work Order Maintenance 16 1 Purchase Requisition Maintenance 5 1 4 and Line Schedule Workbench 18 1 10 or 18 22 1 10 Approving Planned Purchase Orders Approving a planned purchase order deletes the planned order and creates a purchase requisition which can be filled by a purchase order Approving Planned Work Orders Approving a planned work order changes its status to firm planned MRP does not replan firm planned orders but generates action messages as needed A firm planned order has a work order bill and a routing with scheduled operations These are not fixed Bills are re exploded by MRP while routings are re exploded
193. defaults from the work order routing The system uses the work center setup labor and burden rates to calculate costs and create GL transactions Changing the work center code results in method change variances when the work center rates differ Item Quantities For each work order operation you can record the item quantities completed rejected and reworked Note Labor feedback transactions cannot be modified or deleted once they have been processed To reverse the effect of incorrect transactions you can enter transactions for negative values When you enter a transaction the system moves either the quantity ordered or the quantity reported complete at the last operation to the operation being reported Which quantity displays depends on the setting of Move Next Operation for the previous operation The quantity open for an operation is this starting quantity minus the quantities completed and rejected at that operation Quantity Completed The number of acceptable units produced at this operation used to calculate variances work center efficiency and GL transactions If Move Next Operation is Yes the quantity completed for an operation automatically moves to the next operation This occurs regardless of whether the previous operation is complete If Move Next Operation is No the quantity completed for an operation does not affect the quantity open at the next operation Set the default value for this field in Shop Floor
194. demand 356 demand sources 357 forecasting 336 item planning data 360 items not seen by 366 lead times and 364 Line Schedule Workbench 171 multiple base processes 77 output 373 past due forecasts 342 pegged requirements 370 repetitive explosion 175 safety stock 363 scrap factor in 18 shop calendar 375 substitute items 22 supply 356 supply sources 357 yield calculations 41 359 364 368 material shortage examples of check 246 matrix in Supply Demand Summary 242 messages advanced repetitive warnings 189 MRP action 373 FAQAD 396 User Guide QAD Manufacturing method change variance MCV 190 milestones operations 33 167 operations and WIP lot tracing 260 mix variances accounts co products by products 59 84 calculating co products by products 89 97 modifying work order bill 119 work order routings 120 work orders 119 Move Next Op field 204 Move Next Op in Backflush Transaction 212 moving items into inventory 224 MPS See master production scheduling MPS MRP Control 358 MRP Detail Inquiry 370 MRP Detail Report 370 co products by products 61 80 MRP Summary Report co products by products 61 MRP totals 242 MRP See material requirements planning MRP multiple sites work order components 125 Multiple Work Order Release Print 109 120 co products by products 84 Multiple Work Order Status Change co products by products 80 multiplicative factors forecasting 332 N negative quantities on receipt 217
195. der effective dates to match the product structure and routing effective dates Move Next Op When Yes the Receipt Data frame displays when reporting against the last operation The Move Next Op field indicates whether the quantity processed minus rejected and scrapped quantities is moved to the input queue of the next operation If the operation being reported is the last operation the move increases finished goods inventory This value defaults from the routing operation Note You cannot add an operation to the routing for an open cumulative order You must close the cumulative order make the routing changes roll up the cost then open a new cumulative order Run and Setup Labor Transactions Use these programs to easily report run and setup labor only for non milestone or milestone operations Use Run Labor Transaction 18 22 14 to report regular labor chargeable against WIP Use Setup Labor Transaction 18 22 15 to enter separate setup times also charged against WIP Use Down Time Transaction 18 22 20 and Non Productive Labor Feedback 18 22 22 to report indirect labor These transactions are not subject to applied burden Reject Transaction Reject Transaction 18 22 16 has two uses To reject previously backflushed units from an operation s output queue to the same operation s reject queue or to the reject queue of any preceding operation QAD 194 User Guide QAD Manufacturing FAQAD To re
196. ders Shop Floor Control and Purchasing programs use WIP Lot Trace frames to collect record and update tracing records The following sections discuss when these frames are activated and how they are used within each program Routing and routing operations become WLT controlled when Trace Parents is Yes in WIP Lot Trace Control 3 22 13 24 and a routing registration does not exist for the routing being used AII operations for that routing become WLT controlled A WLT routing registration is active for the routing WLT control begins at the start operation specified in the registration record A component item becomes WLT controlled when it is consumed at a WLT controlled operation and either of the following is true Trace Components is Yes in WIP Lot Trace Control or Trace Components is Yes in WLT BOM registrations for any BOMs that use the component Destination Work Center and Machine The Destination Work Center and Machine frame appears in Repetitive Advanced Repetitive and Work Orders programs Use it to specify where to move the WIP material produced at the current operation The information entered in this frame is used to update QOH balances for the affected queues Example In your Advanced Repetitive environment you have three machines in a work center that do the same job for operation 30 To trace WIP material processed by a machine backflush the WIP material at operation 20 and use this frame to specify t
197. determines Work Order 1006 1D 41 how the Item Number 1 BB Red Bean Bag order is Site 10000 processed Quantity Ordered 1 0 Order Date 02 22 2007 Status Quantity Completed 0 0 Release Date 02 22 2007 indicates Qty Rejected 0 0 Due Date 02 22 2007 the position Work Order Status F Site 10000 Pp i Sales Job P Routing Code 1001 P n the order Supplier P BOM Formula Code 1001 P life cycle Yield Percent 100 0096 Remarks Comments Post variances at SFC M Important elements of a work order include The type which identifies the source of the order and indicates how it should be processed The status which determines where a work order is in its life cycle The bill of material BOM which lists the quantities of components required to fulfill an order The routing which lists the operations required to complete the order Note The BOM and routing are also called a process sheet These elements are discussed in the following sections Work Order Type Most work orders are entered with a blank type These represent normal manufacturing orders with a standard product structure and routing The other types indicate special kinds of work orders Table 6 2 lists work order type codes Table 6 2 Work Order Types Type Code Description Type Code Description Blank Standard S Scheduled F Final Assembly C Cumulative R Rework W Flow E Expense AQAD Work Orders 107 All work order types are similar in t
198. determining costs for GL transactions Use Work Center Maintenance 14 5 to set up work centers FAQAD 30 User Guide QAD Manufacturing Fig 3 3 Work Center Maintenance 14 5 Work Genter Maintenance Go To Actions Work Center 400 01 Machine Description REE aE Ean Department 300 P Subcontract Dept Queue Time 3 0 Wait Time 1 0 Mach Op 1 Setup Crew 1 00 Setup Rate 15 00 Run Crew 2 000 Labor Rate 12 00 Machines 1 000 Labor Burden Rate 5 00 Mach Bdn Rate 2 00 Labor Bdn 96 3 0096 Work Center and Machine Uniquely identify a work center by a work center code along with an optional machine code Leave Machine blank if only one type of machine is in the work center If there are multiple machine types or models set up a different record for each machine using the same work center ID Department Enter a department code set up in Department Maintenance 14 1 You must assign each work center to a department Queue and Wait Time Enter the standard time in decimal hours a job normally spends waiting at this work center before it is set up and processed and after processing has been completed These values display as defaults when you reference this work center as part of a standard routing or process operation P See Work Center Machines Op Enter the number of machines at this work center that Capacity on page 31 can work at the same time to process a given operation CRP uses this number to c
199. duct ries By product Window Casing Metal Shavings Window Hole To Seat Bracket Assembly Plant The co products and by products of a base process do not have their own product structures or routings These are defined in the base process Base processes are items containing formulas for co by product operations and are defined in the same way as regular items A base process has An associated item record A product structure listing its co products and by products A formula product structure listing its component requirements optional A routing listing its operations optional The BOM formula code for a co product is the item number of the co product s base process There are some important distinctions between base process items and regular items Base process items are never regarded as items to be stocked Item status codes are used to restrict inventory transactions related to base process items and to ensure that these items never appear on sales or purchase orders Should base process items end up in inventory or on sales or purchase orders they are ignored by MRP Base process items cannot be used as components in another process FAQAD Co products and By products 57 More About Co products and By products Demand for co products drives the planning of base processes and the co product that has the most demand is the one planned for Example Base process X produces two co produ
200. e Items reworked can come from a previous operation s reject queue Use the lookup on the Lot Serial field to select the correct value Before moving the reworked WIP lot serial to the destination locations the system checks the following settings in WIP Lot Trace Control or in the corresponding WLT routing and BOM registrations Split WIP Lots Combine WIP Lots Max Lot Size When you move reworked WIP lot serial quantities to the last operation in a routing you must enter material receipt information for the reworked WIP lot serial Receipt information is entered using the Receipt Data Input data frame Values for Qty UM and Lot Serial default from the values you previously entered in the transaction Multi Entry is not editable Lot Serial and Ref default from the values you entered in the WIP Lot Rework Data frame WIP Lot Trace 283 QOH and Queue Balances The information you enter in the WLT frames is used to adjust QOH balances and cumulative accounts for the input and output queues of the affected operations The reject queue from where material was moved is reduced by the quantity reworked The quantity reworked is added to the cumulative reworked consumed and produced quantities for the WIP lot serial When you receive reworked material into finished material inventory that quantity is reduced from the QOH of the output queue of the last operation WIP Lot Move Data Use the WIP Lot Move Data frame to rec
201. e You should forecast at least as many weeks as are required to cover the cumulative lead time of the item which is the maximum time it takes to produce that item if none of its lower level components are in stock Forecasting an item based on cumulative lead time ensures sufficient time to respond to changes in the requirements for that item Note Shipment forecasts do not represent the quantity of incoming orders but rather the quantity expected to be shipped during a one week period Forecast Worksheet Maintenance 22 2 includes the following display fields Forecast The shipment forecast for a given week Sales The quantity of an item on confirmed sales orders and required ship schedules to be shipped this week Abnormal Confirmed sales for this week that should not consume P See page 340 forecast Production Forecast system calculated forecast quantity used in P See page 346 multilevel master scheduling Net Forecast The total forecast quantity seen as demand by MRP P See Chapter 13 Consuming Forecasts MRP and master production scheduling use shipment forecasts to See Chapter 13 calculate net forecasts This is done by consuming the forecast that is nm subtracting sales order demand from the shipment forecast MRP and Planning on master production scheduling then use the calculated net forecasts to page 355 determine gross item requirements QAD 340 User Guide QAD Manufacturing AQAD S
202. e Planning 327 Table 12 4 01 02 03 04 05 06 Overview of Cyclical Yes Forecast Methods Trend Lags Lags Yes Yes Seasonal Yes Yes Horizontal Yes Years of History 1 1 1 2 2 3 1 Trend Factor Yes Alpha Factor Yes Yes Alpha and Trend Factors Some forecast methods use alpha and trend factors to weight shipment history when calculating forecasts When method 03 or 04 is used to calculate forecasts alpha factors determine the relative importance given to more recent sales history For new products with rapidly changing sales quantities you may want to enter an alpha value closer to one to give more weight to recent sales history However for products with long and stable sales histories you might specify a smaller alpha value to produce smoother forecast results When method 04 is used to calculate forecasts trend factors determine the relative weight given to sharp increases or decreases in sales history when calculating forecasts Table 12 5 shows the effects of alpha and trend factors on forecasting calculations Alpha and trend values must be between zero and one Table 12 5 Factor Zero One Alpha and Trend Factors Alpha Factor Equal weight on all history Weighs recent history Trend Factor Ignores sharp changes in Weighs heavily sharp changes in history history Creating Additional Forecast Methods Forecast methods identify the Progress program the system uses to calcul
203. e Shipper Details frame The fields are display only except for Employee Shift and Scrap Qty 3 Enter the scrap quantity 4 When prompted enter the employee and shift ID Note The fields are identical to those that appear when scrapping in the Subcontract Shippers frame when receiving or returning subcontract items Use Subcontract Item Status Report 18 22 5 16 to view scrapped items gt See Scrapping Subcontract Items on page 220 FAQAD 224 User Guide QAD Manufacturing Table 8 4 Subcontract Reports Inquiries FAQAD Moving Finished Subcontract Items to Inventory If the last operation is a subcontract operation and the items are lot or serial controlled you can move items automatically into inventory during the receipt Note If WIP item components are lot serial controlled you must use the Advanced Repetitive Move Transaction 18 22 19 to record the WIP item placement into inventory Use Purchase Order Receipts 5 13 1 or PO Shipper Receipt 5 5 5 5 and 5 13 14 to place items received from subcontractors into finished goods automatically You must Set Move to Next Operation to Yes in Purchase Order Receipts The system displays the Receipt Data Input frame where you can edit received item information before an inventory record is created The system updates the quantity completed and reduces the quantity open on the repetitive schedule Viewing Subcontracted WIP Materials Table 8 4 lists repor
204. e a place a machine or group of machines a person or group of people Work centers are the most basic units used for operation scheduling capacity requirements planning and cost determinations for GL transactions In Work Center Maintenance 14 5 set up work centers by entering for each a unique work center code and a unique machine code Setting Up Product Lines A product line is a group of similar items or products At many companies sales and operations are planned reported and analyzed by product line rather than by individual item or product To establish a product line use Product Line Maintenance 1 2 1 Setting Up Item Status Codes for the Base Process Base process items are never stocked in inventory As a result although base processes are entered as regular items they are not processed as inventory items Use item status codes to prevent any inventory transactions related to base process items Item status codes are created and maintained in Item Status Code Maintenance 1 1 5 Only two transactions should be allowed for the base item ADD PS which occurs when the item is added to a product structure ADD WO which occurs when the item is added to a work order Setting Up the Base Process Item 1 Create a base process item in Item Master Maintenance 1 4 1 Enter the unit of measure for each batch Assign an item status that restricts inventory transactions 2 Enter the following information in the Item P
205. e field only affects repetitive manufacturing operations Inventory Value Optionally enter accumulated cost through this operation Only this value is used by the Repetitive WIP Cost Report 18 4 12 Subcontract Cost and LT If this is a subcontract operation enter the normal average cost per unit charged by the subcontractor and the normal number of calendar days the subcontractor takes to complete the operation Overlap Units Enter the number of units that must be completed before they are moved to the next operation When there are two consecutive operations you can sometimes save time by moving partial quantities from one operation to the next before the first operation has been completed Operation Capacity As the number of machines increases work center capacity and the number of hours a work center is available for work also increases If there are 8 hours in a work day and an operation has 2 machines per operation the work center has 16 hours of capacity for that operation Operation Capacity Calendar Hours Available Machines per Operation The number of machines per operation is also used for calculating the lead time and machine burden cost for an operation QAD 34 User Guide QAD Manufacturing Fig 3 5 Routing Maintenance 14 13 1 b See page 32 b See Alternate Routings on page 36 AQAD Routings A routing consists of one or more operations steps needed to make an item Each ope
206. e information available in Work Order Maintenance 16 1 without work order bill or routing details Report 16 3 2 Work Order by Item Designed for managers who need the information available in Work Order Maintenance 16 1 without work order bill or routing detail 16 3 3 Work Order Status Report Designed for managers who need information on the current status of work orders including bills and routings receipt and close dates and the user ID of the person who receives or closes them FAQAD Work Orders 133 Menu Report Description 16 3 4 Work Order Cost Report Designed for accountants and managers who need to analyze the costs and variances associated with work orders This report is normally used for closed work orders It identifies work order costs grouping them into five categories material labor burden subcontract and method change Material costs are supported by inventory transaction data for work order components Labor burden and subcontract costs are supported by transactions for operations If this report is run for work orders that have not been processed by Work Order Accounting Close 16 21 the variances calculated may be incomplete 16 3 5 Work Order WIP Cost Report Designed for accountants who need to see how the WIP balance is supported by work order activity It sorts first by WIP account then work order displaying the ac
207. e used to receive a base process item or process an item with a base process as its BOM Formula code Purchasing Purchase Order Maintenance 5 7 A subcontract purchase order line Type is Subcontract cannot reference a work order that is a co product by product or base process work order FAQAD 98 User Guide QAD Manufacturing FAQAD Purchase Order Receipts 5 13 1 A joint work order cannot be referenced when processing a receipt of an item on a subcontract purchase order line Supplier Schedule Update from MRP 5 5 3 1 A supplier schedule cannot be updated with an MRP planned order for a co product or base process from a joint order set Repetitive and Advanced Repetitive The Repetitive and Advanced Repetitive modules do not support joint schedules like the Work Orders module supports joint order sets Line Schedule Workbench 18 1 10 18 22 1 10 The line schedule workbench can be updated using normal MRP planned orders for an item on a production line but not using MRP planned orders for a co product or base process from a joint order set Schedule Maintenance 18 2 1 18 22 2 1 and Schedule Explosion 18 2 4 18 22 2 4 A repetitive schedule can be entered for a co product but the schedule that is exploded from it does not include the other co products and or by products for its base process Similarly a repetitive schedule can be entered for a base process but the schedule that is exploded from it d
208. ead Time Composite Lead Sunglasses with coated lenses 1 Tue Frame assembly 29 1 28 Left or right lenses 3 1 2 Lens blank 10 1 2 7 Tint 31 1 2 28 Coating 38 1 2 35 The cumulative lead time the longest of these lead time paths is the lead time for coating 38 days It could take up to 38 days to produce sunglasses if the critical components left or right lenses and coating are not available Use Cumulative Lead Time Roll Up 13 12 14 to calculate and store the cumulative lead time in the item planning data for either the item master or the item site Engineering Effectivity In some instances you can use an engineering change order or engineering change notice so that existing inventory of an old component is consumed before a new component can be used Note If you are using Product Change Control you can use the Incorporation Planning Report 1 9 7 3 to determine the best time to introduce an engineering change Example A particular coating material is to be replaced by new coating material after the old material runs out Setup the new material up as a component of the existing coating material FAQAD 24 User Guide QAD Manufacturing Change the existing coating material to a phantom item in Item Planning Maintenance 1 4 7 and or Item Site Planning Maintenance 1 4 17 Work order picklists use phantom use up logic to pick available inventory of the existing coating material until
209. easonal Trend Demand Patterns 1100 1100 1000 1000 900 900 123 412 3 441 2 3 4 JFMAMJJASOND Horizontal Cyclical 1100 1100 1000 1000 900 900 JFMAMJJASOND Forecast Methods Forecast methods are identified by two digit method numbers Table 12 2 lists the forecast method numbers available Table 12 2 Method Number Usage Method Numbers 00 Indicates that a forecast detail record was not generated by the system but was created manually using the copy programs or using CIM interface 01 06 Predefined forecast methods 07 50 Reserved for QAD usage 51 99 Use these numbers to identify your own forecasting methods There are six predefined forecast methods described in Table 12 3 You P See page 327 can create additional methods using User Forecast Method Maintenance 22 7 17 FAQAD 326 User Guide QAD Manufacturing Table 12 3 Predefined Forecast Method Type Description Mergas 01 Best Fit Uses all predefined methods 02 through 06 and selects the results with the least mean absolute deviation This is the default forecast method 02 Double Moving The simplest of the forecasting techniques It uses a Average set of simple moving averages based on historical data and then computes another set of moving averages based on the first set The moving averages are based on four months of data This method produces a forecast that lags behind trend effects 03 Double The most popular of the forecast techniques It is Exponential
210. ecific routing code Operation numbers must be unique within a routing Routing operations are always printed in ascending sequence by operation operation 20 follows operation 10 Number by 10s or 100s so you can add new intermediate steps without renumbering existing ones Routings and Work Centers 35 At least one operation is required to process repetitive labor feedback Start and End Date Optionally define effective dates for this operation This lets you phase in engineering changes and maintain history online Functions that reference the routing always use the routing steps in effect on the current date Most reports and inquiries can be selected for a specific effective date Standard Operation Enter the code for the standard operation to use See Standard as the basis of this operation step Many values then default from that al d standard operation You can then modify them as needed to create the specific operation for this routing Machines per Operation Enter the number of machines that can process work at the same time at this operation This value defaults from the work center machines per operation Queue and Wait Time Enter the times in decimal hours a job normally waits at this work center before this operation is set up and processed and after this operation has been completed Setup and Run Crew Enter the number of people normally required to set up and run this operation These fields are for refere
211. ect first articles processes or items in process and perform destructive testing For all but in process inspection you manage quality with quality orders documents that specify what is tested how and when You can define specifications test procedures and inventory sampling and record the results of testing Fig 11 1 Inspection Methods Stand Alone Testing Inventory Supplier Location 200 PO Receipts Inventory Audit Inspection In Process Testing Inventory Location 100 Operation Operation Operation 10 20 30 Testing is generally done in one of two ways Asa stand alone task at purchase receipt or at an inspection station For this method you create a quality order to control quantities and dates The order provides authority to move inventory perform work and route items to various locations after the work is completed e As an operation within a work order or repetitive schedule routing In this case material is moved to a location where the quality tests are performed Reporting occurs in the Shop Floor Control or Repetitive modules For work orders without shop floor control reporting use Test Results Maintenance 19 13 to record results Material that is spoiled damaged or made obsolete by an engineering change can be quarantined by changing its inventory status code in Inventory Detail Maintenance 3 1 1 to restrict inventory transactions AQAD Quality Managem
212. ected as discussed in the planning section to register control program exception records for specific BOMs or BOM components BOM Code Enter a BOM code for which you are creating a registration record Start Date Enter the date when this BOM registration record is effective When a start date is not specified this registration is effective immediately When multiple registration records have overlapping effective dates the registration with the most recent start date is used End Date Enter the last date that this BOM registration record is effective Leave blank to indicate that this registration should not end WIP Lot Trace 273 Optionally use the second frame to further define whether to trace components or references and whether to allow combining of component lots for specific component items in the BOM Fig 10 6 BOM Registration 5 Component Item Component Item 2 Trace Components Detail Frame Trace Reference Combine Component Lots Component Item Enter the component for which you are creating a detail BOM registration record In the first frame of this program you set up control fields that apply to all components of the specified BOM In this frame you can override these settings for specific components Trace Components Enter Yes to trace lots of this component consumed in manufacturing operations otherwise enter No To trace component items you must also trace their corresponding parent i
213. ed always has a zero mix variance This is because the base process quantity complete is derived directly from the actual quantity complete for that co product Order If the Quantity Complete Method for the co by product structure is ORD the base process quantity complete is equal to the quantity ordered on the original base process work order 100 Co products and By products 97 In this case expected co product and by product order receipt quantities are calculated as shown in Table 5 17 Table 5 17 Order ID Product Expected Receipt Calculation Sample Expected 1001 Orange Juice 100 50 100 100 0 5 50 E oUm 1002 Pulp 100 30 100 100 0 3 30 ORD Method 1003 Seeds 100 10 100 100 0 1 10 Based on these expected quantities mix variance calculations are as shown in Table 5 18 Table 5 18 Order ID Product Mix Variance Calculation Sample Mix 1001 Orange Juice 60 56 1 50 4 1 50 6 00 e 1002 Pulp 30 28 0 50 2 0 50 1 00 ORD Method 1003 Seeds 10 15 0 60 5 0 60 3 00 The Order method may be appropriate in environments where batch quantities for co products and by products are determined by some external factor such as the production equipment used and are therefore constant Restrictions Inventory Receipts Backward Exploded 3 12 The inventory backflush program can be used to receive an item using a normal BOM Formula code but cannot b
214. ed items passing down gross requirements to the next non selected level but not replanning orders It does not implode product structures to replan higher level items before planning selected items nor does it explode resulting orders to calculate component demand Reviewing MRP Output The primary outputs of MRP are planned orders and action messages These are generated if MRP sees an imbalance of supply and demand If supply exceeds demand MRP automatically reschedules or cancels planned orders and generates messages suggesting you de expedite or cancel open orders If demand exceeds supply MRP reschedules or creates planned orders and generates messages suggesting you expedite or create orders Action Messages MRP generates action messages for all items with non blank order policies Action messages recommend the actions a planner should take to balance supply with demand such as rescheduling canceling or releasing orders Review action messages using Action Message Review Update 23 5 Or use Action Message Report 23 7 to review messages by item site buyer planner Pur Mfg code or action message number Table 13 5 lists the messages generated by MRP with a brief explanation In the explanation a supply order can be a work order purchase order repetitive schedule or intersite request Table 13 5 Message Meaning MRP Action Messages Beginning Quantity Less The initial nettable quantity on hand is negati
215. ed Bean Bag Issue Picked 7 Yes streamlines data entry Item Number Qty Open Qty Alloc Qty Picked Qty to Iss Qty B O Item Number 2 Op A Site Loc Description Lot Serial Quantity UM Reference Substitute Cancel B O Multi Entry Issues are not restricted to what the system has allocated You can override the selections manually The work order and inventory balances are updated only after approval of the quantities to issue from inventory The system does not prohibit shipments from using inventory already allocated to another order This makes timing important The longer the period between the time a picklist is printed and the time it is picked for shipment the greater the chances inventory will not be available when you finally try to pick it In some instances when an item is not available it is possible to substitute a different item Philips head screws for slotted head screws for example When this is required first set up valid substitute relationships in Alternate Structure Maintenance 13 15 or Item Substitution Maintenance 13 19 When a substitute item is issued to a work order the requirement for the original component item is reduced Work Orders 125 Note If you enter additional quantities or negative quantities for an item during Work Order Component Issue or a Work Order Receipt Backflush the quantity allocated cannot become more than the quantity required or less than zero 0 It is set to
216. ed Repetitive Accounting Control Set up production lines by defining line allocations shifts if you use them production line capacities and changeover times Defining Control Program Settings If you have previously used the Repetitive module you must run Cumulative Ord Accounting Close 18 9 to close any open cumulative orders Then set the Enable New Repetitive field in Repetitive Control 18 22 24 to Yes Note In addition to these Repetitive Control settings use the WIP Transfer Account fields in Advanced Repetitive Accounting Control 36 9 12 to specify the account type GL account sub account and cost center debited or credited when closing a cumulative order and transferring WIP to a new cumulative order Repetitive Control x Repetitive Control Go To Actions Next Picklist P L Prefix PL Enable New Repetitive v Transfer Work in Process End Eff Default Method End Effective Days Include Yield Zero Balance Work in Process ZI NSF Is Reason Code Criticality Allow Zero Run Rate Next Picklist and P L Prefix Enter values to be used for automatic numbering of repetitive picklists Transfer Work in Process Enter Yes or No to set the default for the same field in Cumulative Order Close 18 22 10 End Eff Default Method Specify the method you normally use to set end effective dates on cumulative orders Choices are Blank Start and end effecti
217. ed for any of the parent s component items MRP generates component requirements using the standard product structure or formula effective for that item site or site on the date of the requirement Alternate structures and substitute items are not considered by planning Yield is also considered by MRP when it calculates component requirements These calculations are based either on the parent item yield percentage or the yield associated with each operation in the parent s routing Operation based yield is used when both of the following are true Enable Op Based Yield is Yes in MRP Control Op Based Yield is Yes for the parent item in Item Master Maintenance or Item Site Planning Maintenance If the parent item qualifies for operation based yield calculation each component could potentially have a different yield percentage If a component item is a global phantom MRP may need to blow through the phantom and plan another order for any required components of the phantom The system automatically applies the yield percentage of a global phantom to each of its components This is true even if the parent item s planned order includes components of local phantoms Co products and Base Processes MRP plans co products and base processes differently than other items Net requirements for co products are passed down to their respective base process items MRP then generates planned orders for base process items to meet these requi
218. ed from the operation s output queue to the reject queue Fig 10 10 f ee WIP Lot Reject WIP Lot Reject Data Qty Rejected 5EA Data Lot Serial Ref Code Quantity L5 Defect 5 0 Work Center 12000 Machine General 2 Department 10 General Qty Processed 5 0 Qty Scrapped 0 0 Otv Peierted c n UM EA Conversion 1 0000 Reason Code Multi Entry Peacon Code Multi Entru Lot Serial L5 Code Quantity 5 0 Defect FAQAD WIP Lot Trace This frame appears in the following programs when the output queue of the operation for which labor is being reported is WLT controlled and a quantity is entered in Qty Reject Backflush Transaction 18 22 13 Repetitive Labor Transaction 18 14 Reject Transaction 18 22 16 Repetitive Reject Transaction 18 17 Reporting Scrap Data Four WLT frames are used to record lot serials references scrap codes and quantities of WLT controlled material being scrapped from an operation s input output or reject queues WIP Lot Scrap Data WIP Lot Reject Queue Scrap Data WIP Lot Input Queue Scrap Data WIP Lot Output Queue Scrap Data WIP Lot Scrap Data Backflush Transaction 18 22 13 uses this frame when the output queue of the operation for which labor is being reported is WLT controlled and a quantity is entered in Qty Scrapped Fig 10 11 X WIP Lot WIP Lot Scrap Data Qty Scrapped 3 EA Scrap Data ROUT WICID UI DUNT coue WILIO DI T
219. em is manufactured can change over time New components can be added or unnecessary ones deleted Use effective dates to store relationships for historical current and future product structures All parent component relationships are identified by a start and an end effective date The start and end effective dates indicate when a relationship is active A relationship is effective through the end date and becomes obsolete the next day Example The hinges and fasteners for a frame are being upgraded The existing components have an end effective date of March 14 and the new components have a start date of March 15 If an adhesive is added to prevent the screws from coming loose you can also record the new product structure with the start date of March 15 Quantity Per Specify how much of this component is needed to make the parent item In discrete manufacturing items are made in individual units and the component quantity is the amount needed for a single unit of a parent product For example two screws are required for one pair of sunglass frames In process manufacturing products are made in batches and the component quantity per parent on a formula or recipe is stated with respect to a batch quantity for the parent product Since the only economical way to coat lenses is in batches the amount of a particular coating might be specified for a batch of several hundred lenses Scrap Depending on the product some components may be
220. embly subassembly intermediate and fabricated part FAQAD Introduction to Manufacturing 7 Routings Work Centers The Routings Work Centers module defines the areas where manufacturing activities are performed departments work centers and the manufacturing process itself operations and routings Formula Process The Formula Process module defines and maintains the relationships between products and the ingredients that go into them as well as the process by which they are created Other Formula Process functionality is discussed in conjunction with co products and by products Co products By products is used to manage processes that create more than one product Co products By products Co product By product features manage processes that create more than one product The module includes tools for setting up items structures and routings and supports MRP work orders shop floor control and costing Work Orders The Work Orders module is used in discrete production environments to control manufacturing orders Create work orders manually or generate them from MRP planned orders Generate work orders for configured products directly from a sales order The Work Orders module supports co product and by product manufacturing Shop Floor Control The Shop Floor Control module tracks activities and records operation status and labor times for manufacturing jobs released through the Work Orders module b See Routing
221. enance 11 3 7 In Work Order Maintenance 16 1 set the WIP account sub account cost center and project to an appropriate expense account for posting rework costs FAQAD 108 User Guide QAD Manufacturing b See User Guide QAD Sales for more information about configured items FAQAD Final Assembly Work Orders Final assembly FAS orders are used to manufacture configured products of type assemble to order ATO Kit configured items do not require a work order These are indicated by a Pur Mfg code of Configured in Item Master Maintenance 1 4 1 FAS orders are generated when a sales order for a configured product is released to manufacturing using Sales Order Release to Work Order 8 13 An FAS order uses the standard item routing but its BOM contain only the items specified in the sales order configuration Release and process FAS orders the same as regular work orders Expense Work Orders Use expense work orders for non inventory jobs such as engineering prototypes or design projects Expense work orders have no bill or routing but you can attach these manually as needed Note You should define a separate site item code and product line for expense orders to keep their planning and manufacturing separate from regular manufacturing To separate cost accounting specify an expense account rather than the default WIP account Or use the Project field to track expenses in the GL If you process expense wor
222. ent 305 Setting Up Quality Management Before using Quality Management set up appropriate control program values Before you can report quality test results you must define a quality document called a specification Test specifications control the testing process describing each test step the characteristic to be measured the measurement tolerance and the sequence for conducting tests If you have tests that apply to more than one item you can define master specifications These serve as templates for defining specifications for individual items If multiple steps are required for a stand alone quality test define them as a procedure in Procedure Maintenance 19 2 1 You may also want to establish a sampling pattern These define how items will be selected for testing if all items are not to be tested The two options are lot intervals and number of days before expiration Setting Up Control Programs Enter appropriate values in Quality Management Control 19 24 Most of the settings affect quality orders Fig 11 2 zx Quality Quality Management Control Go To Actions Management Control 19 24 Auto Order Numbers v Next Order Number 1004 Next Batch 6 Quality Order Comments Inspection Site 30000 Inspection Location inspect Procedure Comments If you want quality orders to be numbered automatically set Auto Order Numbers to Yes The system then uses the Next Order Number and
223. ent Check By WO Pro X F Actions Ej Print y Add to Favorites ly Chart Chart Designer Refresh Search 1 WO Component Stat gt starts at v shortage x Search Viewing 1 100 of 1975 Records per page 100 DO WOID Parentltem WO Component Status StatusID Quantity Scheduled Quantity Completed Quantity Open 892 nmp_Par Shortage 8 10 0 0 0 10 0 r BES ca633544 Shortage 8 10 0 0 0 10 0 1151 ca533544c Shortage 8 10 0 0 0 10 0 1157 isn carlin base Shortage 8 10 0 0 0 10 0 1170 isn carlin base Shortage 8 10 0 0 0 10 0 1180 gas carlin Shortage 8 10 0 0 0 10 0 1264 ibl Shortage 8 20 0 0 2 0 al m To wn WO Component Availability Schedule Maintenance Net Change Materials Plan Actions Print ulg Chart EP Chart Designer Viewing 1 1 of 1 Records per page 100 fa 9 WOIDRef Y Componentllem Y Component Status Y Component Status WY Component PQOH Y gt MES ca533544a Shortage 8 10 0 An asterisk in lower screen ial i n helps you Supply Demand Summary Supply Demand Details Inventory Detail by Site trace data 7 Actions C Print ulo Chart 8 Chart Designer back to the Viewing 1 100 of 2000 Records per page 100 X 4 source WOIDRet WORef Componentltem Date GrossReq Gross Supply AlocPQOH FimPQOH H display ca633644a 00 00 gt DIES j cab33644a 11 07 2007 10 10
224. epetitive Reject Transaction 18 17 displays the WIP Lot Input Queue Issue Data and WIP Lot Reject Data frames Use these frames to enter the input lot serials to issue and reject WIP lot serials to produce The information entered in these frames updates tracing history records and WIP lot serial QOH balances Tracing Scrap Material When scrapping WLT controlled material the Repetitive Scrap Transaction 18 18 displays the WIP Lot Reject Queue Scrap Data frame Use it to enter the WIP lot serial and quantity of the material being scrapped The information you enter updates tracing history records and WIP lot serial QOH balances Reporting Repetitive Transaction History The Repetitive Trans Detail Inquiry 18 4 2 is modified to display WIP lot serial information connected with an operation history record Any tracing records associated with the operation history record are displayed Additionally any WIP lot serials recorded by a scrap reject rework or adjust transaction are also displayed Reporting WIP Lot Trace Data The WIP Lot Trace module provides 10 reports and inquiries for reviewing WLT data These reports and inquiries are designed to clearly show consumption and production data at the operation and WIP lot serial level b See page 277 b See page 275 b See page 278 b See page 278 b See page 277 and page 278 b See page 280 FAQAD 300 User Guide QAD Manufacturing Table 10 12 WIP Lot
225. er Accounting Close 16 21 When an operation is complete you cannot process additional transactions against it However you can reopen operations if required using Work Order Routing Maintenance 16 13 13 Hold Indicates the operation is on hold This status can only be set manually in Work Order Routing Maintenance A blank status indicates an inactive operation An operation s status is blank when the work order routing is first exploded and remains blank until you record activity for it Use Work Order Routing Maintenance to manually change an operation s status if required Shop Floor Control 145 Recording Nonproductive Labor Shop floor control functions let you record nonproductive or indirect labor for employees for example preventive maintenance and meetings and downtime for work centers for example machine failures Shop floor reports use this information when calculating utilization and efficiency For nonproductive labor or downtime not associated with a specific work order use Non Productive Labor Feedback 16 20 4 Otherwise record nonproductive labor and downtime using the Down Time field in standard labor feedback transactions Nonproductive labor transactions reference reason codes set up in Reason Codes Maintenance 36 2 17 with a reason type of Down Note Many types of nonproductive labor such as paid vacations paid holidays and paid sick leave should be handled in a payroll system Fig 7
226. er and do not affect costing Reports for reporting reject quantities are available in Repetitive The Repetitive module includes some reports specific to that module Repetitive Completions When a routing has many operations there may be a few that are used to report completions called milestone operations Milestone Operations In Routing Maintenance 14 13 1 you can define any operation including standard operations to be a milestone At a milestone operation that operation and all previous non milestone operations are backflushed when repetitive labor is reported The last operation is always treated as a milestone The following rules govern reporting You cannot report labor against a non milestone operation e You can report setup downtime reject and scrap against a non milestone operation However this reporting does not affect WIP f you report scrap or reject at a non milestone operation it will backflush at that operation If you do not report setup at non milestone operations and report labor at milestone operations the standard setup will be backflushed If you report setup at the milestone operation then no setup will be backflushed Repetitive 233 Reporting Completions Completed units are received into inventory when quantities are reported as complete for the last operation for an item using Repetitive Labor Transaction 18 14 Components can be backflushed when completed units a
227. er when they cannot find one with the same profile site item production line routing BOM or formula code where the effective date range includes the effective date of the repetitive transaction The system sets effective dates on new cumulative orders using the parameters defined in Repetitive Control When you run an Advanced Repetitive transaction or create a cumulative See Managing ID with an Advanced Repetitive maintenance program the system ms Searches for discrete or scheduled subcontract purchase orders associated with subcontract routing operations Automatically updates blank ID fields on subcontract purchase order lines with the newly created cumulative order ID Automatically updates blank subcontract operation fields with the subcontract operation for the item on the purchase order Replaces any existing expired cumulative order IDs with an open cumulative order ID on subcontract purchase orders For scheduled orders the system first checks the effective dates for the scheduled order line If the effective dates indicate that the scheduled order line expired the system does not update the line with the new open cumulative order ID QAD 182 User Guide QAD Manufacturing b See End Eff Default Method on page 158 FAQAD When standard costing is used at the site on the cumulative order recording repetitive transactions generates rate variances and creates GL entries for them Usage and m
228. erials Plan 360 372 master production scheduling MPS 345 setting up subcontract items 202 Setup Labor Transaction 193 Labor WIP Lots frame 292 setup time 143 Shift Maintenance 163 Shift Report 165 shifts advanced repetitive 163 capacity 164 shippers connecting to items 216 shop floor control 139 151 co products by products 88 labor feedback 140 nonproductive labor 145 operation close 146 reports 148 Shop Floor Control program 142 Simulated Batch Ingredient Check local phantoms 16 Simulated Forecast Calculation 328 Simulated Picklist Item Check 16 local phantoms 16 Simulation Criteria Maintenance 322 Simulation Structure Cost Roll Up co products by products 72 Simulation To Simulation Copy 332 copying forecasts 334 multipliers 333 Simulation To Summarized Forecast 336 simulations forecast 321 line schedules 169 Single Item Simulation Copy 332 copying forecasts 335 multipliers 333 Site Maintenance co products by products 59 sites co products by products 59 security for 102 work order control by 102 specifications 305 values for 306 specifying active lines when allocating MRP 206 FAQAD specifying received subcontract quantities 217 splitting work orders 121 Standard Operation Maintenance 32 202 standard operations 32 changes to 32 overlap 33 standard work orders 106 status operation 144 work order 110 status for components 240 status for work orders 240 Status ID field 239 Sub Shipper Issue 204 215 Sub
229. eric value should be the first characters of a run sequence This convention provides enhanced control over the sorting of run sequences QAD 362 User Guide QAD Manufacturing Table 13 1 Production Line Sequence Using Run Sequences FAQAD Example Items 100 200 and 300 are produced on production line 500 These items are made of plastic and have different colors items 100 and 200 are green item 300 is white To minimize the change over time between items they must be scheduled in the following sequence tems 200 and 300 produced before item 100 tem 300 produced before item 200 To make sure approved orders with the same due date for items 200 and 300 are scheduled before orders for item 100 enter 01Plastic as the primary run sequence for items 200 and 300 and 02Plastic for item 100 To schedule approved orders for item 300 before orders for item 200 enter O1 White as the secondary run sequence for item 300 and 02Green for item 200 When approving planned orders for these items with Planned Repetitive Schedule Approve 23 8 set Sort by Run Sequence to Yes Table 13 1 illustrates the resulting production schedule for line 500 Production Item Number Primary Run Secondary Run Sequence Sequence Sequence 1 300 01Plastic 01 White 2 200 01Plastic 02Green 3 100 02Plastic 02Green Order Policy The order policy determines the number and size of each MRP planned order If an item s Order Policy is blank it is ig
230. erms of planning inventory and P See Work Order accounting They differ in their default bills routings and status codes SS These defaults are shown in Table 6 3 for each order type more details Note Scheduled and cumulative orders are managed using repetitive functions and are not included in this table Table 6 3 Work Order Type Default Default Default Work Order Type Type Code Bill Routing Status Defaults Standard blank Standard Standard Firm Planned Rework R Parent Item None Allocated Final Assembly F Sales Order Standard Exploded Expense E None None Released Flow W Standard Standard Exploded Rework Work Orders Use rework orders to manage repair reprocessing or completion of non conforming items A rework order has the parent item as its only component and no routing After creating a rework order you can modify its bill and routing by adding components and operations before it is released If additional items are needed use Work Order Component Issue 16 10 or directly modify the bill using Work Order Bill Maintenance 16 13 1 If rework activity is a common procedure consider establishing a rework routing in Routing Maintenance 14 13 1 and attaching it in Work Order Maintenance 16 1 or create one in Work Order Bill Maintenance 16 13 1 If you are using the Service Support Management module to receive items from customers and rework them you can establish default service routings in Service Item Maint
231. es WLT in Repetitive and Advanced Repetitive WLT makes many of the same changes to Repetitive and Advanced Repetitive programs The changes made to Rework Transaction 18 22 17 are also made to Repetitive Rework Transaction 18 16 Likewise Repetitive Setup Transaction 18 13 is modified in the same way as the Advanced Repetitive module s Setup Labor Transaction 18 22 15 When you use these programs to process any WLT controlled material the same WLT frames appear Reporting Labor Repetitive Labor Transaction 18 14 uses the same WLT frames as Backflush Transaction 18 22 13 WLT frames appear and are used only when processing WLT controlled material The WLT frames are used to enter input output and reject WIP lot serials and quantities This information is used to record the appropriate tracing records and update WIP lot serial QOH balances Use the WLT frames to enter WIP material lot serial information for the current operation s input output and reject queues Use the Destination Work Center and Machine frame to specify where the backflushed material will be moved This frame appears only when Move to Next Op is Yes WIP Lot Trace 299 WLT frames added to this program appear in this order when the corresponding queue is WLT controlled WIP Lot Input Queue Issue Data Destination Work Center and Machine WIP Lot Output Queue Receipt Data WIP Lot Reject Data Handling Reject Material The R
232. es Use Production Line Schedule Inquiry 18 22 2 13 to review the production schedule for a selected production line and day Use Production Line Schedule Report 18 22 2 15 to review the production schedule for a range of production lines and dates Advanced Repetitive 175 Exploding Repetitive Schedules Once you establish a schedule you must explode it using Schedule Explosion 18 22 2 4 The explosion creates the material and work center operation requirements necessary to support the schedule Until exploded changes to the schedule are not reflected in component demand or work center load MRP reports for the components or CRP reports for the affected work centers do not reflect the current repetitive schedule until it is exploded The schedule explodes automatically when MRP plans the item and site or when you run Schedule Explosion An exploded schedule creates scheduled work orders for each day of production Review these work orders in the Work Orders module They have a type of S scheduled Run Repetitive Picklist Calculation 18 22 3 1 to see if shortages at work centers need to be corrected Using Repetitive Picklists In most repetitive operations issues are managed solely by backflushing However in many operations you also need to manage the movement of inventory to the point where it is used In environments where inventory is stored on the production line the repetitive picklist lets you easily replenish t
233. es Maintenance nonproductive labor 145 Recalculate Capacity Plan 380 effect on operation schedules 118 Receipt Data Input frame 224 226 receipt date work order 135 receipt of subcontract items 200 receiving against a subshipper 216 receiving subcontract items 215 recyclable by products 64 reference codes product structures 17 Regenerate Materials Plan 372 Regulatory Attributes and WIP Lot Trace 253 lot numbers 128 Regulatory Attributes Control co products by products 68 87 Reject Analysis Report 199 Reject Transaction 193 release category 241 Released status work orders 241 FAQAD released work orders 113 releasing work orders 120 repetitive 227 235 completions 233 consume forward backward 229 contrast with advanced repetitive 154 cumulative orders 231 differences from advanced repetitive 228 milestone operations 232 picklists 175 calculation 176 setting up 228 tracing WIP 298 299 transactions 231 reporting 231 scrap cost 235 Repetitive Control 229 advanced 158 consume forward and backward 229 Next Picklist field 178 Repetitive Labor Transaction 233 test results 314 Repetitive module co products by products 98 Repetitive Operations Accounting Report 235 Repetitive Picklist Calculation 175 176 troubleshooting 178 Repetitive Picklist Delete 179 Repetitive Picklist Print 179 product structure Op field 20 Repetitive Picklist Transfer 176 179 Repetitive Picklist Undo 179 repetitive picklists deleting 179 inventor
234. es accepted and rejected are issued from inspection and expensed to cost of production For process inspection there is no special provision for destructive testing If rejected or scrapped quantities exist at an inspection operation they remain in WIP Quantities are taken out of WIP when received or rejected by a work order receipt function or by Repetitive Labor Transaction 18 14 or Backflush Operation 18 22 13 Nonconforming components can be returned from WIP by processing a Work Order Component Issue 16 10 for a negative quantity Printing Test Results Print test results for quality or manufacturing orders with Certificate of Analysis Print 19 20 An option to disregard the test results lets you print a certificate whether or not an order has passed all specifications Printing certificates for materials that have failed to meet specifications provides a record when dispositioning non conforming material The certificate can be attached to the material and used as data entry to take the material out of inventory tion Schedules 343 320 User Guide QAD Manufacturing b See page 321 b See page 330 b See page 338 b See page 332 AQAD Introduction Using functions in the Forecast Master Schedule Planning module you can calculate and record the number of units of a given item you expect to ship each week from a given site These forecasts are used to develop the master production schedule and drive ma
235. es the selected orders As a general rule production quantities should be directly related to the period used for scheduling production If production is scheduled by day the production quantity should not be sufficient to cover an entire week This becomes important when a production line is scheduled to process different products during a given week If MRP uses a POQ order policy and the period is a week or longer the production quantities recommended by MRP planned orders might cover a week In this case separate the quantity recommended by MRP into smaller quantities One day is the shortest period you can use to schedule production You can schedule multiple items each day but if scheduled production is by shift then you must summarize production into daily quantities before entering it into the workbench QAD 172 User Guide QAD Manufacturing FAQAD Scheduling and Lead Times In some situations different products manufactured on a line have significantly different lead times Even if flow rates are similar through most of the line some products might spend more or less time at an operation for example products that are burned in dried aged or cured When a line is changed over from processing one product to another with a significantly longer lead time the line s output is interrupted by the changeover time plus the new lead time This might not be important if you are manually determining the due date for e
236. es when displaying item requirements summarized by week Order Release Horizon Enter the number of calendar days before a planned order s release date on which the Re1ease Due For action message should appear The order release horizon should be based on your normal paperwork lead time and how often you run MRP For example if you run MRP weekly you should set the order release horizon to at least seven days If you run MRP daily you can set it to zero Material Requirements Planning 359 Enable Op Based Yield This field determines how the system b See Operation calculates yield for component items when product structures and ae IA SOR routings are exploded in material requirements planning MRP programs work orders repetitive advanced repetitive and configured products No The system uses the Yield 46 field associated with the parent item in Item Planning Maintenance or Item Site Planning Maintenance to calculate component requirements Yes The system derives the yield percentage amount for components from operations on the parent item s routing The Yield 46 field associated with the item is used for the parent item only not the components Even when Enable Op Based Yield is Yes operation based yield is only calculated for parent items with Operation Based Yield set to Yes in either Item Planning Maintenance 1 4 1 or 1 4 7 or Item Site Planning Maintenance 1 4 17 Setting this field to Yes typically results in
237. eschedule supply the planner can reschedule a purchase order receipt if the component is purchased Or if the component is manufactured the planner can reschedule a work order To reschedule demand the planner can reschedule a sales order or forecast demand Viewing Receipt Data When drilling down to find the reason for shortages you can view receipts You can also view the expected receipt dates based upon the date of an Advance Ship Notice ASN Figure 9 9 shows an unconfirmed shipper receipt in supply Note The system consumes the unconfirmed ASN receipt quantities from scheduled and planned receipt quantities to avoid double counting the receipt Production Line Schedule Ingu Schedule Inquiry 7 18 2008 Component Check By WO Pro Excel b Print yip AddtoFavortes ali 18 chart Desmer Seach 1 Production Line gt equas A100 J each Chew Al Viewing 1 3 of 3 Records per page 100 3 60 6 WOID Parent tem 2 WO Component Status Quanity Completed 2 QuartityOpan Relesse Date Prmay Lire 700 30 07 20 2008 A 100 07 21 2008 A 100 Firiihed Product Finished Product Uncontumed Shope Rept Unconfimed Shipper Rept Repetitive 249 If you click on the unconfirmed receipt the system factors in the unconfirmed receipt Click the refresh button to view results shown in Figure 9 10 m k Fig 9 10 Demand Supolv Summary Demand Suppty Detail Inventory D
238. ess Inspections When inspection occurs in process work orders and repetitive schedules control the movement of material Quality orders are not needed Process inspections are typically performed on a factory floor You can do this by defining inspection operations in an item s routing in Routing Maintenance 14 13 1 These operations are linked to test specifications in the same way that test steps in quality orders are linked Reporting test results can be part of regular labor reporting For work orders with routings enter inspection results in The labor feedback transactions in Shop Floor Control 17 e For a repetitive schedule in Repetitive Labor Transaction 18 14 For an advanced repetitive schedule in Backflush Transaction 18 22 13 For scheduled work orders or work orders without routings enter test results manually in Test Results Maintenance 19 13 Results entered here are processed in the same way as in Quality Order Results Entry Figure 11 9 illustrates how test results are reported as part of labor feedback Quality Management 315 Fig 11 9 x Reporting Test Labor Feedback by Work Order Go To Actions Results in Labor Feedback by Work Order 16 20 1 Work Order matwo 1000 ID 122 Operation 10 Op Status Employee 0001 OO1alh Pay Code Department 10 Work Center 100 01 Time Ind Decimal Hours Enter the Shift Machine Project results while Specification Tests report
239. et up the shop calendar departments and work centers Product Lines Items Products a i Formula Routings Process Work Centers While Routing Maintenance sets up operation run time in hours per unit and Routing Maintenance Rate Based 14 13 2 in terms of units per hour Formula Process lets you define a formula in terms of batch size and process it in hours per batch The batch size is expressed in the parent item s unit of measure and represents the quantity in which the item is to be produced In Formula Process all definitions reference a specific batch size You can specify ingredient quantities as a quantity per batch or as percent of a batch Process definitions are always expressed as run times per batch Unlike product structures formulas relate to a particular batch size The Formula Process module also manages processes that create co products and by products along with the base process that produces them Formulas and Processes 47 The Formula Process module works in conjunction with lot serial control which is sometimes necessary to comply with government regulations Lot control can also help companies improve quality process control and inventory accuracy Defining Formulas Formulas are defined as parent item component relationships To define a formula for a product enter the product as the parent and the formula ingredients as components of the product
240. etail records With Simulation to Simulation Copy you can copy forecast records for multiple items in a single transaction whereas with Single Item to Simulation Copy you can copy only for a single item Note To manually adjust forecast detail records created using these functions use Detail Forecast Maintenance 22 7 7 Multipliers When copying or combining forecast detail records using Simulation to Simulation Copy 22 7 11 or Single Item Simulation Copy 22 7 12 you can apply multipliers to the resulting forecast quantities Multipliers also called multiplicative factors allow you to increase decrease or scale forecast quantities by a specified percentage Multipliers can be useful when you have prior knowledge of an unscheduled demand such as a future sales promotion There are three types of multipliers Base Increase Decrease Scale Trend Forecasting Master Schedule Planning 333 In Single Item Simulation Copy multipliers let you scale the forecast results for a new item as some percentage of an old item This is useful when you want to match the seasonal demand but not the quantity of an old item for a new item Simulation to Simulation Copy lets you apply multipliers to a range of items Base Increase Decrease The percentage by which a forecast quantity is increased or decreased A negative percentage indicates that the quantity is decreased Table 12 6 Month Units 10 10 Base Increase Tags 10
241. etall by Site Calculated BS exe Gorm d chon BR chat Deger Unconfirmed Veg 1 4 d 4 Records per page 100 0 Receipt WOID Re Componenti Type Swe Pace GrossReq 2 Gose S NetAvaV PQO Uno Shipper Reph PQO gt ScheddedReh PQO MAP Pts MEA AANO Supiy 00 00 00 eno oo MEA AANO Demand Abocated 00 00 00 w0 TEA AANO If you have planned orders only you can see planned receipts too Fig 9 11 Production Line Schedule Inqu Schedule Inquiry 7 16 2008 Component Check By WO Pro Planned Receipts E excel amp print ip Add to Favorites uly Chart E Chart Designer Search 1 Production Line saus A100 p H xX Seach cent Viewing 1 4 of 4 Records per page 100 2 90 5 WOID Parertitem S WO Component Status gt Quantity Completed Quanity Open Release Due Primary Line 7465 AF100 Unconfirmed Shipper Rept 00 300 07 20 2008 A 100 F 7474 AF100 Unconirmed Shipper Rept oo 300 07 27 2008 A100 Finis 7475 AF10 Planned Receipts 00 300 08 03 2008 A 100 You can rectify shortages by moving up receipts Then you can change the schedule in Schedule Maintenance launched from the browse collection then optionally rerun Net Change Materials Plan to clear any planned receipts Finally you refresh the top component availability portion of the screen to determine if this resolved the shortage FAQAD 250 User Guide QAD Manufacturing FAQAD 274 299 252 U
242. ete Archive 16 20 23 to archive old transactions and delete them from the database Use this programs carefully to prevent deleting data or archiving data that may be needed online While recovery of archived data is relatively easy it is not possible to recover deleted data that has not been archived 157 in the Workbench 169 173 175 186 Managing Subcontracting _ 200 154 User Guide QAD Manufacturing Introduction Repetitive manufacturing is executed with schedules rather than work orders Schedules require fewer steps and less paperwork to execute and are typical in manufacturing environments that use assembly lines to produce similar products using the same process Since the same activities are repeated regularly there is little variation Repetitive scheduling enables you to Build to a repetitive schedule e Run a production line without finite schedules e Runa production line with repetitive schedules forward scheduled to capacity limits Report production and let MRP adjust inventory plans Advanced Repetitive and Repetitive You can use one of two ways to manage repetitive production appropriate in different business environments The Repetitive module works well when one or more of the following is true Manufacturing lead times are relatively short and batches do not overlap All work in process is complete by the end of each day Work in process WIP costs are either insignificant o
243. ethod variances are accumulated and posted when you run one of the following Post Accumulated Usage Variances 18 22 9 generates GL entries for usage and method change variances accumulated since this function was last run Cumulative Order Close 18 22 10 closes cumulative orders and creates GL entries for usage and method variances accumulated since Post Accumulated Usage Variances was last run You can transfer WIP balances to another cumulative order or post them to Method Change Variance Post Accumulated Usage Variances and Cumulative Order Close can be run in report only mode if needed All rate and usage variances are measured against the cumulative order cost GL scrap entries are not created until you run either Post Accumulated Usage Variances or Cumulative Order Close Use Cumulative Order Browse 18 22 7 or Cumulative Order Report 18 22 8 to review cumulative order information including start and end effective dates and status Cumulative Order Create Use Cumulative Order Create 18 22 11 to create new cumulative orders in advance in a batch oriented setting This prevents the system from having to create them during repetitive transactions and ensures a better response time for items with many components To use this function orders must already exist in the system The new order is based on the old with a different effective date For each cumulative order selected the system checks to see if a cumulative
244. exceptions you can define item specific run rates just for them Setting Up Production Lines A production line is defined at a site by specifying the hourly production rate for items produced on that line during a normal shift One or more items can be made on the same production line and the same item can be produced on several production lines all at the same or at different production rates Fig 8 3 DN Production Line React nee ea Rr j Maintenance roduction Line aintenance o flo ctions 18 22 1 1 Production Line Linei Site QPS Description Casing Production Lining Units Hour 100 00 Items Item Number 1 BB Red Bean Bag Start Date 02 22 2007 Units Hour 100 00 EA Primary Line Setup Crew Size 0 Run Crew STD Size 1 Tool ID Run Sequence 1 2P Cut 2 4G Mold 2 Comments FAQAD 162 User Guide QAD Manufacturing P See Setting Up Line Allocations on page 163 b See Allow Zero Run Rate on page 161 gt See Run Sequences on page 361 b See Approving Planned Line Orders on page 376 FAQAD When an item is produced on one line only this line can be assigned a primary line status for that item A primary line produces all orders for an item To indicate a primary line set the Primary Line field to Yes Optionally orders for an item can be allocated to several different production lines To set up multiple production lines for an item
245. for l Co products Allocate costs to co products Define average cost allocation methods to be applied at work order close Have system calculate by product costs from structures or enter costs manually Roll up lead times Freeze by product costs Verify that costs are correct for base process items and their lower level components Roll up lower level costs Allocating Costs to Co products Assign cost allocation percentages in Process Formula Maintenance P See Setting Up a 15 18 or Co By Product Maintenance 15 12 1 a EE age 62 The same co product can result from more than one base process but ES only one base process determines a co product s cost at a particular site That is a co product receives costs only from the base process specified in the BOM Formula field of the co product s item record Example Base Process A produces three co products pitted prunes prune juice and prune pur e used to make Danish pastry It also produces one by product pits The net cost calculation for Base Process A is as follows Gross Cost Base Process A 105 By product Costs 5 Net Cost Base Process A 100 FAQAD 70 User Guide QAD Manufacturing FAQAD Although prune juice is a significant co product of Base Process A it is also a co product of Base Process B and as defined in the BOM Formula field of Item Master Maintenance 1 4 1 takes its costs fro
246. from current operation s output queue For this reason the input queue of the following operation must also be allowed to have negative WIP balances To do this set WIP Lot Overissue to No in the first frame indicating that for this routing registration record WIP lot balances cannot be negative In the second frame specify Operation 5 and set WIP Lot Overissue to Yes The value you set for operation 5 overrides the general routing value set in the first frame QAD 272 User Guide QAD Manufacturing Fig 10 5 BOM Registration Maintenance 3 22 13 4 AQAD Registering BOM Exceptions BOM Registration Maintenance 3 22 13 4 is similar to Routing Registration Maintenance Use this program to create exceptions to the control program settings by creating new settings for BOMs Example In WIP Lot Trace Control you indicate No in Trace Reference because you typically do not trace inventory references in your manufacturing operations However for BOM code 007 you need to trace references Use BOM Registration Maintenance to indicate that references need to be traced for BOM 007 BOM Registration Maintenan vx BOM Registration Maintenance Go To Actions BOM Code Fe Start Date 2 26 2007 Trace Components Trace Reference Combine Component Lots End Date Some field values default from the control program Additional fields are described below Use the following field descriptions and any data you coll
247. g Fig 8 9 Schedule Maintenance 18 22 2 1 FAQAD Example A four week repetitive schedule for an item on a production line needs an additional week added every week Use the workbench to schedule the new week and Repetitive Schedule Update to update the schedule After updating repetitive schedules run MRP to synchronize planned orders with the schedule changes Schedule Maintenance Use Schedule Maintenance 18 22 2 1 to enter or maintain daily schedules for each production line at a site If the production line has multiple shifts the schedule represents the total for all shifts If there are no production lines at the site you can enter a schedule for the whole site Schedule Maintenance Go To Actions Item Number 100C Finished Good C Site 12000 Production Line 1001 Start 06 18 2007 Due Date Scheduled Routing BOM Code Monday 06 25 2007 8 0 MDR100 P 1 BB Fe Tuesday 06 26 2007 8 0 MDR100 JJ 1 BB 2 Wednesday 06 27 2007 8 0 MDR100 P 1 BB P Thursday 06 28 2007 8 0 MDR100 1 BB P Friday 06 29 2007 8 0 MDR100 P 1 BB 49 Saturday 06 30 2007 0 0 MDR100 A 1 BB Fe Sunday 07 01 2007 0 0 MDR100 P 49 Total 40 0 The bill of material BOM and routing for an item on a repetitive schedule default from Item Master Maintenance 1 4 1 or Item Site Planning Maintenance 1 4 17 You can specify valid alternates but you cannot combine different BOMs and routings on one order Reviewing Repetitive Schedul
248. g average 326 simple regression 326 Winter s linear exponential smoothing 326 modifying results 330 multiplicative factors 332 net forecast calculation 340 new items 335 rolling forecasts 321 simulations 321 single items 335 summary forecast records 336 Formula Code Maintenance 14 48 Formula Copy 49 Formula Maintenance 47 co products by products 65 lead time offset 122 work order 114 formulas 45 49 batch size 48 batch type 48 co product by product 49 copying 49 defining 47 FAQAD 394 User Guide QAD Manufacturing defining BOM Formula code 48 MRP use of 366 setup for 46 used for multiple items 14 freezing costs by products 70 G general ledger GL period end 136 global phantoms 16 H horizon forecasting 321 horizontal pattern 324 l indicating quantity scrapped 210 Input Output Inquiry 383 Input Output Report 151 383 Integrate with SA field effect on forecasting 322 inventory moving finished items into 224 placement of finished goods 200 inventory audits 316 Inventory Control picking logic 120 work order 122 Inventory Detail Report auditing items 316 inventory sampling 309 Issues Unplanned floor stock 21 issuing work order components 123 Item Cost Maintenance co products by products 71 Item Master Maintenance 174 202 base process item 60 co products by products 61 71 planning parameters 360 Item Planning Data Frame 202 Item Planning Maintenance BOM code 14 co products by products 61 M
249. ge 16 8 Work Order Receipt 16 11 Work Order Receipt Backflush 16 12 Work Order Operation Backflush 16 19 Although you are not prompted to enter the work order close date or your user ID these items are captured by the system and appear automatically on two work order reports Work Order Status Report 16 3 3 Work Order History Report 16 3 6 Work order close and receipt dates are recorded on discrete work orders only Scheduled and cumulative work orders created through Repetitive and Advance Repetitive do not include this functionality The work order close and receipt dates do not affect the effective date of See General the accounting close function GL period control does not apply to the a a work order and receipt dates page 136 Work Order Accounting Close Work Order Accounting Close 16 21 Completes open work order operations FAQAD 136 User Guide QAD Manufacturing FAQAD Calculates and posts work order variances for material labor burden and subcontract costs Calculates and posts usage variances when the labor quantity used differs from the standard For example if it took six hours to complete an operation scheduled for five hours a labor usage variance of one hour is posted Calculates and posts rate variances for material and subcontract when cost used differs from standard cost If pay rates are defined in Actual Pay Rate Maintenance 14 13 21 rate variances
250. gs and Work Centers 39 The total run time for an operation is a function of order quantity If the unit run time is 1 hour and the item order quantity is 48 a total of 48 hours of run time is needed The run time for an operation is a function of total run time work center or shop calendar hours and the machines per operation If a work center is open for 8 hours per day and there is one machine per operation run time is 6 manufacturing days 48 hours over 6 days with 8 machine hours per day However if there are 3 machines per operation run time will take only 2 days 48 hours over 2 days with 24 machine hours per day Wait time is the amount of time a lot must remain at a work center after an operation is completed before it can be moved to the next operation It is calculated from a straight 24 hour clock since no machines or people are required Subcontract lead time is stated in days It is added directly to the other lead time components The system schedules work order and repetitive operations sequentially assigning start and due dates for each operation The duration of a specific operation the time between its start date and due date is determined by the setup run and subcontract times for the operation The interoperation lead time the time between the due date of one operation and the start date of the next operation is calculated using the first operation s wait and move times and the following operatio
251. h 18 22 1 10 to create simulated schedules when Many different items are produced on a single line Several different lines produce the same item The production rate of a line varies You can use Line Schedule Workbench to Create a simulated repetitive schedule line schedule for a specific production line and site combination Have the system automatically modify line schedules based on the capacity constraints of the specified production line In addition Line Schedule Workbench lets you update or create repetitive schedules from MRP planned orders When planned orders for line manufactured items are approved these orders are added to the item s line schedule The sequence in which orders are added to a schedule can be controlled using the Sort by Run Sequence field in Planned Repetitive Sched Approve 23 8 You can review and modify sequences quantities and dates as needed b See Approving Planned Line Orders on page 376 FAQAD 170 User Guide QAD Manufacturing b See Updating a Repetitive Schedule from a Line Schedule on page 173 Fig 8 7 Line Schedule Workbench 18 22 1 10 FAQAD Simulation usually takes place during production planning The planner creates a line schedule that meets production requirements and balances line utilization and then uses it to generate repetitive production schedules The line schedules you create in the workbench are simulations only and are
252. h P See Pur Mfg Plan Orders set to Yes and non blank order policies specified in the item muse al planning data MRP generates planned work orders for manufactured items planned line orders for items manufactured on production lines and planned purchase orders for purchased items based on the item Pur Mfg code The scheduled release date for a planned order is the item due date minus See Lead the purchasing or manufacturing lead time For manufactured items MRP ber calculates planned order release dates using the manufacturing lead time For planned purchase orders both the inspection lead time and the purchasing lead time are used If a planned order release date falls on a non workday MRP schedules it for the last prior workday When MRP plans orders it uses the default shop calendar for the site If there is no shop calendar MRP does not plan orders for that site Planned purchase work and line orders are stored with status Planned Work orders and line orders are created with work order bills purchase orders are not A planned order regardless of its type can be approved using any of the planned order approval programs If you do not plan to act on a planned order you should delete it particularly if MRP will not be run soon The system assumes you will take action on planned orders Master schedule inquiries and reports include master scheduled order quantities which are assumed to be supply and therefore inclu
253. h the due date item quantity parent item number and type of requirement whether forecast production forecast sales order customer schedule work order or repetitive Note Run MRP reports and inquiries immediately after MRP since they are sensitive to changes in inventory demand and supply MRP Planning Modes MRP can be run in three operational modes Regenerative MRP plans for all items at selected sites Net change MRP plans only for items that have changed since MRP was last run It produces the same results as regenerative MRP but generally requires less time to execute Selective MRP plans only for the items you select Net Change Maierials Plan Net Change Materials Plan 23 1 considers only items with MRP Required set to Yes in their item planning data The system sets this field to Yes automatically when changes occur for an item in any of the following areas tem or item site planning data Product structures Sales or purchase orders Work orders or repetitive schedules FAQAD 372 User Guide QAD Manufacturing b See User Guide QAD Supply Chain Planning FAQAD Inventory Forecasts Master production schedule Intersite demand In addition to planning items that have changed net change MRP recalculates lower level requirements for items planned Typically Net Change MRP is run daily Both net change and regenerative MRP plan items based on low level codes They dete
254. he exact quantity required prints on the picklist and no rounding is applied by the system Set this field to No when you are using lean manufacturing techniques and do not want any extra items on the shop floor Detail Requirements When Yes the system prints all repetitive schedules generating requirements for a component including the quantity required parent item due and start dates machine and operation Delete When Done When Yes the picklist is automatically deleted after the calculation Use this option to review shortages without actually allocating inventory The Next Picklist field in Repetitive Control 18 22 24 is not incremented Troubleshooting Problems If problems occur with the picklist calculation remember the following A location must be created with the same name as the work center The calculation does not create a picklist if there is no inventory to detail allocate You cannot allocate negative quantities The system does not warn you if inventory is insufficient to meet the requirements it just does not create a picklist The system does not create a picklist if there is sufficient inventory at the work center FAQAD Advanced Repetitive 179 Detail allocations are not associated with specific orders so no order IDs are shown in the allocated inventory inquiry Depending on the setting of Use Work Center Inventory in Repetitive Picklist Calculation the system may use untransferred picklist
255. he expected receipt quantity for a co product or by product Expected Receipt Quantity Base Process Quantity Complete Co product or By product Qty Ordered Base Process Quantity Ordered Co products and By products 91 To calculate the mix variance amount for a co product or by product work order the system compares the actual work order receipt quantity with what the system expected to receive based on the base process quantity complete The equation used to calculate mix variance is as follows Mix Variance Expected Receipt Quantity Co By product Actual Receipt Qty Co By product Unit Cost The base process quantity complete as determined by the quantity complete method is also used in place of the work order quantity when calculating material and labor usage variances for a base process work order The following examples illustrate how the setting of Quantity Complete Method on the co by product structure determines how mix variances are calculated for co products and by product work orders Each example uses the sample co by product structure shown in Figure 5 10 Base Process Extract Juice from Oranges nm Co product Co product By product Orange Juice Orange Pulp Orange Seeds Ca The sample base process has only one component oranges Base process work orders have a batch quantity of 100 base process units and the expected yield quantities per batch order quantities
256. he line s work centers Use repetitive picklists to move inventory from stocking locations to a work center To use this method you must define work centers as inventory locations Each repetitive schedule creates inventory requirements at the work centers in its routing When you run Repetitive Picklist Calculation 18 22 3 1 the system Determines the available inventory and requirements at each work center for the specified range of parent items Determines where shortages exist Allocates inventory to meet shortages Creates a picklist for each work center shortage FAQAD 176 User Guide QAD Manufacturing Fig 8 10 Picklist Processing Flow FAQAD Calculate picklist or create detail allocations Transfer inventory to work centers The system creates a picklist if there is a shortage and inventory is available to be picked When you print the picklist the inventory is picked Use Repetitive Picklist Transfer 18 22 3 6 to transfer the inventory from its current inventory location to the work center This move is a location transfer not an issue to WIP so there are no GL transactions until the inventory is backflushed Pick inventory Example Item A is installed in four different end items at work center OPS The work center has 900 of Item A on location For the next week the repetitive schedules for these items have a total requirement of 1 000 The repetitive picklist calculation
257. he machine where that WIP material will be processed during operation 30 Fig 10 7 Destination Work Center and Machine Frame Destination Work Genter and Machine Work Center D Machine 2 FAQAD 276 User Guide QAD Manufacturing Table 10 9 Programs Displaying Destination Work Center and Machine Frame Table 10 10 Programs Displaying WIP Lot Input Queue Issue Data Frame FAQAD When using Reject Transaction 18 22 16 this frame appears only when the reject from queue is WLT controlled When using Rework Transaction 18 22 17 this frame appears only when the rework from queue is WLT controlled For all other programs this frame appears when The current operation output queue is WLT controlled The current operation is not the last operation Move To Next Op is Yes Table 10 9 lists the material transfer programs that use this WLT frame Menu Program 16 19 Work Order Operation Backflush 16 20 1 Labor Feedback by Work Order 18 14 Repetitive Labor Transaction 18 16 Repetitive Rework Transaction 18 22 13 Backflush Transaction 18 22 16 Reject Transaction 18 22 17 Rework Transaction 18 22 19 Move Transaction WIP Lot Input Queue Issue Data Use the WIP Lot Input Queue Issue Data frame to register lot serials of the WIP material being consumed at the current operation This frame appears when the previous operation s output queue and the current operation s input queue are WLT controlled Table
258. hedule used to further define items to forecast Fig 12 2 Simulation Criteria Maintenance 22 7 1 b See Forecasting Horizon on page 321 b See Forecast Methods on page 325 See Alpha and Trend Factors on page 327 FAQAD 324 User Guide QAD Manufacturing Table 12 1 Demand Patterns FAQAD Note When you specify both Ship To and Region as criteria for selecting sales history data only permanent ship to addresses that is those defined for customers in Financials are in the selected region range Demand Patterns Sales history can contain four underlying patterns of demand Forecasting methods quantify these patterns Pattern Description Example Trend Sales quantities increase or decrease The growth pattern of a new over time product Seasonal Sales quantities fluctuate according to Sales of soft drinks which some seasonal factor such as weather increase in the summer or the way a firm handles its months operations Cyclical This pattern is similar to seasonal but The sale of houses the length is greater than one year The pattern does not repeat at constant intervals and is the hardest to predict Horizontal Sales quantities do not increase or decrease substantially A stable product with consistent demand Figure 12 3 shows examples of these demand patterns in graph format Forecasting Master Schedule Planning 325 Fig 12 3 S
259. historical data to generate an accurate forecast The calculated forecast quantities are stored in forecast detail records identified by the forecast ID year and item You can manually modify forecast detail records as needed Note You must enter forecast detail records created outside the system manually using Detail Forecast Maintenance 22 7 7 or load them using the CIM interface Fig 12 4 Simulated Forecast Calculation 22 7 5 See Creating Criteria Templates on page 322 P See Manually Creating Forecasts on page 330 FAQAD 330 User Guide QAD Manufacturing b See User Guide QAD System Administration for information about the CIM interface FAQAD When you run a forecast calculation any existing criteria templates or forecast detail records with the same forecast ID are automatically deleted Criteria templates used to calculate forecasts can be further modified only when doing another calculation using Simulated Forecast Calculation Manually Creating Forecasts You can use Detail Maintenance Forecast 22 7 7 to manually create forecast detail records Note You cannot manually create a rolling forecast When loading forecast results using the CIM interface or manually entering forecasts using Detail Forecast Maintenance you must specify a forecast ID year and item number The system automatically sets the forecast method to 00 and generates a criteria template which is stored
260. ial capital or all capital letters Contact the appropriate companies for more information regarding trademarks and registration Copyright 2009 by QAD Inc QAD Inc 100 Innovation Place Santa Barbara California 93108 Phone 805 684 6614 Fax 805 684 1890 http www qad com Contents About This QUIOG Luisa dx ARRA aree a AHOGER FRE AUR RR RR 1 Other QAD Documentation 00 000 ccc cece eens 2 QAD Web Sit o ncieae sche heated headed ae ee bbe nea eee ecb died 2 CONVENUONS ia ed haw CoA e A RT CS DRM ER Na 3 Screen Illustrations i cesera eee wis y exl ub ved ada ede 3 Typographi 2a ce eee awe ned waned oo De gage eot 3 Chapter 1 Introduction to Manufacturing 5 Product Structures oiec lessen 6 Routings Work Centers lese 7 Formula Process 1 21 eta ER ede aded eR ha ue doi ate defen 7 Co products By products eseseeeeeeeee eee ees 7 Work Orders conset secu sherk ee haa amc UY ede dux vibe xp RR da 7 Shop Floor Control sseleeeeeeeeee ee ene nee eee 7 Plow Sched ling eee eth or a eo d a a ale 8 Kanal mec 8 Advanced Repetitive 0 0 eee ete eee nee 8 uad PP alee eh eae eee eee es 8 Work in Process Lot Trace 1 1 0 2c eects 8 Quality Management 0 ee eect eens 9 Forecasting Master Schedule Planning eese 9 Material Requirements Planning MRP 0 0 ee ee eee eee 9 Capacity Requirements Planning CRP esee 9
261. ices Specifying Subcontractors for a Routing Operation If your company contracts various subcontractors for one routing operation you can associate each subcontract with a single routing operation If you use scheduled orders for subcontracts use Subcontract Order MRP Maint 5 5 1 21 to associate subcontractors with a single routing operation If you use discrete purchase orders use Subcontract Routing Op PO Maint 5 11 When you specify subcontract orders for a specific routing operation the system uses the information to Create schedules for subcontractors if using scheduled orders Set defaults in Advanced Repetitive subcontract shipper programs Find subcontract purchase orders and automatically update the cumulative ID and Operation fields when an Advanced Repetitive transaction creates a cumulative ID Populate subcontract related browses and reports Specifying Subcontractors for Scheduled Orders In Subcontract Order MRP Maint you allocate a percentage of the total subcontract services required for the routing operation to each subcontractor Enter the site item effective date routing and subcontract operation in the header Then enter the percentage for each subcontract order in the Purchase Order Percents frame Percentages must equal either 10046 for each item or be 0 If 0 the system does not allocate planned orders for the scheduled order To phase in new percentages enter the same ship to
262. ieval of work order component availability maintenance manipulation viewing and reporting of production details Component Check by WO Production Line Component Check by WO Work Center Component Check by Item Work Order The Component Check browse collections let you perform material component shortage checks across your selected range of work orders and order statuses Since most manufacturers experience shortages the component check programs let you quickly identify and analyze the shortage so that your orders can still be met The Component Check browse collections let you look at current and future component projected quantity on hand PQOH statuses And the status check is automated in a single display so there is no need to manually search through various reports programs and browses to check for shortages You can use the Component Check browse collections to drill down into component shortage information for selected jobs work orders to identify the root cause and possible solutions Using Browse Collections The Component Check programs are embedded in browse collections Component Check by Work Order Production Line and Component Check by Work Order Work Center are browse collections that consist of these browses Work Order Browse Lists selected work orders along with component shortage severity status The WO component status that displays is the most severe component status found among the components The
263. ill be completed on time provided that it is released on time Work Orders 115 Fig 6 5 Work Order Maintenance 16 1 gt For more details see Releasing Work Orders on page 120 FAQAD 116 User Guide QAD Manufacturing Table 6 6 Sample Schedule Setup FAQAD Manually Controlling Due Dates When you create an order in Work Order Maintenance the due date is calculated from the release date The calculation begins by setting the release date to the current date then uses the manufacturing lead time and shop calendar to calculate the due date To define either the release or due date and have the program calculate the undefined date enter the defined date and enter a question mark for the date you want calculated The system calculates the date for the field containing the question mark using the date from the other field and the operation times from the item routing If you enter a release date and enter a question mark in the Due Date field the system calculates the due date by starting at the beginning of the release date and forward scheduling starting with queue time for the first operation If you enter a due date and enter a question mark in the Release Date field the system starts at the end of the due date and backward schedules by starting with the last move time for the last operation If you leave both dates blank the release date is set to today s date and forward scheduling is used
264. ime 1 0 Run Crew 5 00 Setup Time 0 0 Tool Code WIP Item 100A 01 P Move Next Operation M Auto Labor Report Yield Percent 100 0096 Repetitive reporting typically uses milestone operations Determines how labor is reported Milestone and Non Milestone Operations Milestone operations are routing operations where production counts are recorded Milestone operations are normally used to report all labor and completions the last operation is always treated as a milestone However you can also use non milestone operations to report scrap rejects rework or discrepant labor In this case you create WIP balances at non milestones This allows for more accurate tracking of WIP costs and quantities Normally however non milestones are maintained at zero inventory This can be done automatically by the system or manually based on the setting of Zero Balance WIP in Repetitive Control 18 22 24 When Zero Balance WIP is Yes and you report a processed quantity or a subcontract issue or receipt at any repetitive operation the system moves any quantities remaining at previous non milestone operations to the input queue of the non milestone operation that directly follows the closest preceding milestone operation Example Operation 10 is a milestone operation and operations 20 and 30 are non milestones You report a quantity complete at the next operation 40 At this time if an open quantity remains at operation
265. in Repetitive Control the dates in the new order are adjusted forward or backward to prevent overlap The cumulative order creation process retrieves the routing in effect as of the transaction effective date and copies it to the cumulative order For each operation in the routing this process retrieves the product structure in effect as of the transaction effective date and copies it to the cumulative order operation Any phantoms are blown through A cost rollup is then performed in the new cumulative order and the calculated operation costs are recorded by operation in the cumulative order routing These costs are used for WIP valuation reporting and calculating variances The costs are independent of the item cost and routing cost The Cumulative Order Cost Report 18 22 4 10 displays the operation costs stored in the cumulative order Advanced Repetitive 189 Warning Messages All transaction programs issue warning messages when one of the following occurs The operation being accessed is a non milestone operation A transaction would cause a WIP queue for an operation to become negative All transaction programs write operation history records to record the transaction events Rate Variances All transactions consuming resources immediately calculate and post rate variances These are generated when the standard costs in effect for components or labor at the time of the transaction differ from the resource co
266. in conjunction with distribution requirements planning DRP which balances supply and demand among sites Sources of Demand and Supply MRP uses the master production schedule MPS to calculate dependent component demand Dependent demand is directly derived from the demand for other items and includes demand for components items raw materials and subassemblies Independent demand is demand that cannot be calculated or derived from demand for other products It is represented through forecasts and sales orders and includes demand for end products and replacement items Independent demand generally passes to MRP through the master production schedule Material Requirements Planning 357 Sources of Demand MRP considers the following as sources of demand Forecasts Sales orders Customer scheduled orders from a required ship schedule Intersite orders generated by DRP Component requirements from manufacturing Production forecasts Safety stock requirements MRP does not consider unconfirmed sales orders or component requirements from batch firm planned orders as sources of demand Sources of Supply MRP considers the following as sources of supply Nettable quantity on hand QOH Purchase orders Intersite requests generated by DRP Manufacturing orders work orders and repetitive schedules System generated work orders resulting from flow scheduled orders Quality orders e Supplier scheduled orders M
267. in the cumulative orders selected for processing 1 Posts the value of the WIP queue inventory to the appropriate cost account When Transfer WIP is Yes this is the WIP Transfer account specified in Advanced Repetitive Accounting Control 36 9 12 When Transfer WIP is No this is the Method Change Variance account 2 Records the posting event by creating an operation history record of type Close 3 Changes the cumulative order status to Closed Transferring WIP When Transfer WIP is Yes the system transfers WIP queue quantities from each cumulative order operation that meets the following conditions The WIP quantity is not zero Advanced Repetitive 185 It has a corresponding operation record in the receiving cumulative order The system follows these steps to transfer WIP queue balances from closed cumulative orders to new orders 1 For each operation with a WIP quantity to transfer the system searches for an operation in the receiving order with the same operation code If it finds one it proceeds with the transfer Otherwise it ignores that operation and does not transfer the WIP Note For the system to transfer WIP to the first operation in the receiving order the corresponding operation in the transferring order must also be the first operation in addition to having the same operation code Unless both these conditions are met the system ignores the operation and does not transfer WIP 2 The system
268. in the Qty Scrapped and Qty Rejected fields Entering a value in this field has two effects The input queue quantity is reduced by the amount entered The output queue quantity is increased by the amount entered Components for the operation are backflushed by the quantities per unit extended by the quantity processed Qty Scrapped Reason Code Multi Entry Report scrap quantity along with the processed quantity Enter up to 10 scrap quantities and reason codes in a separate pop up Qty Rejected Reason Code Multi Entry Reject To Op Report reject quantity along with the processed quantity Enter up to 10 scrap quantities and reason codes in a separate pop up Reject To Op must reference either the current operation or the one that precedes it The default is the current operation Modify Backflush When Yes the Component Issue frame displays so you can modify the default list of sites locations lot and serial numbers and quantities used for component backflush and finished material receipt AQAD Advanced Repetitive 193 The component backflush logic considers the product structure in effect on the transaction effective date If components are added changed or removed from the current product structure during the life of a cumulative order and backflush transactions occur the differences cause material usage variances Product structure and routing changes can be phased into cumulative orders by setting the cumulative or
269. in the Work Orders module affected by WLT changes WIP Lot Trace 285 Processing a Work Order The workflow in Figure 10 19 shows two alternative methods of processing a work order The process consists of three steps Issue components to the work order Report labor performed Receive finished goods WLT frames are used to collect information at each of these steps when you process a WLT controlled work order A work order is WLT controlled when Trace Parents is Yes in WIP Lot Trace Control or AWLT BOM registration is active for the parent item being manufactured and Trace Parents is Yes for that registration Fig 10 19 Work Orders Create work orders or approve Workflow MRP planned orders Work Order Component Issue Labor Feedback by Work Order Work Order Operation Backflush Work Order Receipts i Work Order Accounting Close Assume that you trace WIP material through all work order operations First issue components to the first operation using Work Order Component Issue 16 10 Use these three WLT frames to collect WIP lot serial tracing information FAQAD 286 User Guide QAD Manufacturing b See page 287 b See page 284 b See page 277 b See page 275 and page 278 FAQAD Issued to WIP Lots Current Work Center and Machine WIP Lot Input Queue Issue Data Note Issued to WIP Lots is the only frame used when issuing
270. in the rework transaction is reported only if the WIP lot or serial numbers remained the same for the reworked material QAD 302 User Guide QAD Manufacturing FAQAD Report Menu Number Description WIP Lot 3 22 13 17 Displays WIP lot cumulative quantities by lot or Inquiry work order ID at each operation The cumulative totals displayed at each operation are for cumulative quantity produced consumed scrapped adjusted rejected reworked transferred in and transferred out Supplier Lot 3 22 13 18 Displays PO Receipt transactions for the selected Transaction item where a supplier s lot number was entered into Report the Supplier Lot number field Use the report to identify the supplier lot associated with an internally assigned lot WIP Lot 3 22 13 19 Generates a where used report for selected Where Used component or WIP material lots showing where Report WIP material or component lots were consumed and what material lots were produced from them WIP Lot Actual 3 22 13 20 Displays which material was used to make a WLT Bill Report tracked finished or WIP lot The report shows issue and receipt transactions related to the WIP or parent material y inspection of ent 305 lone Tests 310 spections 314 304 User Guide QAD Manufacturing Introduction The Quality Management module 19 enables you to test incoming material finished products and inventory insp
271. ine Allocation Maintenance 163 Line Changeover Maintenance 165 Line Schedule Workbench 169 co products by products 98 deleting sequence records 172 lead times 172 multiples 170 production quantities 171 sequence numbers 171 Line Utilization Report 172 lines production 161 list of status for components 240 load reporting 383 local phantoms 16 Lot Actual Bill Inquiry co products by products 89 Lot Actual Bill Report 302 lot control co products by products 88 lot numbers WIP Lot Trace custom number format 263 Lot Where Used Inquiry co products by products 89 Low Level Code Update 371 M manufacturing lead time 37 40 yield 41 master specifications 306 master production scheduling MPS 343 354 Index 395 available to promise ATP 345 computer assisted scheduling 344 creating schedule 343 fully automatic 343 fully manual scheduling 344 items for 343 360 master schedule orders 349 MRP use of 356 multilevel 346 multilevel scheduling techniques 349 planning bills 347 production forecast 348 repetitive schedules 350 seasonality 351 Master Schedule Detail Inquiry 354 Master Schedule Detail Report 354 Master Schedule Order Maintenance 105 344 350 Master Specification Maintenance 306 material requirements planning MRP 355 376 action messages 373 by products 77 co products by products 61 77 action messages 79 base processes 77 79 co products 77 80 planned order reports 80 planned work orders 80 summary reports 80
272. iner Maintenance rsctmt p 5 13 14 PO Shipper Maintenance rsshmt p 5 13 20 PO Shipper Receipt rsporc p Work Orders Table 10 3 shows the Work Orders programs affected by enabling the WIP Lot Trace module Table 10 3 Menu Description Program Work Orders Programs Affected 16 9 Work Order Split wowosp p by WLT 16 10 Work Order Component Issue wowois p FAQAD 256 User Guide QAD Manufacturing Menu Description Program 16 11 Work Order Receipt woworc p 16 12 Work Order Receipt Backflush wowoisrc p 16 19 Work Order Operation Backflush wobkfl p Shop Floor Control Table 10 4 shows the Shop Floor Control programs affected by enabling the WIP Lot Trace module Table 10 4 Shop Floor Menu Description Program Programs Affected by WLT 16 20 1 Labor Feedback By Work Order sfoptr01 p 16 20 2 Labor Feedback By Employee sfoptr02 p 16 20 3 Labor Feedback By Work Center sfoptr03 p 16 20 6 Operation Move Transaction sfoptr06 p 16 20 7 Operation Scrap Transaction sfscrap p 16 20 13 8 Operation Transaction Browse sfbr001 p 16 20 13 9 Operation Transaction Detail Inquiry sfopigq12 p 16 20 13 13 Operations by Work Center Report sfoprpll p 16 20 13 14 Operations by Work Order Report sfoprp12 p 16 20 13 15 Operations by Employee Report sfoprp13 p Standard Repetitive Table 10 5 shows the standard Repetitive programs affected by enabling the WIP Lot Trace module Table 10 5 Repetitive Menu Description Program Programs Affected Dn F by WLT
273. ing Characteristic Measure Results labor for the Purity Clear E m E zm E wor inspection Finish glossy n operation n After you enter the quantities accepted and rejected for an operation the system prompts you to record results and comments The system compares your entry with the specification for the result If the result is out of tolerance a warning displays As with quality orders you can enter only one result per specification Enter additional information as comments If you have several samples you may want to enter the best worst or typical case for each group During inspection process material remains in WIP After an inspection is complete material moves to the next operation From the last operation the accepted material is received back into inventory and rejected material is scrapped Figure 11 10 illustrates the process inspection FAQAD 316 User Guide QAD Manufacturing Fig 11 10 Process Inspection b See Defining Sampling Patterns on page 309 for more details FAQAD Routing 108A Operation 10 20 30 Inspection Manufacturing Order Work Order or Repetitive Schedule Specification Order 95 Item 108 Routing 108A Item 108 Procedure 500 Operation 30 No Specification Results 1 Voltage 2 Current 3 Noise Conducting Other Tests You can use quality orders to conduct other specialized kinds of tests Inventory Audits Materia
274. ing 50 the quantity to issue for a component with a Qty Per of 1 is 50 When this is the only special condition leave Quantity Calculation Method set to Component Required Quantity FAQAD 130 User Guide QAD Manufacturing FAQAD A variation on the previous example occurs when you complete a partial receipt and then modify the Qty Required and or the Qty Per values for a component in Work Order Bill Maintenance 16 13 1 For the quantity to issue calculation to take into account full requirements for prior completions use Net of Prior Issues and Receipts in the Backflush Method field Otherwise the quantity to issue reflects component requirements for the open order quantity only The last instance occurs when you change the work order bill Qty Per for a component without recalculating the quantity required To recalculate the quantity to issue including the revised component Qty Per use the Work Order Bill Qty Per in the Quantity Calculation Method field Example The work order bill quantity is reset from 1 0 to 1 5 on an order for 100 With a calculation method of Work Order Bill Qty Per the quantity to issue is 150 Otherwise it remains 100 If this is the only special condition on an order leave Backflush Method set to Standard Backflush If you have a combination of the two circumstances use Net of Prior Issues and Receipts and Work Order Bill Qty Per Use the Component Required Quantity option for the Quantity Cal
275. ing Maintenance 1 4 17 Set up alternate base processes using Alternate Structure Maintenance 13 15 Item Number Enter the co product item number BOM Formula Enter the base process item number Setting Up Alternate Base Process Routings Alternate routings are useful for managing variations in the manufacturing process of an item For example a substitute machine is used while the primary machine for a process is being repaired Like routings for regular items alternate routings for co products are assigned when work orders are generated Routings are not required and are not used in MRP or for developing standard costs Only a base process can have alternate processes or routings This is not true for co products and by products because they do not have a formula or process independent of the base process Define alternate routings for a base process in Alternate Routing Maintenance 14 15 1 Item Number Enter the base process item number Routing Code Enter the alternate routing number previously defined in Routing Maintenance 14 13 1 or Process Definition Maintenance 15 13 Bill of Material Leave blank FAQAD 68 User Guide QAD Manufacturing b See User Guide QAD Master Data for details on the Regulatory Attributes module FAQAD Setting Up Definitions for Valid Substitute Items Receipt of items on joint work orders is not limited to items set up as co products or by products of a base proce
276. ing Subcontract Purchase Orders Before you can delete or archive a closed subcontract order you must follow these steps to ensure that all records associated with the subcontract order are also deleted 1 Delete all releases for the subcontract schedule in Schedule Maintenance 5 5 3 3 Note You can use Schedule Delete Archive 5 5 3 23 to delete all releases when there are a large number of schedule releases 2 Delete the MRP percentage in Subcontract Order MRP Maint 5 5 1 21 3 Delete records in Subcontract Routing Op PO Maint 5 11 4 Delete the subcontract scheduled order with Closed PO Delete Archive You can use Closed PO Delete Archive to delete and archive subcontractor purchase orders that do not have an associated active or inactive schedule FAQAD 226 User Guide QAD Manufacturing b See Connecting Shippers to Received Items on page 216 b See Moving Finished Subcontract Items to Inventory on page 224 AQAD Subcontract Shipping Limitations in API Mode When using programs in application programming interface API mode the user interface is suppressed therefore the Subcontract Shippers frame and Receipt Data Input frame do not display when you receive subcontracted goods in Purchase Order Receipts 5 13 1 PO Shipper Receipt 5 5 511 Without the Subcontract Shippers frame displaying you cannot Scrap material Manually record a partial or full receipt against a subc
277. intenance 14 1 to set up departments You must define at least one department before setting up work centers or routings Account numbers default from Domain Account Control 36 9 24 The Default Sub Account Cost Center and Override fields let you enter the same sub account or cost center code for all accounts in a department These fields are useful if you use standard account codes but differentiate departments with sub accounts or cost centers Fig 3 2 zx Department Department Maintenance Go To Actions Maintenance 14 1 Department 15 Default Sub Account 10 2 Override CRP uses this Default Cost Center P Override to calculate Description Assembly over and Labor Capacity 14 Cost of Production 6300 under capacity Labor 6500 conditions Burden 6400 Labor Usage Variance Acct 6850 Labor Rate Variance Acct 6800 Burden Usage Variance 6470 Burden Rate Variance 6460 Work Centers A work center is a group of people and or machines Work centers also link departments with routing operations Work centers are the basic unit for operation scheduling and CRP Depending on how you plan and schedule work you can set up work centers for an individual machine or for groups of similar machines If for example there are separate machines for polishing plastic lenses and polishing glass lenses they would be set up as separate work centers The system uses work centers for scheduling planning and
278. ion 18 22 21 to adjust quantities at an operation s input output or reject queues The current queue balances display when you run the program When you adjust the output or reject queues you change their balances at the current operation When you adjust the input queue the net change is made to the prior operation s output queue as well as to the current operation s input queue Each adjustment creates operation history records and generates GL transactions A queue increase debits WIP and credits the Inventory Discrepancy account Negative adjustments credit WIP and debit the Inventory Discrepancy account You can designate a GL account sub account and cost center for the transaction The default is the Inventory Discrepancy account from Product Line Maintenance 1 2 1 or Inventory Account Maintenance 1 2 13 FAQAD 196 User Guide QAD Manufacturing b See Managing Cumulative Orders on page 181 FAQAD Open schedule quantities are also updated by this transaction Increases in the balances of the final operation s output queue increase scheduled completions and vice versa Move Transaction Move Transaction 18 22 19 transfers quantities from an operation s output queue to the following operation s input queue For the final operation items are moved to finished material inventory In this case the Modify Receipt field lets you modify the default list of sites locations lot and serial numbers
279. ion You can use a master specification as a template You can change and add to the information that comes from a master specification An item specification can list several characteristics and specifications but only for a single item and a single operation Also a quality control operation is linked to only one item specification Each specification can include any number of steps indicated by the Number field If several item specifications are required to inspect an item they must be spread out over several operations one operation for each specification QAD 308 User Guide QAD Manufacturing Fig 11 4 Item Specification Maintenance 19 1 13 b See User Guide QAD Master Data for information about the PCC module b See Executing Stand Alone Tests on page 310 FAQAD x Item Specification Maintenance Go To Actions Item Number WLT18 P1 WIP Lot Std Rep Routing Procedure WLT18 P1 Operation 10 Document PROC 111 Standard Test Procedure Number 1 Start Effective Characteristic Attribute Test Method Specification gt 99 9 Measure Start Effective v End Effective y Comments If an item does not have a routing or procedure you can still link it toa specification by leaving Routing Procedure blank and Operation as zero the default Use specifications to record information about sample size For instance you can set up an item specification with three test steps
280. ion Message Review Update 373 co products by products 79 action messages material requirements planning MRP 373 Actual Pay Rate Maintenance labor rate 141 Adjust Valuation Report 200 advanced repetitive 153 226 adding operations and 120 backflush transactions 156 changeover times 165 consume earliest open 157 contrast with repetitive 154 creating schedules 173 Cumulative Completed Maintenance 157 cumulative orders 181 End Eff Days field 159 line schedule simulations 169 Index 389 milestone operations 167 MRP planned orders 171 picklists 175 production lines 161 reports 199 routings 166 schedules creating 173 explosion 175 subcontracts 200 processing 156 tracing WIP 291 293 transactions 186 backflush 187 191 common data 187 common information 187 labor 193 method change variance 190 post accumulated usage variances 196 rate variance 189 reject 193 rework 194 scrap 195 WIP adjust 195 updating schedules 173 warning messages 189 Advanced Repetitive Accounting Control 158 Advanced Repetitive Backflush 204 Advanced Repetitive defaults 206 advanced repetitive scheduled orders 204 Advanced Repetitive Scrap Transaction 210 allocate production line percentages 163 Allocated status work orders 240 allocated work orders 113 alpha factor forecasting 327 alternate base processes 67 work orders for 84 formulas 15 routings 36 base process 67 structures 15 Alternate Routing Maintenance 15 36 co products by products 67
281. iple sites you can set up planning data differently for each site using Item Site Planning Maintenance 1 4 17 Data not defined in Item Site Planning Maintenance defaults from Item Master Maintenance or Item Planning Maintenance Item Planning Maintenance X Item Go To ACTIONS Item Number P Description Unit of Measure Item Planning Data Mstr Sched F Buyer Planner Phantom M Plan Orders F Supplier Minimum Order Time Fence PO Site Maximum Order MRP Required F Purchase Manufacture Order Multiple Order Policy Configuration Type Op Based Yield Order Qty Inspect uH Yield Percent Batch Qty Ins LT Cum LT Run Time Order Period Mfg LT Pur LT Setup Time Safety Stock EMT Type Safety Time ATP Enforcement Auto EMT Processing F Reorder Point Family ATP F Network Code Item Rev ATP Harizon Routing Code Issue Policy I Run Seq 1 BOM Formula 2 Master Schedule For non master scheduled items planned by MRP set Master Schedule to No This lets you plan master scheduled and MRP planned items separately if required using Selective Materials Plan 23 3 Items with Master Schedule set to No are excluded from reports and inquiries in the Forecasting Master Plan 22 module For master scheduled items set Master Schedule to Yes Items subject to independent demand such as end products or service parts are usually master scheduled Material Requirements Planning 361 Plan Orders When P
282. ippers frame to display in Purchase ee 208 on Order Receipt 5 13 1 or Purchase Order Returns 5 13 7 2 In Subcontract Shipping Control set Scrap Unreturned Material to Yes This lets you enter a scrap quantity in the Subcontract Shippers frame when you receive or return items and update a subcontract shipper with the scrap quantity Note The Subcontract Shippers frame also displays in PO Shipper Maintenance 5 5 5 5 or 5 13 14 however you cannot enter scrap quantities in the frame and the Scrap Details frame does not display 3 Inthe Subcontract Shippers frame enter the quantity you are short in the Scrap Qty field Fig 8 26 tx Subcontract DD NY U90 5 19 7 Purchose Order Returns 09 12 07 GoTo ACTIONS Shippers Frame Scrap Quantity Purchase Order 3cp2A Susplier SIPOL Status RTV br Field Subcontract Shippors Shipper Number Lot Serial Reference Open Qty Receipt Qty 5H01 80 00 0 00 Shipper Number 5H 1 Lot Serial Ry ference Receipt Quantity 3 0 Scrap Quantity 9 Close Sub Shippar f Comments f SCRAP DETAILS Employee Shift Queue Reason Code Set Subcontract Shipping Control option to edit this field then enter the quantity to scrap The system informs you that unreceived quantities for subcontract shipper items will be scrapped and prompts you to continue FAQAD 222 User Guide QAD Manufacturing Note If you enter a quantity that equals the open quantity the system closes the subcontract
283. ish planning bills and forecast and master schedule at the family item level the system automatically calculates the derived demand for components of the family or upper level item These calculations are based on the ATP quantities for the family level item and the quantity per and forecast percentage for the components of that family item The result is called a production forecast since it derives from the master production schedule and the forecast percentage specified in the planning bill Production forecasts are only created for components with structure codes P and O Production forecast amounts display in MPS reports and inquiries and contribute to the total demand that MRP regards as input As forecast for the family level item is consumed the ATP quantity for that item changes resulting in revised calculations for the production forecast the next time MRP is run Forecasting Master Schedule Planning 349 Fig 12 10 Multilevel Master Forecast Independent Family item Level ype Scheduling Example Pianning ltem Level Model A Model B Model C Keyboard Structure Type P 20 30 50 100 roduction Forecast Dependent 7 Standard Extended e ai mM Keyboard Keyboard Us 25 75 Multilevel Scheduling Techniques When using multilevel master scheduling you can plan family level P See Approaches items using either the fully automatic or the computer assisted technique Scheduli
284. it runs out Afterward the system explodes the product structure formula to pick the new coating material There are three trade offs to doing this Product costs and cumulative lead times are not calculated correctly Phantom use up logic is not used when backflushing components in the Repetitive module However it is used when backflushing work orders and in Receipts Backward Exploded 3 12 The product structure will not conform to the engineering structure so the where used and product structure programs will be less accurate Avoid these potential problems by managing the use of effective dates for engineering changes FAQAD Stan Routings 26 User Guide QAD Manufacturing FAQAD Introduction To manufacture an item or product you must complete one or more activities or operations The list of required operations is called a routing which basically defines the process needed to make the item If a product structure is the list of ingredients in a recipe a routing is the directions The routing operations indicate the machines expected times and instructions for completing specific tasks For example in manufacturing sunglass lenses there might be a routing with four operations with instructions to grind polish tint and coat the lenses These would be separate operations because they involve different machines tools skills and tasks In the Shop Floor Control and Repetitive modules you recor
285. items only Available to Promise Available to promise ATP is the uncommitted portion of inventory or planned production available to be promised to new sales orders The system displays ATP quantities on master schedule reports and inquiries ATP can be used to verify whether a sales order can be filled within a specific time frame given other demands and currently scheduled supply orders By setting ATP Enforcement to Yes in Sales Order Control 7 1 24 and associating an ATP enforcement level with individual items you can have the system check ATP during order entry and display a warning or error message when ATP is inadequate for the due date b See User Guide QAD Sales for information on ATP processing FAQAD 346 User Guide QAD Manufacturing b See page 351 b See Generating Master Schedule Reports on page 353 FAQAD The system calculates ATP by time period by deducting real demand from real supply Real demand includes requirements for work order components sales orders and required ship schedules but excludes forecast and production forecast Real supply includes quantity on hand purchase orders work orders and repetitive schedules A net decrease in demand increases ATP while a net increase in demand decreases ATP Note The system regards seasonal build quantities as real demand The system performs the following calculation for each date when a Master Scheduled receipt is due or a seasonal build
286. ject units from an operation s input queue and record the reject at the previous operation Enter up to 10 different reject codes at a time You cannot report hours and no backflushing takes place Use Backflush Transaction 18 22 13 for most reject reporting This transaction backflushes the rejected units and records all costs at the operation When you use this transaction to report rejects at a milestone operation the quantity must be in the input queue of the current operation or in the input or output queues of prior non milestone operations Note If you are rejecting with backflush at a non milestone operation the quantity to be rejected must be in the input queue of that non milestone operation Rework Transaction When you first report rejected quantities use the Reject To Op field in Backflush Transaction 18 22 13 or the To Operation field in Reject Transaction 18 22 16 to send the quantity to the operation where rework occurs In WIP Status Inquiry 18 22 12 the rejected quantities appear as negative numbers in the output queue of the operation where the reject occurred and as a positive number in the reject queue of the receiving operation Reworked units are backflushed at the operation rejecting them After reworking items use Rework Transaction 18 22 17 to move the reworked items back into the production line Use the To Operation and To Queue fields to select the operation and queue typically one of the follo
287. k by Item Work Order to quickly identify the components they manage and determine if there are shortages that impact production Material managers or expediters typically use this program to ensure that there are no component shortages for scheduled production orders They can view a list of items and the jobs work orders that are impacted by item shortages Having this information helps keep production running and expedites order processing Material planners use Component Check by Item Work Order to Select from a wide range of item attributes to include in the component check such as buyer planner codes Identify which items have component or material shortages related to them Identify the work order to which the shortage is related Locate and determine the cause of material shortages FAQAD 246 User Guide QAD Manufacturing Fig 9 8 Component Check by Item Work Order AQAD empenert Check By emfelo Seach Wes abes mma gt F E pen en Viewing 1 100 of 1218 Records p pape 100 290t Dem Number Descroton Puchae Mandaae Quantity Open Component uus Component Status PramctedNettwalable fes Date DueDae DS Wok Onder Seats Hem Number 12 WO Come Avaiabiity Susph Demand Summary WO Component fvaiat ty Calculation Details inventory Deted by Site Browse Schede Recon Recaiculste Capaciy Plan A Aches Sy Pret Wy AddtoFavertes ly I Chet Denigrer
288. k orders frequently streamline the process by 1 Creating a product line with account numbers for this type of work 2 Creating an item of type E to use for expense orders Define a blank order quantity to prevent planning functions from treating it like a normal item 3 Creating a status code that restricts all inventory transactions and assign it to the item Work Orders 109 Scheduled Work Orders Scheduled work orders are generated by the system when repetitive P See Chapter 8 schedules are entered Like standard work orders they have a standard jdn nd work order bill and routing Chapter 9 Repetitive for A scheduled work order cannot be processed as a standard work order more information on scheduled unless you change its status to Allocated or Released Changing a orders scheduled order to a regular order automatically updates the repetitive schedule to exclude it however the work order type remains Scheduled Cumulative Work Orders Cumulative orders are generated by the system to track repetitive See Managing production costs They cannot be processed using work order functions e E page 181 Routable Work Orders The system manages one other kind of work order that is not represented by a separate type code Subassemblies can be set up so that work orders are automatically created for them when a parent item is allocated or released using Work Order Release Print 16 6 Multiple Work Order Re
289. k orders with status A Ilocated and R eleased only The system considers the status of a work order Work orders can have a status of P lanned FAQAD Repetitive 241 Firm B atch B xploded A llocated R eleased The system groups the work order statuses into three commitment categories when calculating component availability Planned work orders are in the Plan category Firm Batch and Exploded work orders are in the Firm category Allocated and Released work orders are in the Release category Demand Supply Browse These categories correspond to the three PQOH columns that display in the Supply Demand Detail Browse Fig 9 4 Supply Demand Columns correspond to WO Detail Browse commitment categories PQOH Columns hal 1 Supply Demand Summary Supply Demand Details Inventory Detail by Site x Actions Print lly Chart 8 Chart Designer Viewing 1 100 of 2000 Records per page 100 DOA WOIDRef WORef Componentltem Date 1136 ca633644a GrossReq Gross Supply Alloc PQOH Fi PQOH Plan PQOH Source 0 0 0 0 0 0 Beginning Available 11 07 2007 10 0 10 0 V 04 01 2008 Work Order Component 0 0 Work Order ca633644a They system uses the commitment category to determine into which PQOH column it compiles the work order Use the information in Supply Demand Detail to view MRP supply and demand detail data for a compone
290. l for comparing production progress with production plans Receiving Work Orders When a work order is completed on the shop floor the items are typically sent to the stockroom Use Work Order Receipt 16 11 to receive items close the order and backflush components of final assembly work orders If you did not issue items previously issue them when completed products are received with Work Order Receipt Backflush 16 12 Use Work Order Operation Backflush 16 19 to issue items report labor and receive completed items at an operation If you use the Shop Floor Control module you can enter labor feedback and test results at receipt and report individual operations as completed When a work order is received nventory increases by the amount of the receipt FAQAD 128 User Guide QAD Manufacturing b See User Guide QAD Master Data P See Closing Work Orders on page 134 AQAD The open order quantity decreases by the amount of the receipt Any reject quantity is written off to the Scrap account and not placed in inventory If Auto Lot Numbers is Yes in Item Inventory Data Maintenance 1 4 5 the system automatically assigns the work order ID as the lot number for inventory received from a work order This is true regardless of the value of Lot Serial Control for the item Note If you are using the Regulatory Attributes module you can set up lot groups for assigning automatic numbers
291. l from the prior operation to the subcontract operation X Backflush Transaction Go To Actions Employee MFSO1 Effective 06 18 2007 Shift Site 10000 Item Number WLT18 P1 WIP Lot Std Rep Operation 10 Line 1000 Repetitive Production Li Routing WLT18 P1 BOM Code WLT18 P1 ID 129 Work Center 10000 Machine General 1 Department 10 P General Qty Processed 0 0 UM EA 2 Conversion 1 0000 Qty Scrapped 0 0 Reason Code P Multi Entry F Qty Rejected 0 0 Reason Code P Multi Entry Reject To Op 10 Modify Backflush Move Next opir Actual Run Time D O Start Time Earning Code Elapsed or Stop Time S No f b Updates subcontract purchase et to No for subcontract operations orders with thie ID Advanced Repetitive 213 Creating Subcontract Shippers Use Sub Shipper Maintenance 18 22 5 5 to create shippers for shipment of items to subcontractors The subcontract shipper can consist of container items WIP items and the components used at this operation that are also being shipped to the subcontractor You specify only one subcontractor per subcontract shipper Identify the subcontractor in the Ship To Dock field in the header frame You indicate the correct work order or cumulative ID routing operation item production line and other data pertinent to this subcontractor shipment in the Contents Items frame You can use the subcontractor data in the Contents Items frame for a P
292. l record To use this function you must specify a source forecast ID identifying the forecast detail record to copy to or combine with the target record and a target forecast ID identifying the forecast detail record to which the source information is copied A criteria template must exist for the specified source forecast ID The target forecast ID you specify does not need to correspond to an existing forecast detail record or criteria template If a corresponding record does exist for the specified target ID its forecast method must be 00 If no such record exists the system creates a target forecast detail record with a method of 00 If you want to copy detail records for a subset of the items in the source record you can also specify an item range to be copied Note If the item ranges for the target and source records differ then the target record s range is expanded The system combines or copies forecast records only in terms of item units The Combine Replace field indicates whether to replace the target forecast quantity with the source quantity or combine the target and source quantities When you combine forecast quantities the quantity for an item in the source detail record is added to the quantity for that item in the target detail record When you replace forecast quantities the quantity for an item in the source record replaces the quantity for that item in the target detail record Note You cannot separate combined f
293. l subject to an inventory audit is like material processed by incoming inspection Both use quality orders and material never leaves inventory The difference is that material is selected from inventory for audit based on criteria such as expiration date or item Use inventory sampling patterns to determine which items are to be audited Sampling is based on expiration dates or lot intervals You can also use Inventory Detail Report 3 6 5 to identify inventory items based on expiration date site location assay percentage or grade It is not always practical to move an entire lot from inventory for testing As an alternative you can test a sample and leave the remainder in inventory To prevent these from being issued or transferred before results are available change the inventory status to a code that restricts issues or transfers Quality Management 317 The quantity for a quality order must reflect the quantity of an item moved to inspection for testing This quantity is the same as the lot size if an entire lot is moved to inspection and it is the lot sample size if only a portion is tested First Article Inspection First article inspections are used to qualify a machine a tool or the setup of a machine or tool by determining whether it can produce items within design limits It is assumed that if a few items can be produced correctly the machine or tool is set up properly First article inspection differs from regular inspe
294. la when it is a base process item should be the same as the UM in the item master for the base process Fig 4 3 T Formula Code Formula Code Maintenance Go To Actions Maintenance 15 1 BOM Code BRACKBCT4 None 00 Description EMINA 108 Batch Size 1 0 UM EA Formula v Comments Formula Copy 15 8 creates a new formula by copying another one useful when items share similar formulas or to create alternates If the destination structure already has components the system displays a warning and prompts you to continue Using the Combine Common Components field you can choose to either combine or overwrite the existing item quantity components being transferred from the source to the destination structure After copying use Formula Maintenance to modify the new formula by adding deleting or changing requirements FAQAD 50 User Guide QAD Manufacturing b See page 34 Fig 4 4 Process Definition Maintenance 15 13 AQAD Defining Processes A process like a routing is a sequence of steps to follow in the production of an item A process definition however defines its control information in terms of a batch rather than a completed unit Process Definition Maintenance 15 13 is very similar to Routing Maintenance Only a few fields are different zE Process Definition Maintenance Go To Actions Routing Code PAI n Operation 0 Batch Quantity 1 0 Start Date Ni End Date
295. lan Orders is Yes and a value is specified in the Order Policy field MRP generates planned purchase and work orders to satisfy net requirements for this item If Plan Orders is No and an order policy is specified MRP plans this item but does not generate planned orders for it Only action messages suggesting orders that should be placed are generated Pur Mfg Code MRP uses the Pur Mfg code to distinguish manufactured items from purchased items A code of Manufactured Routable Configurable Family Line Flow or blank indicates that an item is usually manufactured while a code of Purchased indicates that it is usually purchased MRP generates planned work or line orders for manufactured items and planned purchase orders for purchased items However you can create and approve planned work or line orders for purchased items or planned purchase orders for manufactured items This field indicates only what the normal procedure is not what it must be Run Sequences Run sequences are used when MRP planned orders are approved for line manufacture using Planned Repetitive Schedule Approve 23 8 If multiple items are produced on a single production line efficiency can be improved by producing the items in a certain order Run sequences let you control the order or sequence in which items are scheduled on a production line An item s run sequences are sorted by primary run sequence and then secondary run sequence A two digit num
296. lances and generates tracing records for components WIP material issued and WIP material produced Location and tracing information is entered in three WLT frames Current Work Center and Machine WIP Lot Input Queue Issue Data Issued to WIP Lots The Issued to WIP Lots frame appears when the operation s output queue is WLT controlled This WLT frame appears only in Work Order Component Issue Use it to specify the produced WIP lot serials to which the specified components and WIP material are being issued The WIP material to be issued is specified in the WIP Lot Input Queue Issue Data frame that appears immediately before this frame Reporting Labor The three Shop Floor Control labor feedback programs use the WLT Destination Work Center and Machine and WIP Lot Output Queue Receipt Data frames to capture tracing information for the labor being reported Labor Feedback By Work Order 16 20 1 Labor Feedback By Employee 16 20 2 Labor Feedback By Work Center 16 20 3 These labor feedback programs perform the following WLT functions Prompt for WIP lot serial produced Update and record WIP lot serial QOH balances for affected queues Record labor feedback and lot serial tracing information Issued To WIP Lots Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial Lot Serial WIP Lot Trace 287 b See page 284 b See page 277 Fig 10 2
297. lanned orders for the other co products of the base process are also created Reviewing Updating and Reporting Action Messages MRP creates action messages for base processes and co products but not for by products Action Message Review Update 23 5 and Action Message Report 23 7 allow reporting of action messages using various selection criteria including BOM Formula code You can also exclude action messages for base process orders FAQAD 80 User Guide QAD Manufacturing FAQAD Approving Planned Work Orders To approve planned work orders use Planned Work Order Approval 23 10 Specify base processes by entering a BOM Formula code range This program changes the status on all orders in a joint set from Planned to Firm The joint set is not updated based on effectivity dates for the co product by product structure as is done when using Work Order Maintenance or Multiple Work Order Status Change and work order detail is not re created When a planned purchase order is approved the system creates a regular firm planned work order even if the item has a BOM Formula code for a base process If an MRP planned order is originally purchased MRP does not create a joint order set when it is approved as a work order Creating Planned Order Reports To create planned order reports use Planned Order Report 23 12 To support features related to base processes you can Select planned orders by BOM Formula code Include e
298. lanning 351 Note When a scheduled order is converted to a regular work order it is no longer part of the repetitive schedule Verifying Capacity for Master Schedules You can verify master schedule orders against user defined resources as for product lines using the Resource Plan module The resource plan functions convert ordered end item quantities into resource units to calculate resource consumption You can also verify capacity for master schedule orders by department work center or machine using the Capacity Requirements Planning CRP functions Master Scheduling for Seasonality For products with seasonal demand cycles you may need to build up inventory in advance of periods of peak demand You can do this using work orders or repetitive schedules or you can use seasonal build requirements to build up inventory to a predetermined level prior to its expected demand Seasonal build requirements let master schedulers specify a target inventory level for seasonal demand items that is not included when calculating ATP quantities but can still be allocated and shipped on sales orders and customer schedules Seasonal build quantities appear separately on master schedule reports that display ATP quantities Example 600 snowmobiles are scheduled to be completed in July due to a seasonal build requirement A rush order for 200 snowmobiles arrives from Australia for shipment in July The current production of snowmobiles would not
299. lanning Data frame Batch Qty This is established in Formula Code Maintenance 15 1 or Process Formula Maintenance 15 18 Plan Orders Enter Yes Co products and By products 61 Order Policy Enter POQ or FOQ MRP does not use LFL or OTO for base processes Pur Mfg Code Enter M manufactured or leave blank BOM Formula Leave blank A base process item cannot refer to another BOM Formula Phantom Enter No Setting Up Items for Co products and By products Create items for co products and by products using standard procedures For co products it is important to set the BOM Formula field equal to a base process item number In Item Master Maintenance 1 4 1 Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 enter the following for each co product and by product of a given base process Item Number Enter an item number for the co product or by product Planning Parameters Normally you accept default values for these fields MRP does not use planning parameters for co products Instead it uses the parameters of the base process MRP does not plan the base process to satisfy demand for a by product Rather it plans by products using the conventional method Pur Mfg Leave blank or enter M manufactured for co products Enter any value for by products BOM Formula Enter the item number for the base process normally used to produce this co product or by product This field is used for pl
300. le Subcontractors Follow the procedure for a single subcontractor with the following additional steps Create a separate subcontract purchase order for each subcontractor being used at the work order operation When you issue the components and WIP for the subcontract operation use the WLT Current Work Center and Machine frame to specify the specific subcontractor that will process the operation Use the WIP Lot Inventory Status Report 3 22 13 13 to see where specific WIP and item component material reside during manufacturing Using WLT with Advanced Repetitive The following sections describe the Advanced Repetitive programs affected by WLT changes Backflushing WIP Material Use Backflush Transaction 18 22 13 to report production activity This program uses five frames to collect WLT information WLT frames appear and are used only when backflushing operations for WLT controlled routings b See Receiving Subcontract POs on page 295 for details b See Processing a Subcontract WO Operation on page 290 FAQAD 292 User Guide QAD Manufacturing b See page 277 b See page 275 b See page 278 b See page 278 b See page 279 P See page 281 b See page 275 and page 282 FAQAD Use the WLT frames to record WIP material lot serial information for the current operation s input output scrap and reject queues Use the Destination Work Center and Machine frame to specify where the produced
301. lease Print 16 7 To do this set the Pur Mfg code for the item to Routable in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 A work order for a routable item has the same number as the parent work order but a unique work order ID These work orders can be allocated released and used for processing component issues inventory receipts and shop floor control transactions When the subassembly is finished Process a work order receipt from the routable work order Then issue the subassembly as a component to the parent work order FAQAD 110 User Guide QAD Manufacturing Flow Work Order Flow work orders are generated by the system when flow scheduled orders are entered and do not include a reference to an existing standard work order Like standard work orders they have a standard work order bill and routing A flow work order cannot be processed as a standard work order It is automatically updated when you process the associated flow scheduled order Work Order Status Work order status codes correspond to stages in a work order s life cycle Planned Firm planned Batch Exploded Allocated Released Closed The status of a work order determines how much control you have over its bill routing inventory allocations inventory transactions and labor feedback You cannot make any changes to orders with status Planned These are managed by MRP For orders with status Firm Pla
302. lect closed work orders and print summary data on each use Work Order History Report 16 3 6 You have the option to print bill of material detail or routing detail To print joint order sets set Print Co By Product Orders to Yes If Yes the report displays information for each of the co product and by product orders for a base process work order To print information for each order related to a base process work order use Work Order WIP Cost Report 16 3 5 To print information on items received and scrapped from a joint order set use Work Order Cost Report 16 3 4 These reports show the costs for joint order sets once they have been closed in Work Order Accounting Close 16 21 Receiving Scrapping and Backflushing To receive and scrap co product and by products in a joint order set use Work Order Receipt 16 11 Work Order Receipt Backflush 16 12 or Work Order Operation Backflush 16 19 You can initiate these programs using any work order in a joint order set In Work Order Receipt 16 11 Work Order Enter any work order number in the joint order set ID Enter the specific ID desired or leave blank to retrieve the first ID in the joint order set Receive All Co By Products Enter Yes if all co products and by products are to be received Enter No if only this particular order is to be received This prompt only applies if the order being received is not for the base process When the base process order is received
303. losed Co product costs are re averaged based on any WIP costs accumulated by this process Costs can be accumulated when the Work Order Accounting Close program closes any work order operations that have not been closed Costs are not re averaged for quantities received to sites other than the work order WIP site Receipts are handled in two ways depending on whether the work order status is closed or not closed Not closed Co product costs are not re averaged Items are received to the work order WIP site using current average costs These costs are deducted from WIP If quantities are received at a different site they are received at the work order WIP site using current average costs then transferred to the indicated site QAD 76 User Guide QAD Manufacturing FAQAD Closed Co product costs are re averaged Items are received to the work order WIP site using current average costs These costs are deducted from WIP The re averaging process takes into account quantities received during previous receipt transactions for the same work order If quantities are received to a different site than the work order WIP site it is likely that the inventory quantity on hand is less than the quantity received This increases the chance that some of the costs cannot be allocated and re averaged at the WIP site and that costs will be booked to the Inventory Discrepancy account for the base process To maximize the accuracy of average c
304. lost or unusable as a result of the manufacturing process There are two ways to anticipate this loss Use the scrap factor Change the component quantity per The scrap factor is the percentage of a component expected to be lost during manufacturing The system uses this with the quantity per to calculate component requirements for work orders and MRP When a scrap factor is used component quantities are almost always extended into fractional amounts and not whole units making it difficult to use with items always handled in discrete quantities Product Structures 19 Example One left lens is required for a pair of sunglasses and the scrap factor is 5 The system calculates a requirement for 105 2631 left lenses to make 100 sunglasses Using scrap percentages other than zero promotes waste and can conceal quality problems If additional quantities are consistently required consider changing the component quantity per directly This avoids the problem of fractional quantities but may result in even greater waste than using the scrap factor Continuing the example of the sunglasses it is not realistic to change the quantity per on the left lens to 2 If you did so the system would always plan that 200 left lenses would be necessary to make 100 pairs of sunglasses Structure Type Product structure relationships normally have a blank structure type code Other codes are used for special applications Code Description Blank A n
305. lts as the input lot serial number in the WIP Lot Input Queue Issue Data frame in Purchase Order Receipts when the order is being received This value also prints on reports generated by Purchase Order Print 5 10 WIP Lot Trace 295 Receiving Subcontract POs Purchase Order Receipts 5 13 1 captures line item receipt data for subcontract type lines that reference Advanced Repetitive cumulative order operations that are WLT controlled This program cannot be used to backflush lot serial controlled components or components that cannot be issued from the default issue location Use Backflush Transaction 18 22 13 to manually backflush the operation for the component material received If you attempt to receive this type of component material only the extended subcontract cost for the PO is added to the cumulative order operation s cumulative subcontract cost Use the WIP Lot Input Queue Issue Data frame to enter details of the WIP material being consumed from the input queue of the subcontract operation Use the WIP Lot Output Queue Receipt Data frames to record details of the material being produced and moved to the output queue of this subcontract operation The system backflushes these WIP lot serial numbers The input WIP lot serials are consumed and the output WIP lot serials are produced WIP lot serial QOH balances cumulative totals and tracing history records are updated accordingly The supplier ID is used as the work center I
306. ly Machine Op Status UM EA Conv 1 0000 Assembly Quantity Reason 0 0 0 0 0 0 0 0 0 0 0 0 Closing Operations You can close an operation by running Operation Complete Transaction 16 20 5 Quantity completed for an operation needs to be entered in any of the Labor Feedback Transactions by Work Order Employee or Work Center Setting Previous Ops Complete to Yes closes all previous open operations For these operations the system reflects quantity completed at the current operation being closed The system calculates labor using the standard setup and run times for the change in completed quantity in prior operations FAQAD Shop Floor Control 147 Fig 7 4 x Operation Operation Complete Transaction Go To Actions Complete Transaction 16 20 5 Work Order mat100 P ID 43 2 Item Number 1 BB Red Bean Bag Operation 10 Operation Status COMPLETE Work Center 100 01 Machine Department 100 Project Quantity Ordered 5 0 Quantity Completed 0 0 Qty Rejected 0 0 Effective Date 02 22 2007 Previous Ops Complete I Comment For example if a work order has five open operations 10 20 30 40 and 50 and no completions were reported for any of these operations when operation 50 is closed for a quantity of 100 the system optionally closes operations 10 20 30 and 40 for 100 units However if operation 50 is closed for 75 units and 90 units had been previously reported as complete at o
307. m generating planned orders for fractional quantities set Order Minimum or Order Multiple to 1 or any whole number Lead time determines when MRP planned orders are due manufacturing lead time for manufactured items and purchasing lead time plus inspection lead time for purchased items Material Requirements Planning 365 For both purchased and manufactured items if the lead time varies you can define a safety time MRP then calculates the planned order due date by adding safety time to the lead time Table 13 4 Lead Time Description Lead Times Manufacturing Lead Time The number of working days it takes to manufacture an item including the time it takes to process paperwork issue components inspect the finished product and receive it into stock For DRP items enter DRP transit and order time in this field so that this value is included in the cumulative lead time for this item Purchasing Lead Time The number of calendar days it takes to complete a purchasing cycle for an item from the date the need for a purchase is recognized to the date the item is received Inspection Lead Time The number of working days it takes to inspect a purchased item after it is received Safety Lead Time The number of working days early that MRP plans to receive orders for an item to allow for late deliveries Cumulative Lead Time The longest number of calendar days it takes to obtain an item assuming that neither it nor any of its co
308. m Base Process B For Base Process A cost allocation percentages are Co product 1 Pitted Prunes 80 Co product 2 Prune Juice 0 Co product 3 Prune Pur e 20 Final allocated costs are Co product 1 Pitted Prunes 100 80 80 Co product 2 Prune Juice 100 0 0 Co product 3 Prune Pur e 100 20 20 By product costs are calculated the same way as regular costs That is they are determined separately from the base process cost roll up Once by product costs are established freeze them to ensure they are not changed during cost roll up Changing by product costs after net base process costs have been calculated may result in unanticipated variances As in the previous example the net cost for the base process should equal the sum of the costs allocated to the co products If these amounts are not equal one or more of the following is likely By product costs were not frozen once subtracted from the base process gross cost The system recalculated the by product costs changing the value of the base process net cost Cost allocation percentages did not add up to 100 Costs were allocated to a co product whose cost was determined from a different base process than the one being rolled up This can happen when a co product is in the product structure of more than one base process If co product costs do not add up to the base process net cost when work orders are closed method change variances resul
309. me and produce that material must be milestone operations Use Routing Maintenance 14 13 1 to update routings for use with WLT Before Tracing Subcontracted WIP Material If you plan to trace WIP material at multiple subcontractor locations you should follow these steps before beginning to set up WLT e Create and plan to maintain detailed records of subcontractors qualified to perform each operation You should note whether they maintain the WIP lot serial numbers you assign or if they assign new ones for the material they process for you For example you send WIP lot AA to one of your subcontractors and the subcontractor later sends you the processed material with a new lot number List all your subcontractors Use Work Center Maintenance 14 5 to create a work center for each subcontractor Use Routing Maintenance 14 13 1 to create or modify existing routing codes that have subcontracted operations These routings should reference an appropriate subcontractor work center Lot Sizing Restrictions With WIP Lot Trace you can restrict the size of lots processed by a routing or routing operation Lot size restrictions are useful when work centers can process only certain quantities of material or when specific WIP Lot Trace 261 operations require certain lot sizes For example if machine capacity lets you produce only 50 items at operation 30 then the maximum lot size would be 50 If any lot sizing restrictions apply in you
310. mponent list of status 240 composite lead times 23 configured products product structures for 17 connecting shippers to received items 216 connecting subcontract POs to a routing 207 consume earliest open 157 consume forecast forecasting 339 control program Advanced Repetitive 158 MRP 358 Quality Management 305 Repetitive 229 Shop Floor Control 142 WIP Lot Trace 265 Work Order 103 Work Order Accounting 104 co products by products 53 98 average costs 72 accounting for 75 allocation methods 73 backflush 85 method 62 base processes alternate routings 67 BOM Formula codes 56 defined 56 defining alternate 67 defining co products for 62 item status codes 60 lead times 76 material requirements planning MRP 77 79 planning for 57 planning for multiple 77 restricting inventory transactions 60 setting up items for 60 WO status codes 82 BOM Formula codes 61 Index 391 by products costs 70 defined 55 freezing costs 70 lead times 77 material requirements planning MRP 77 setting up items for 61 co by product structures 62 co products alternate base processes 57 average costs 72 cost allocation percentages 63 69 defined 55 demand for 80 material requirements planning MRP 77 80 planning demand for 57 setting up items for 61 substitute items 68 cost allocations by price 74 by receipt quantity 74 costs by products 70 reviewing 77 rolling up 72 defined 55 features 54 joint order sets 81 accessing modifying 82 acco
311. mponent and return the old one This results in an unfavorable material usage variance for the new component and a favorable usage variance for the old one Use Work Order Bill Maintenance 16 13 1 to add the new component to the work order before issuing it If an order is allocated or exploded use Work Order Bill Maintenance to add the new component updating the quantity required and quantity allocated and delete the old one After modifying a work order bill you should not change the status back to Firm Planned since that causes the standard bill to be re exploded Work Orders 119 FAQAD 120 User Guide QAD Manufacturing Modifying Work Order Routings Use Work Order Routing Maintenance 16 13 13 to add delete or change the routing of a work order that is exploded allocated or released In general the start and stop dates for work order operations are not frozen The system automatically reschedules the operations from the due date in any of the following situations A work order is processed in Work Order Maintenance 16 1 and the initial status is Batch Planned or Firm Planned A work order is processed using Work Order Maintenance and the final status is Firm Planned A work order s due date changes A work order is replanned by CRP See Advanced Note If you are using the Advanced Repetitive module you cannot add a d a n routing operation to a cumulative order using Work Order Routing page
312. mponents are in stock The system calculates this value by converting manufacturing inspection and safety lead time to calendar days Time Fence The time fence is the number of calendar days inside of which MRP will not generate or adjust any planned orders even if there are net requirements within that period MRP still deletes a planned order even if it is inside the time fence if no demand is generated for that item Time fences are often used with master scheduled items and are usually set to greater than or equal to the manufacturing lead time MRP Required The MRP Required field is set by the system to indicate whether this item See Net Change has had changes made against it and will be replanned the next time you eer ie run net change MRP Yes indicates that the item will be replanned No indicates that it will not QAD 366 User Guide QAD Manufacturing b See Chapter 2 and Chapter 4 for details FAQAD Inventory Status Codes Assign a non nettable inventory status code to inventories that should not be considered quantity on hand by MRP This might include inventory to be returned to a supplier or designated as scrap or salvage Product Structures and Formulas Product structures and formulas provide some of the information used in MRP calculations including component quantities lead times and effective dates Enter and modify product structure and formula information in Product Structure Maintenan
313. n In some instances it may be appropriate to change the structure code See page 319 to Planning Component Substitutions When an item is not available you can sometimes issue a different item For example for the sunglasses it may be possible to substitute Phillips head screws for slotted head screws Substitute components during work order issues or when modifying a backflush transaction Before substituting components use Item Substitution Maintenance 13 19 to define the relationships between standard items and substitute items You can define a substitute item relationship for a component within a specific assembly as a global relationship Specify a quantity of the alternate item that is equivalent to a single unit of the reference item For example Deionized water and sterile water can be defined as alternates for equivalent quantities of distilled water Two 6 pin connectors can be defined as an alternate for a single 12 pin connector FAQAD 22 User Guide QAD Manufacturing A fast setting adhesive can be defined as a substitute for a slower setting adhesive for a specific assembly MRP and work order picking logic do not check substitute item relationships Substitute items that are phantoms are not exploded when issued on an inventory transaction Fig 2 3 Item Substitution x Maintenance Item Substitution Maintenance Go To Actions 13 19 Parent Base Process Item BRACKBCT4 None 00 E
314. n rolling up the percentages associated with each routing operation Lead Times Lead times for operations and manufacturing are expressed in terms of several components Queue Setup a Wait Move Summa Operation Lead Time Queue Amount of time a lot must wait at a work center before the operation is set up and production begins Occurs when there is a backlog of jobs at a work center and is frequently the single longest component of manufacturing lead time Setup Time required to prepare a work center to process a lot or batch quantity for a specific operation e Run In Routing Maintenance 14 13 1 the average time required to manufacture a single unit In Process Definition Maintenance 15 13 the average time to process an entire batch In Routing Maintenance Rate Based 14 13 2 run time is expressed in terms of an hourly production rate In all cases the system stores run time internally as the run time per unit gt For details on costing see User Guide QAD Financials B Fig 3 7 Lead Time Components FAQAD 38 User Guide QAD Manufacturing FAQAD Wait Amount of time a lot or batch must remain at a work center after production is completed before it can be moved to the next operation Move Time a lot or batch spends in transit from one operation to the next Subcontract Number of days required for an outside supplier to pr
315. n s queue time Note Setup and run times are used for operation scheduling lead time calculations product costing calculations and GL transactions created by activities such as reporting labor and completing repetitive operations in the manufacturing modules Changes to setup and run times should be coordinated to prevent adverse effects in any one of these areas Manufacturing Lead Time The manufacturing lead time for an item is the sum of its operation lead times stated in manufacturing days Capacity planning uses manufacturing lead time in conjunction with the work center or shop calendar to determine order release dates FAQAD 40 User Guide QAD Manufacturing b See Managing Subcontracting on page 200 FAQAD There may be differences between operation schedules for an order and the manufacturing lead time for an item due to any one of several reasons The item order quantity used to calculate the manufacturing lead time may be different than the actual order quantity for an operation resulting in differences in the run time for an operation The shop and or work center calendars may be scheduled for more or less hours than the default calendars used to calculate manufacturing lead time Queue time for the first operation does not affect its start date therefore it may fall after the release date of an order Two successive operations may overlap Subcontract Operations Some operations may be
316. nce only Fig 3 6 Routing Maintenance 14 13 1 WIP Item D Move Next Operation V Auto Labor Report WIP Item Optionally enter an item number to represent work in process material for subcontract shipments This field is used by Sub Shipper Print 18 22 5 9 when processing repetitive subcontracts The description and unit weight of the WIP item display on the subcontract shipper Move Next Op Enter Yes or No to determine the default for the same field in Backflush Transaction 18 22 13 and Move Transaction 18 22 19 Auto Labor Report This field is used in the Advanced Repetitive See Automatic module to determine if standard labor is reported automatically by Labor Reporting on page 168 for Backflush Transaction 18 22 13 details FAQAD 36 User Guide QAD Manufacturing FAQAD Alternate Routings After you enter a routing you can link it to an item in several ways depending on whether it should be used as the default routing code or available for use as an alternate routing If the routing should be the default for an item update the routing code in Item Planning Maintenance 1 4 7 This is the routing code used for CRP work orders repetitive and costing If the routing should be the default for an item at a particular site update the routing code using Item Site Planning Maintenance 1 4 17 This is the routing code used for CRP work orders repetitive and co
317. nced Repetitive module The following points should be noted You can enter the lot serial of subcontract material when creating the PO This lot serial prints on the report produced by Purchase Order Print 5 10 PO Shipper Maintenance 5 13 14 PO Container Maintenance 5 13 13 and PO Shipper Receipt 5 13 20 cannot process any subcontract PO line item that references a WLT controlled operation Purchase Order Maintenance Part of the subcontracting process is to use Purchase Order Maintenance 5 7 to create a subcontract PO for the subcontract operation When creating a subcontract PO for line items that reference Advanced Repetitive cumulative orders use the lot serial field to enter the WIP lot serial number of the material being sent for subcontract processing see Figure 10 22 When the system generates the cumulative order ID it searches for purchase orders associated with the cumulative order and automatically updates the work order ID and operation on the purchase order The system also replaces existing closed cumulative order Ds with an open cumulative order ID on the appropriate purchase orders The purchase orders must be connected to a subcontract routing operation through Subcontract Routing OP PO Maint 5 11 or Subcontract Order MRP Maint 5 5 1 21 Work Order 2 ID Operation 0 D Indicate the Subcontract Type P WIP lot serial Lot Serial here The lot serial entered in this field defau
318. ncies in CRP CRP and Order Statuses CRP is normally executed for Planned and Firm Planned orders For these orders CRP explodes the standard item routing and schedules the operations to create work center machine load You can also choose to include orders with other statuses For Exploded and Allocated orders the work order routing is scheduled For Released orders only open operations are rescheduled When you run CRP all open operations for selected work orders are rescheduled That means that if you have manually adjusted your operation start and stop dates they will probably be changed unless you also adjusted the work order release and due date to match Capacity Requirements Planning 383 Generating Load Reports You can generate load reports by department work center or machine using the work center and department load inquiries and reports CRP determines load hours for a work center based on setup and run times Queue wait and move times are excluded from load calculations To include queue times in load calculations set up separate operations for queue CRP then considers these operations when calculating load CRP determines the load an operation exerts on a work center using the following calculation Operation Load Setup Time Run Hours Unit x Quantity Open The quantity open for an operation is the order quantity minus any quantities reported complete Note The system assigns the entire load for an o
319. ng Either way you must use MRP to plan orders in order to generate page 343 production forecasts for the components of these family items Set the following values for family level items in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 Master Schedule Yes Plan Orders Yes Order Policy Any option other than blank Time Fence Optional The components of a multilevel master schedule can be planned using either the fully manual or computer assisted technique Maintaining Master Schedule Orders You can enter master schedule orders as firm planned work orders or create them using repetitive schedules Under some circumstances they are also automatically generated when you create flow scheduled orders FAQAD 350 User Guide QAD Manufacturing b See Chapter 6 Work Orders on page 99 b See User Guide QAD Lean Manufacturing b See Chapter 8 Advanced Repetitive on page 153 and Chapter 9 Repetitive on page 227 AQAD Work Orders You can enter master schedule orders as firm planned orders using Master Schedule Order Maintenance 22 13 or Work Order Maintenance 16 1 When you set the order status to Firm Planned MRP explodes the parent item s product structure when planning the gross requirements for its components Master schedule orders are managed and released like normal work orders Flow Scheduled Orders When you enter a flow scheduled order using Flow
320. ng EDI eCommerce to support electronic data interchange EDI transactions lets you receive an advance ship notice ASN from your supplier to register the receipt of processed materials Non Milestone Operation Processing The Backflush Transaction 18 22 13 and subcontract processing activities let you use non milestone backflushing This replaces the Repetitive Labor Transaction in basic Repetitive Non milestone backflushing uses a demand pull strategy to determine the units needed from non milestone operations The amount depends on the net requirement of the processing milestone operations The net requirement is satisfied by consuming units in the output and input queues of preceding non milestone operations until either the requirement is satisfied or another milestone operation is encountered You can use any repetitive transaction at a non milestone operation Advanced Repetitive 157 Scheduling In Advanced Repetitive the earliest open schedule is always consumed not just completions over the scheduled quantity for that date Cumulative Completed Maintenance 18 22 2 6 lets you modify the quantity completed on a repetitive schedule Changes to a schedule s cumulative completed are reapplied to the schedule using the consume earliest open logic WIP inventory is visible to the Schedule Explosion 18 22 2 4 and MRP programs This prevents overplanning for components that might result from not including WIP
321. ng the operation lead time components queue setup run wait and move to calculate operation start dates The start date of an operation is the same as the due date of the previous operation Note CRP calculates run times based on the actual order quantity that is the order quantity less the quantity completed FAQAD 382 User Guide QAD Manufacturing b See Chapter 13 Material Requirements Planning on page 355 Tip Repetitive schedules are treated like Exploded orders FAQAD When manufacturing order operations overlap the system smoothes the scheduled start and due dates to prevent the scheduled due date for one operation from occurring later than the due date for a subsequent operation Schedule Discrepancies MRP calculates manufacturing order release dates using a manufacturing lead time that is based on an average order quantity defined in Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 If the order quantities used in CRP calculations differ from this average quantity CRP may schedule the start date for an order s first operation before the release date for that order When this occurs a message displays to alert you of the conflict You can resolve such conflicts by adjusting the order release or due date and rerunning CRP Note Exceptions to the normal work week in the work center and shop calendars for example planned overtime may also cause schedule discrepa
322. nned you can change the dates and quantities as needed and specify an approved alternate bill or routing For orders with status Exploded Allocated or Released bills and routings can be modified or alternate ones specified A work order progresses from one status code to the next and unless prematurely released does not return to an earlier status FAQAD Work Orders 111 Table 6 4 Type Code Description Life Cycle Work Order Life Cycle Blank Standard Planned Firm Planned Exploded Allocated Released Closed F Final Assembly Exploded Allocated Released Closed R Rework Allocated Released Closed E Expense Released Closed S Scheduled Exploded Closed C Cumulative Released Closed W Flow Exploded Deleted system action After entering an order change its status to Firm Planned Exploded or Allocated using Multiple Work Order Status Change 16 8 Table 6 5 shows how the status changes affect a work order s BOM and routing Table 6 5 Firm Effect of Status Planned Planned Exploded Allocated Released Closed E on Bill and outin Bills Bill Components Inventory Inventory created frozen allocated picked Routings Routing Routing created and operations scheduled frozen Planned Planned orders are generated by MRP and are replanned as requirements b See Chapter 13 8 y p q ap change You cannot record inventory transactions or labor feedback eae E against them or change quantities date
323. nored by MRP and planned orders or action messages are not generated for it Any value entered in the Order Policy field other than those listed in Table 13 2 is processed by MRP as lot for lot Leave Order Policy blank for items planned manually based on a reorder point Material Requirements Planning 363 Table 13 2 Order Policy Description Order Policy Period order quantity MRP calculates demand for this item over the number of POQ calendar days specified as the Order Period and creates one order to satisfy this demand Fixed order quantity MRP generates planned orders for the quantity specified as FOQ the Order Quantity If the quantity required exceeds this quantity multiple orders are generated If the quantity in the Min Ord field is greater than the specified order quantity planned orders are generated for this minimum quantity Lot for lot LFL MRP generates a separate planned order to satisfy each net requirement If there are many sources of demand MRP creates many planned orders When LFL policies are used across multiple product levels running MRP may produce unmanageable numbers of manufacturing orders One time only OTO MRP generates a single planned order with a quantity of one unit As long as one order for this item exists the system will not create another OTO can be used for prototype items or for planning project activities and one time events Order Modifiers MRP uses order modifiers along with order
324. ns with multiple sites MRP can be used in conjunction with distributed requirements planning DRP which balances supply and demand among sites Capacity Requirements Planning CRP The Capacity Requirements Planning CRP module uses MRP planned orders other work orders and repetitive schedules to determine work center load and generate a capacity requirements plan for a department work center or machine See Quality Management on page 303 See Forecasting Mas ter Schedule Planning on page 319 b See Material Requirements Planning on page 355 b See Capacity Requirements Planning on page 379 FAQAD 10 User Guide QAD Manufacturing FAQAD 12 User Guide QAD Manufacturing b See Chapter 4 Formulas and Processes on page 45 Table 2 1 Product Structure for Sunglasses with Coated Lenses FAQAD Introduction Product structures and formulas are much like the list of ingredients for a recipe they indicate the components and quantities needed to make a product Unlike a recipe in many cases these documents also list the ingredients for each component Graphically if a formula or product structure is considered in its entirety it looks like a tree with the parent item at the top level 0 and all the components branching off down to the raw material level levels 1 2 3 and so on Product structures are recorded as single level relationships between paren
325. nt by date FAQAD 242 User Guide QAD Manufacturing Demand Supply Summary Browse There can be hundreds of MRP detail records for the component you select but how do the records relate to the component of the work order you selected For a selected work order and work order component the system collects and totals all MRP supply and demand records prior to and including the work order record you selected You can see these aggregated records in the Supply Demand Detail Browse The Supply Demand Summary Browse lets you view the aggregated records from a matrix point of view The first row in the display is the Supply Row It lists the current QOH for the work order component item and other sources of cumulative supply up through the work order component s demand release date The next three rows are Demand Rows They list the three categories of demand Each row starts with prior demand requirements and the gross requirements of the selected work order Then from left to right it adds in the current QOH then adds in the cumulative supply to calculate the component PQOH This supply and demand matrix format provides you with a global view of component supply demand Fig 9 5 Supply Demand Summary Supply added in starting with current QOH MAP Pian Acata POOH Demand added in The following sections provide more information on individual component check programs FAQAD Repetitive 243 Com
326. nt material usage variance is calculated as the difference between the actual and expected quantities issued extended by the cumulative order operation component cost The expected issue quantity is the cumulative order operation standard quantity required per unit multiplied by the quantity processed at the operation When you issue component materials that are not in the cumulative order BOM for that operation they are considered nonstandard and treated entirely as usage variance WIP Material Scrap Usage Variances WIP material scrap usage variance is calculated as the difference between the actual and expected scrap quantities extended by the cumulative order operation cost The expected scrap quantity is the quantity processed less the cumulative order expected yield for that operation For example if the yield factor at an operation is 75 and 100 units were processed at the operation the expected scrap quantity would be 100 less 75 or 25 The variance amount is posted to the Scrap account from the end item product line You can scrap a quantity without producing a scrap posting Consider the above example where yield is 75 and the expected scrap quantity is 25 If the actual quantity scrapped is 25 then no variance results If there is no labor or component usage variance elsewhere WIP is charged with exactly the amount of resources expected to produce 75 This is reflected in the fact that the operation cost includes an expected s
327. ntory If only the WIP item is lot serial controlled then the placement into inventory occurs during receipt Optionally scrap unreturned subcontracted items Optionally close the subcontract shipper See Defining To receive against a subcontract shipper set Manual Shipper Update to Sur one Coppe Yes in Subcontract Shipping Control 18 22 5 24 When you set this field Options on to Yes the Subcontract Shippers frame displays in Purchase Order page 208 Receipts 5 13 1 PO Shipper Maintenance 5 5 5 5 or 5 13 14 and Purchase Order Returns 5 13 7 After you select a shipper the system displays shipper data in the lower portion of the screen FAQAD Advanced Repetitive 217 Fig 8 24 vx Subcontract DB NY USD 5 13 7 Purchase Order Returns 03 12 07 GoTo ACTIONS Shippers Frame 5 13 1 Purchase Order BCPOA Suppier SUPO Status RTY Nar Subcontract Shippers Shipper Number Lot Serial Reference Open Qty Receipt Qty SHN1 an nn n nn Snipper Number SHO1 Lot Serial Reference Receipt Quantity 0 0 Scrap Quanrity 1 3 Cose Sub Shippe 7 Comments M Shipper Number Accept the ID that displays or enter another ID of the subcontract shipper you want to track Entering the number here lets you track subcontract shippers sent to and received from subcontractors Use Subcontract Item Status Report 18 22 5 16 to display the status and history of items sent to and received from subcontractors Lot Serial If the
328. o be used for Repetitive In particular Work Order Cost Report 16 3 4 Work Order WIP Cost Report 16 3 5 and Work Order History Report 16 3 6 play an important role in reporting activity against cumulative work orders Closing Work Orders To close a work order complete the following steps 1 Change the order s status to Closed You can do this by setting Close to Yes when completed units are received or by using Work Order Maintenance 16 1 P See User Guide Note When a work order is referenced by a flow scheduled order an m and you close the flow scheduled order using Flow Schedule Close 17 13 19 the system automatically changes the work order s status to Closed You can reopen it using Work Order Maintenance FAQAD Work Orders 135 2 Run Work Order Accounting Close 16 21 to post variances clear WIP and close outstanding operations Execute this program regularly at least at the end of each fiscal month for completed orders The system prevents component issues and work order receipts for a closed work order If you want to process inventory for a closed work order you must change its status back to Released The system records the work order close date the system date The system also records the user ID of the person who closed the work order The work order close date and user ID are captured when the work order is closed through the following Work Order Maintenance 16 1 Multiple WO Status Chan
329. o for the item site or item For an order with several operations components can be grouped together on separate picklists by setting their lead time offset LT Offset to indicate when they are required with respect to the release date Define lead time offset in Product Structure Maintenance 13 5 or Formula Maintenance 15 5 Work Orders 123 Reprinting Picklists You may need to reprint a picklist if not all items were available when it was first issued Use Work Order Release Print 16 6 and set Reprint Picked Quantities to No the default All items that were not available before are listed Another way to reprint a picklist while tracking components already issued to an order is to change the status to Allocated then re release the order Changing the status to Exploded is possible but this can cause differences in how phantom use up logic is applied If no components have been issued and no changes made to the work order bill or routing then the status can be changed to Firm Planned Exploded or Allocated before re releasing Changing the status to Firm Planned eliminates changes entered manually to the work order bill or routing Issuing Components Work order operations begin when a work order is released and its P See Chapter 7 components issued Monitor operations using the Shop Floor Control cu module page 139 There are three ways to issue inventory to a work order For more on using Work Order ssue
330. ocess the lot Operation Lead Time Planning programs use these lead times to determine the duration of an operation and the time between successive operations The amount of time a work center is actively involved in producing an item is determined by setup run and subcontract times The time between operations interoperation time is determined by queue wait and move times Most of these times are stated in hours except for subcontract which is stated in days The operation lead time is calculated using each of the lead time components the number of machines per operation and the item order quantity The work center or shop calendar is used to convert queue setup run and move times from hours to manufacturing days Queue Setup Move Run Order Quantity Wait Hours Available Hrs Avail Mach per Op 24 Operation LT Subcontract LT If you examine this formula several concepts become apparent Queue setup and move times are completely independent of the order quantity or lot size Queue setup and move times are also independent of machines per operation since these do not require that a machine be available Queue setup and move times are a function of available work center or shop calendar hours since the operation can only be performed during working hours If queue setup and move times add up to 16 hours and there are 8 working hours in a day 2 manufacturing days are needed Routin
331. od based on operation quantity completed transactions for work orders and repetitive schedules You can report completed quantities for order operations using labor feedback transactions in the Shop Floor Control Advanced Repetitive and Repetitive modules or using Work Order Accounting Close 16 21 Actual output is determined using the following calculation Actual Setup Standard Run Quantity Completed Planned Queue The planned queue is the difference between planned input and planned output Actual Queue The actual queue is the difference between actual input and actual output Adjusting Capacity and Load If a work center or machine is over or under loaded you can modify either its capacity or the timing or amount of the load Adjusting Capacity Adjust capacity using one of the following functions Holiday Maintenance 36 2 1 Calendar Maintenance 36 2 5 Capacity Requirements Planning 385 Add or subtract workday hours as needed for work center or shop calendars Adjusting Load Adjust the timing or amount of load by modifying Work order due dates Operation lead time components Repetitive schedules Note If you manually adjust operation start or stop dates CRP reschedules them the next time it is run FAQAD 386 User Guide QAD Manufacturing FAQAD Numerics 1 1 13 59 1 2 1 60 1 4 1 60 71 174 1 4 9 71 1 4 17 60 174 1 4 18 71 1 13 66 1 22 4 88 1 22 24 68 87 1 4 1 202
332. odes as a restricted transaction then enter one of these codes in the Status field in Item Master Maintenance 1 4 1 or Item Data Maintenance 1 4 3 for any item you want to prevent from being released on a work order If you attempt to release an order for such an item in Work Order Maintenance 16 1 Work Order Release Print 16 6 or Multiple WO Release Print 16 7 the system displays an error message Key Items If there are shortages of important work order components you can prevent the system from releasing an order or printing a picklist Do this by designating these items as key items in tem Master Maintenance 1 4 1 Item Inventory Data Maintenance 1 4 5 Item Site Inventory Data Maintenance 1 4 6 You can also change any component on a work order bill to a key item using Work Order Bill Maintenance 16 13 1 If detail allocations cannot be made for the total quantity required for a key item the order is not released To check availability of non key items before releasing an order use Work Order Component Check 16 5 Splitting Work Orders Even if you check for potential shortages before an order is released quality problems and inaccurate inventory balances may result in a shortage of components These shortages can be monitored using Work Order Bill Shortage Report 16 16 and Work Order Bill Shortage by Item Report 16 17 QAD 122 User Guide QAD Manufacturing b See User Guide QAD Maste
333. oduct In another case one product can be produced with several different product structures or formulas Example A computer workstation is assembled in different countries around the world Several different product structures use slightly different components produced by different manufacturers No matter which product structure is used the end product is functionally equivalent Depending on where the product is manufactured one structure may be more favorable as a result of cost differences due to price and or tax considerations In both cases enter product structures and formulas by using a product structure formula or bill of material BOM code as the parent item instead of an item number Use two programs to set up BOM codes Product Structure Code Maintenance 13 1 Formula Code Maintenance 15 1 Note The system automatically creates BOM codes for parent items that are defined in the item master when adding product structures and formulas BOM codes and item numbers are entirely independent You can use the same product structure or formula for multiple items and any one of several product structures or formulas to make the same item When an item number and its BOM code are the same they are automatically linked If an item s BOM code is blank the item number is used as the BOM code When they are different you can change the BOM code in Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4
334. oes not include co products or by products Releasing 120 rating Reports 132 sing Work Order Deleting Work Orders 100 User Guide QAD Manufacturing Introduction A work order is an authorization to produce a specific quantity of an item for a specific date A work order may represent a manufacturing production order a repetitive schedule or a sequenced production line Work orders are typically created in response to current or projected demand for an item You can also use them to build up inventory in anticipation of future demand when there is unused manufacturing capacity Work Order Life Cycle Figure 6 1 illustrates a typical work order life cycle Fig 6 1 Work Order Life Cycle Create work orders or approve MRP planned order Modify work order bill and routing Issue work order components and optionally record labor in Shop Floor Control Receive work order Release and print work order Check for work order components Perform work order Delete archive obsolete work Work Order Operation Backflush 16 19 combines The issuing functions of Work Order Component Issue 16 10 The labor reporting functions of Labor Feedback by Work Order 16 20 1 The receipt functions of Work Order Receipts 16 11 FAQAD If you use Work Order Operation Backflush the typical workflow for work orders is simplified since you can c
335. oint work orders Code Status Description P Planned MRP creates an imploded joint order set reflecting the base product structure as of the order release date B Batch An order is created for a single co product or base process item Orders are not imploded F Firm Orders are imploded to reflect the base product structure as of the order release date You can modify co product by product quantities and the base process quantity All quantities are automatically rescaled When an MRP planned order in a joint order set is approved all joint orders in the set are changed to status Firm E Exploded The same as Firm except you can modify quantities for co product or by product orders without automatically rescaling other orders You can add or delete orders from a joint order set Delete is not allowed if quantities or costs have been received for an item on that order A Allocated Same as exploded wn Released Same as exploded C Closed When the status of a joint order set is changed to Closed and average cost method is used updates are made to current AVG current LAST and GL average costs Joint order sets can be created for regular work orders where Type is blank but not for work order types such as Expense Rework Scheduled Cumulative and Final Assembly Joint orders can be added to or deleted from a joint set when the status is Exploded Allocated or Released Note A joint order set must have only one base proce
336. ombine three separate steps into one Work orders are tightly integrated with other manufacturing modules Define bills of material and product structures for work orders in the Product Structures module Define routings and operations for work orders in the Routings Work Centers module Create planned orders to fill demand with Material Requirements Planning Schedule operations with Capacity Requirements Plan Monitor and report on the progress of a work order in the Shop Floor Control module Manufacturing Environments Features that support different manufacturing environments are provided The Work Orders and Shop Floor Control modules are typically used to manage job shop manufacturing The Advanced Repetitive or Repetitive modules manage manufacturing in an assembly line environment Table 6 1 compares and contrasts the two types of environments Work Orders Repetitive Plant Organization Variable by product Fixed by assembly line Routing Functional departments Fixed by line Material Handling Fork lifts tote bins Conveyors containers Product Mix Many products Similar products Amount of Work in Process High Low Time to Manufacture Variable by product Short Examples Tools furniture Auto assembly tires Work Orders 101 P See page 11 b See page 25 b See page 355 b See page 379 P See page 139 See Chapter 8 and Chapter 9 for details Table 6 1 M
337. omplete status If Show Shipped Complete is No the system displays open subcontract shippers only If Yes the system displays both open and closed subcontract shippers When you receive subcontracted items you can return items to the subcontractor scrap items or move finished items into inventory The following sections cover these optional receipt related tasks Advanced Repetitive 219 Returning Items to Subcontractors In some instances you may have to return items to the subcontractor that you received You can control whether subcontract shippers are manually updated with return quantities and return items against the same cumulative ID To return against a subcontract shipper set Manual Shipper Update to Yes in Subcontract Shipping Control 18 22 5 24 When you set this field to Yes the Subcontract Shippers frame displays in the following programs for each different purchase order line against which you are returning items PO Shipper Maintenance 5 5 5 5 and 5 13 14 Purchase Order Receipts 5 13 1 Purchase Order Returns 5 13 7 Use the following procedure to return items against a subcontract shipper 1 Selecta subcontract shipper from a list of all open and closed subcontract shippers in the Subcontract Shippers frame 2 Choose one of the following a Enter a negative number in the Receipt Quantity field to indicate returned quantities if the Subcontract Shippers frame displays in PO Shipper Maintenance o
338. ompleted assembly Routings and Work Centers 43 Four operations are needed to build ITEM A and one component is used at each operation The first component is used at the first operation the second component at the second operation and so on for each component Each operation has a yield of 90 percent Based on the demand for 100 ITEM A MRP generates a planned order for 151 based on the following calculations Item Yield 90 90 90 90 66 Planned Order Quantity 100 66 151 of ITEM A The system uses the same calculation for the parent item regardless of the yield calculation method in effect However when calculating component requirements the different methods yield different results as illustrated in Table 3 2 Table 3 2 Op Based Yield Op Based Yield Operation Based BOM Op Eff Yes No Yield Example Operation Component Qty Yield Yield Comp Qty Req Comp Qty Req 10 COMP 1 10 90 100 151 151 20 COMP 2 10 90 90 135 151 30 COMP 3 10 90 81 122 151 40 COMP 4 10 90 73 110 151 Because Operation 10 is the first operation it requires 100 percent of the components When Op Based Yield is No the component quantity is calculated from the yield percentage of the parent item The system applies the same 66 percent item yield to each operation to determine component requirements of 151 according to the formula 100 1 66 When Op Based Yield is Yes the system uses the yield percentages of the p
339. omponent lots consumed in manufacturing operations otherwise enter No To trace component lot serials you must also trace their corresponding parent items This value defaults to Trace Components in BOM Registration Maintenance Trace Heference Enter Yes to trace references assigned to traced component item inventory To trace inventory references you must also trace their corresponding component and parent items QAD 268 User Guide QAD Manufacturing FAQAD Example Lot 3A of steel wire comes in three spools Each spool is separately identified in inventory using the Reference field as Spl Sp2 and Sp3 When steel wire is consumed you must enter the spool number in the Reference field during backflush If Trace Reference is Yes the spool numbers are recorded in tracing history and display in the Lot Where Used and Lot Actual Bill reports They also appear in transaction detail reports and inquiries This value defaults to Trace Reference in BOM Registration Maintenance Combine Component Lots Enter Yes if multiple lots of the same component or raw material can be consumed into a single WIP lot serial Example Combine Component Lots is No for steel Two lots of steel lot A and lot B are in the storeroom Lot A is processed at the first operation becomes WIP lot W1 and is backflushed accordingly If you try to backflush steel lot B into WIP lot W1 the system displays an error Only one lot of steel can be consume
340. ons to activate or deactivate WIP lot serial tracking for all or specific BOMs routing codes parent items component item routings and routing operations Maintain complete WIP tracing history Generate reports providing visibility of WIP lot serial numbers and quantities Optionally generate and assign WIP lot serial numbers automatically using Number Range Management NRM features Control the lot sizes for all traced material Control combining and splitting of lot and component material being traced FAQAD 254 User Guide QAD Manufacturing FAQAD Control the WIP inventory quantity on hand balances for WIP material lot serials being traced Trace component material lots consumed at any operation in a routing to WIP or finished material lots Trace WIP material lots from operation to operation Renumber lot serials from one operation to the next or retain the same numbers throughout all operations Determine the constituent WIP or component material lots of finished or WIP material lots Maintain up to date cumulative scrapped consumed and produced quantities for traced WIP lot serials at the operation level Maintain quantity on hand balances at the operation level for traced WIP lot serials Subcontract Processing Features With WIP Lot Trace you can track all subcontracted WIP material With the subcontract tracing features you can Capture WIP lot serial information and maintain quantity on h
341. ontract shipper Note You update a subcontract shipper during a receipt through Purchase Order Receipt not PO Shipper Receipt You can manually process scrap by using Subcontract Scrap Maintenance 18 22 5 13 Without the Receipt Data Input frame displaying you cannot automatically move received material into finished goods You must manually move the received material into finished goods Use either of the following transactions to manually move received finished goods Advanced Repetitive Move Transaction 18 22 19 Shop Floor Control Move Transaction 17 6 Since you cannot update subcontract shippers during PO receipt while in API mode the system automatically updates them for you The system sorts shippers by effective date and cumulative ID and uses first in first out FIFO and last in first out LIFO logic to process them The system updates shippers starting with the oldest shipper for the subcontractor being processed This includes expired subshippers and closed cumulative orders that are not complete If the system is processing a negative receipt the system processes subshippers starting with the most recent subshipper s between Repetitive and Advance fer to ter 8 Advanced Repetitive for a ive functionality 228 ules in the Workbench 230 ing Repetitive Schedules 231 231 rs 231 Executing Repetiti nsactions 231 Checking Component Avail ility 236 228 User Guide QAD Manufac
342. or short components you can always take into account the worst case items that is you can factor in orders receipts or work centers for items that take the longest time to process Component Check by Work Order Production Line Example As a production planner you want to ensure that all work orders scheduled over the next week have enough components available You run Component Check by Work Order Production Line to look at work orders that have a release date during the next seven days To do this you set search criteria for work order release date for seven days away You add secondary search criteria to find work order component status that contains a shortage The system displays all work orders with a status of 7 Projected Shortage or 8 Shortage You look at the Supply Demand Summary Browse to see the cumulative supply and demand information for that work order component detail record To get more information you look at the Supply Demand Detail Browse to view the MRP details the system used to calculate the work order component status You have several options to resolve the shortage You can reschedule either supply or demand For example to reschedule supply you can reschedule a purchase order receipt if the component is purchased Or if the component is manufactured you can reschedule a work order To reschedule demand you could reschedule a sales order or forecast demand Note The functions and programs described are
343. ord the WIP lot serials references and quantities of material being moved This frame does not appear if you are moving WIP quantities to finished goods inventory Instead the Receipt Data Input frame appears for receipt of finished goods into inventory You can use a WIP lot serial number as the finished item lot serial number If you are using lot groups a feature of the Regulatory Attributes module to create automatic lot numbers that function creates and assigns the lot serial number for this finished item The lot serial assigned to the finished item is saved to WLT tracing history Fig 10 17 WIP Lot Move Data Qty To Move 20 EA a i Move ILot Serial Ref Quantity ID 100 ata Frame L100 20 0 Work Center 12000 Machine General 2 Department 10 General Unit of Measure EA Conversion 1 0000 Lot Serial Ref Quantity L100 20 0 The WIP Lot Move Data frame follows the Work Center and Machine frame in Move Transaction 18 22 19 Use the frame to specify quantities to move from the output queue of the indicated operation to the input queue of the next operation FAQAD 284 User Guide QAD Manufacturing Fig 10 18 Current Work Center and Machine Frame FAQAD This frame appears in Sub Shipper Maintenance 18 22 5 5 and Sub Container Maintenance 18 22 5 4 when moving WLT controlled WIP material to a subcontract operation The lot serial quantities you enter are moved to the subcontract location
344. order exists with an effective date range that includes the day after the entered End Effective date A new cumulative order is created if none exists The Start and End Effective dates of the new cumulative order are set based on the End Eff Default Method in Repetitive Control Advanced Repetitive 183 A cumulative order is created for a profile that defines the site item number production line routing code and BOM formula code for the order and start and end effective dates Two orders that have the same profile cannot have overlapping effective dates When a cumulative order is created The work order ID is automatically assigned The work order number is blank The work order type is C The work order status is R Blank cumulative order ID and operation fields on subcontract scheduled orders or discrete purchase orders are updated with the new ID and the subcontract operation from the routing Cumulative Order Close Use Cumulative Order Close 18 22 10 to select and close open cumulative orders according to various criteria You can optionally create successive cumulative orders and transfer WIP queue balances to them Cumulative orders must have an end effective date on or before the End Effective value you enter Orders with a blank end effective date will not be selected Note To close orders with blank end effective dates first enter an end effective date using Cumulative Order Maintenance 18 22 6 Closing a
345. orecast Maintenance 22 1 or Forecast Worksheet Maintenance 22 2 8 RunMRE Forecasting Simulation Forecasting simulation functions enable you to analyze sales shipment history calculate forecasts and update demand for material requirements planning MRP creating a closed loop system Forecasting simulation functions generate forecasts based on shipment history They use statistical methods and extrapolation techniques to evaluate underlying patterns in sales history data and predict future demand Forecasting assumes that historical sales patterns are repeated to varying degrees in the future The accuracy of any forecast depends on the value of the sales information used to create it The more sales history available the more accurate the forecast Figure 12 1 outlines the flow of information in forecasting simulation functions Simulation Simulated Detail Simulation to Forecast Criteria Forecast Forecast Summarized Maintenance MRP Maintenance Calculation Maintenance Forecast amp Worksheet y Simulation Shipment Simulation to Simulated Criteria History Simulation Forecast Inquiry Data Copy Reports Forecasting Horizon Forecasts generated using forecasting simulation functions are produced in monthly buckets They can either be for a given year or for the next 12 months beginning with the current month The latter is called a rolling forecast Fig 12
346. orecast records You can increase decrease or scale the resulting detail record or multiply the detail record by a trend factor Forecasting Master Schedule Planning 335 Using this function to copy or combine forecast detail records automatically deletes the original or target forecast record and replaces it with the copied or combined record The source detail record and criteria template remain unchanged Single ltem Simulation Copy Single Item Simulation Copy 22 7 12 enables you to create a forecast for a single item based on the historical sales data for another item Since there is often little or no sales history for new items you may want to use the demand history for a similar product to produce forecasts for a new product Note Ifthe Target Forecast ID Item Number or Forecast Year fields are left blank the system sets them to the target values You must specify an item number to copy from the source detail record This item must exist in the item master Forecast records are copied only in terms of units The source and target items must have identical units of measure or a unit of measure conversion must exist If the specified target forecast detail record already exists in the system its forecast method must be 00 If the target does not exist the system creates a forecast detail record with a method of 00 When copying forecast records forecast amounts can be multiplied by a P See Multipliers Base
347. orecasting use of 324 underlying patterns 324 Index 399 Sales Order Control Consume Forward field 341 Integrate with SA field 322 Sales Order Maintenance abnormal demand 340 consuming forecast 340 sales orders abnormal demand 340 demand 340 Sample by Lot Interval Inquiry 310 Sampling Pattern Maintenance 309 Days to Expire field 309 lot interval 310 Schedule Delete 157 Schedule Explosion 175 211 Schedule Maintenance 174 Schedule Print 211 Schedule Update from MRP 206 211 co products by products 98 Scheduled Order MRP Maintenance 206 scheduled orders repetitive subcontracts 204 scheduled work orders 109 schedules advanced repetitive explosion 175 line simulations 169 repetitive 173 work orders 115 scheduling See also master production scheduling MPS scrap compared to yield 41 component loss 131 co products by products 85 cycle 131 material requirements planning MRP 18 product loss 132 product structures 18 quantities by order 132 types 289 WIP lot serial tracing 289 Scrap Analysis Report 199 scrap quantities during receipt 218 Scrap Transaction 195 tracing WIP 293 scrap transactions 220 Scrap Valuation Report 200 scrapping specified quantities 210 scrapping subcontract items 200 scrapping unreturned material 210 Seasonal Build Maintenance 352 QAD 400 User Guide QAD Manufacturing seasonal pattern 324 seasonality master scheduling for 351 secondary run sequence 361 security site 102 Selective Mat
348. ormal product structure relationship X A local phantom Costed and exploded but never planned as component requirements D Document Records miscellaneous expense items or documents associated with this bill that are not planned exploded or costed O Option An optional component Normally defined using Configured Structure Maintenance 8 1 options may also be entered in planning bills P Plan Planning bill used for multilevel master scheduling Not exploded or costed A Alternate Automatically created by the system for an alternate structure for this parent Not planned exploded or costed Option and planning bills are used to create production forecasts LT Offset Not all of the components of a manufactured item are always required at the beginning Normally the differences in timing are not significant However if components are required long after the start date and or the cost of those components is significant consider using lead time offset Enter a positive or negative number indicating the number of days after or before the start of an order when this component is required MRP uses lead time offset to determine the need date for components and segregate them on separate picklists for individual work orders Table 2 2 Structure Type Codes gt See Forecasting Mas ter Schedule Planning on page 319 FAQAD 20 User Guide QAD Manufacturing b See Backflush Transaction on page 191
349. ormula codes automatically when you define formulas and product structures BOM Code Enter the base process item number Batch Size Displays the batch quantity The default is 0 To modify this field use Batch Quantity Change 15 9 UM The BOM unit of measure Should be the same as the item unit of measure for the base process item 2 Setup the co by product structure using Process Formula Maintenance 15 18 or Co By Product Maintenance 15 12 1 Backflush Method Enter 1 or 2 This determines the calculation method used to backflush base process components Co products and By products 63 Quantity Complete Method Enter one of five valid calculation See page 89 methods This method determines how the expected co product and by product receipt quantities used to calculate variances for joint order sets are determined The default is from Work Order Control 16 24 Co By Type Enter C for co product or B for by product Quantity Enter the quantity per batch if Qty Type is Batch or the quantity per base process unit if Qty Type is blank The system calculates this field automatically when Qty Type is Percent Qty Type Enter B for batch P for percent or leave blank to indicate per base process unit Process Enter the percent per batch when Qty Type is Percent This is calculated automatically when Qty Type is Batch Cost Allocation Enter the percentage of base process cost to be allocated to this co product
350. osts and reduce costs booked to discrepancy accounts the following should be emphasized Complete reporting of co product and by product quantities when all quantities for all items are completed Setting of work order status to Closed when receipt quantities are reported e Running of Work Order Accounting Close on a regular basis to process recently closed work orders Note Re averaging of co product costs is time sensitive The greater the time between receipt and close the greater the probability that some of the products produced have been consumed The cost change taken to inventory is bounded as follows Upper limit Greater of the existing average cost or calculated work order unit cost Lower limit Lesser of the existing average cost or calculated work order unit cost Rolling Up Lead Times The lead time to produce the co products resulting from a base process is the same as the lead time for the base process Cumulative Lead Time Roll Up 13 12 14 copies the manufacturing lead time and the cumulative lead time for a base process to its co products Typically the roll up program is run for all items not just those involved in co product by product structures Co products and By products 77 By product lead times are not derived from the base process but from roll ups of regular product structures and routings Enter by product lead times in Item Planning Maintenance 1 4 7 or Item Site Planning Maintenan
351. ou set this field to Yes you can specify subcontractor supplier C on the subcontract shipper with item A work order 20 the subcontract PAINT operation and other data associated with the order If you set this field to No you can only specify subcontract supplier A or B on the subcontract shipper Manual Shipper Update Indicate if you want to manually track subcontract activity by connecting subcontract shipper numbers to subcontract purchase order lines when you receive or return items No the default The system automatically updates subcontract shipper records with receipt or return quantities The system updates the open subcontract shipper with the oldest ship date As open subcontract shippers are consumed closed the system updates the next open subcontract shipper with the oldest ship date and so on Yes The system lets you specify the subcontract shipper and updates the subcontract shippers with the quantities received or returned beginning with the shippers you selected When Yes the system displays the Subcontract Shippers frame in Purchase Order Receipts 5 13 1 Purchase Order Returns 5 13 7 and PO Shipper Maintenance 5 5 5 5 and 5 13 14 Use the frame to View and associate multiple subcontract shippers with the receipt or return View WIP lot serial numbers of items being received or returned Indicate whether the subcontract shipper is fully received even when the quantity received does not mat
352. overlap units in Routing Maintenance 14 13 1 Rescheduling Operations If you modify the operation start and end dates changes are reflected on CRP and work order dispatch reports However executing Recalculate Capacity Plan 24 1 will return the schedule to the original dates To prevent this do not recalculate Exploded Allocated or Released orders You can also modify the queue or wait time for the operation rather than its start date Modifying Work Orders Every work order has a BOM and a routing code which determine the order s product structure and routing When a routing or BOM code is blank it defaults to the item number value You can specify these for each daily scheduled requirement Modify these codes as needed in Work Order Maintenance 16 1 and then re explode the order Re explode Planned Firm Planned or Batch orders as needed by running MRP or by changing the work order status to Exploded Allocated or Released Modifying Work Order Bills Often you must modify the bill of a rework order by adding components Sometimes as well you must modify the bill of a regular work order For example there may be an engineering change order needing immediate implementation for all work in process including orders that have been exploded allocated or released How you make a replace an existing component with a new one depends on the work order status If an order has been released you can issue the new co
353. p by first considering and listing which parent items need to have component and WIP material traced From this list derive the routings and BOMs used to manufacture the parent items You need these routing and BOM codes to set up this module You should also note whether any special tracing requirements exist such as operations in a routing where tracing should begin or specific BOMs for which component items should not be traced You should have this information prepared before you begin to set up WLT Knowing exactly which routings and BOMs consume components and create the WIP material you need to trace lets you configure the WIP Lot Trace module effectively This is because you can configure the module to FAQAD 260 User Guide QAD Manufacturing AQAD trace components and WIP for all routings and BOMs with the exception of only a few or you can configure it to trace components and WIP for only a few routings and BOMs Milestone and Non Milestone Operations WLT cannot be used to track WIP material at non milestone operations WIP lot serials are produced only by milestone operations Additionally WIP quantity on hand QOH balances cannot reside in the input queue of the first milestone operation of any routing This is true even if the first milestone operation is not the first operation in the routing To track WIP material including the component material consumed and parent items produced routing operations that consu
354. p subcontractors as work centers You can use codes such as PAINT HEAT or STAMP for subcontractor work You can also enter a supplier code if you set up your subcontractor as a supplier in your standard operations Subcontract LT Enter the average number of calendar days it normally takes a subcontractor to perform the operation You should enter either subcontract cost and lead time or setup run and move time Specifying both can overstate lead time and result in incorrect schedules Subcontract Cost Enter the average cost per unit normally charged by the subcontractor to perform the operation Cost calculation functions determine item costs based on subcontract cost Enter either subcontract cost and lead time or setup run and move time Specifying both can overstate cost and lead time and result in incorrect schedules Fig 8 16 Routing Maintenance 14 13 1 FAQAD 204 User Guide QAD Manufacturing b See User Guide QAD Scheduled Order Management FAQAD WIP Item Enter the item that represents WIP material for the subcontractor Sub Shipper Print 18 22 5 9 uses this field to provide the description and unit weight on the subcontractor shipper Move Next Operation This field sets the default for the same named field in Repetitive Backflush 18 22 13 Move Next Op at the milestone operation before the subcontracting operation must be No Sub Shipper Issue 18 22 5 11 transfers items from the output que
355. peration 20 the system closes operations 10 and 20 for a quantity of 90 units and operations 30 and 40 for a quantity of 75 units Previously Operation Completed Completed 10 0 90 20 90 90 30 0 75 40 0 75 50 0 75 If operation 40 was closed for a quantity of 85 units the system closes operation 30 for a quantity of 85 and operations 10 and 20 for a quantity of 90 Previously Operation Completed Completed 10 0 90 20 90 90 FAQAD 148 User Guide QAD Manufacturing AQAD Previously Operation Completed Completed 30 0 85 40 85 85 50 0 75 Note Work Order Accounting Close 16 21 closes open operations using the same logic Closed operations do not contribute to the projected load for a work center Generating Reports The Shop Floor Control Reports menu 16 20 13 contains reports that display data based on the following Transactions Downtime Input and output Utilization and efficiency Transactions Transactions are created when you record labor feedback nonproductive labor downtime and operation completions You can review these transactions by work center work order or employee The system automatically assigns a transaction number and transaction type that identifies the operation history record Table 7 1 lists the system generated types and the name of one or more of the programs that creates the transaction Note Many of these transactions are created in more than one program
356. peration to its scheduled start date Even for operations with run times longer than one day load is not spread between operation start and due dates Reviewing Input and Output You can compare the planned input and output for a work center or machine with actual input and output using Input Output Inquiry 24 4 and Input Output Report 24 5 These functions help you evaluate a work center or machine s response to planned loads You can display planned and actual input and output in daily weekly or monthly periods Planned Input Planned input is load on a work center or machine represented by work order operations scheduled to start in a reporting period It is determined using the following calculation Standard Setup Standard Run Quantity Ordered FAQAD 384 User Guide QAD Manufacturing FAQAD Actual Input Actual input is load that has been moved to the first and subsequent order operations It is calculated for a reporting period based on move transactions entered using work order release and shop floor control functions Actual input is determined using the following calculation Standard Run Hours Quantity Moved Planned Output Planned output is load calculated based on order operations scheduled to be completed in a reporting period It is determined using the following calculation Standard Setup Standard Run Quantity Ordered Actual Output Actual output is load calculated for a reporting peri
357. ply row 242 Supply Demand Summary matrix 242 T templates forecasting 322 Test Results Maintenance 314 The 141 time fence MRP use of 365 tracing source records 237 transactions deleting and archiving 152 transactions scrap 220 transfers inventory repetitive picklists 179 WIP 184 type product structure 19 work order 106 U unassigned suppliers 208 unit of measure co products by products conversion factors 66 Unit of Measure Maintenance co products by products 66 unplanned items co products by products 88 Unplanned Receipts co products by products 88 unreturned material 210 usage variances component 197 co products by products 91 Index 401 labor and burden 198 types 198 WIP material scrap 197 User Forecast Method Maintenance 325 328 user ID captured 135 utilization 151 V variance calculating mix 89 laborrate 141 posting at shop floor control 104 view multiple subcontractors during receipt 209 viewing subcontract operations 224 Ww When 220 WIP Adjust Transaction 195 WIP Lot Queue Adjust frames 293 WIP Adjustments Analysis Reports 199 WIP Lot Convert Trans Report 292 301 WIP Lot Input Queue Issue Data frame 276 WIP Lot Input Queue Scrap Data frame 280 WIP Lot Inquiry 302 WIP Lot Inventory Status Report 298 WIP Lot Move Data frame 283 WIP Lot Non Convert Trans Report 301 WIP Lot Output Queue Issue Data frame 288 WIP Lot Output Queue Receipt Data frame 277 WIP Lot Output Scrap Data frame 28
358. ponent Check by Work Order Production Line Production schedulers can use Component Check by Work Order Production Line to quickly determine if the production schedule is viable for the day week month or any specified period Component Check by Work Order Production Line provides quick answers for production schedulers when they need to know the following Before releasing a work order WO to the floor are all components available For production orders scheduled over the next one days are there component shortages For repetitive production schedules you can determine if there are material shortages which components are short and by when or whether you have enough supply coming in to meet future demand This is accomplished with a time phased component shortage engine that calculates availability and lets you view work order component status in terms of shortage severity That is you can easily determine which components have a shortage and the level of severity for the shortage Because the system provides a time phased view of component supply and demand you can know your supply and demand based on any given date work order or production line You can View production schedule data by any combination of site production line or operation item due or release dates quantity complete open or ordered and more View both planned and scheduled orders associated with a production line Identify which repetitive orde
359. process as their BOM Formula code MRP then creates planned orders to fill the unsatisfied co product demand without regard to projected quantities on hand for the base process Unlike the planning process for regular items MRP does not consider P See Setting Up base process inventory There should never be an on hand balance for a oo base process Use item status codes to prohibit inventory movements Process on sales purchases and repetitive orders on base process items page 60 MRP does use the order policy and order modifiers for the base process except safety stock when creating planned orders If the order policy is not period order quantity POQ or fixed order quantity FOQ MRP uses an order policy of POQ If no order period is specified MRP uses an order period of seven days When MRP plans a base process it searches for the first unsatisfied demand record for a co product Then depending on whether the order policy is POQ or FOQ MRP evaluates unsatisfied demand records for all co products of the base process POQ MRP searches from the first unsatisfied demand record through the end of the order period FOQ MRP looks at all unsatisfied demand records for all co products that fall on the same date as the first unsatisfied demand record MRP creates one or more planned orders to satisfy demand for the co product that presents the greatest demand for the base process for a specific date or date range As a result p
360. processed using the base process order for a joint order set Processing Joint Orders at Work Order Close Use Work Order Accounting Close 16 21 to process joint orders when a base process order is selected to be closed This procedure calculates mix variances updates current average and last costs and updates GL average costs for co products and by products Deleting and Archiving Joint Orders Use Work Order Delete Archive 16 23 to process all orders in a joint set when any one of the work orders in the set is selected for processing Tracing Lots The lot number for a base process is its work order ID number or the lot number assigned to that order using Work Order Attribute Maintenance 1 22 4 The system automatically maintains lot to lot relationships for joint orders by creating receipt and issue transactions between a base process and its joint order set These are memo transactions that do not update inventory or create GL transactions Co products and By products 89 Use Lot Where Used Inquiry 3 22 4 to trace a component lot number to a base process and trace upward from the base process to the co product and by product lots produced from it Use Lot Actual Bill Inquiry 3 22 3 to trace a co product or by product lot number to the base process that produced it and trace downward to the component lots for the base process Accounting for Joint Orders All GL transactions for issues receipts and shop floor cont
361. quantity is made available causing a net increase in supply It takes into account all sales order and required ship schedule demand and gross requirements up to the next increase in available supply Master Scheduled Receipt Sales Orders and Required Ship Schedules Gross Item Requirements Seasonal Build Net Increases Seasonal Build Net Decreases ATP When demand exceeds supply ATP for that period is zero The system applies excess demand as real demand in the following order Excess demand is applied against the ATP quantity for previous periods until all excess demand is eliminated or the ATP quantities for previous periods are exhausted If demand exceeds supply after prior period ATP is consumed the system consumes future period ATP until demand is satisfied or all supply is exhausted When both past and future ATP is exhausted the system displays a negative ATP quantity for first period ATP and the master schedule are bucketless because they are calculated using dates rather than fixed periods However master schedule report functions let you report ATP quantities in monthly weekly daily or GL calendar period buckets Multilevel Master Scheduling Sometimes demand for one item is dependent on demand for another item This is typical in assemble to order environments where it is unrealistic to stock all of the possible combinations of end items included in the selection of available models and options
362. r Data for details FAQAD If necessary use Work Order Split 16 9 to move part of a work order through remaining operations while the rest waits for needed components You can split open operations between the original and new work order When an order is split each portion keeps the same work order number but has a unique ID Component costs are typically tracked under the original ID However when you split the order you are prompted to divide the components between the original work order and the new work order You can divide component only if they have not been issued Use Work Order Bill Maintenance 16 13 1 to adjust the bills as required Labor is tracked separately for each ID on the work order Creating Picklists After you release a work order you can print its picklist The picklist lists the component requirements and the sites locations lot serial numbers and reference numbers for the items to be issued The system creates detail allocations when an order is released regardless of whether or not you print a picklist Detail allocations reserve specific quantities in inventory for a work order The picking logic used is determined by settings in Inventory Control You can release an order without printing a picklist and routing but you cannot print a picklist for an order without releasing it In a picklist floor stock appears separately without site or location Floor stock should have issue policy set to N
363. r Mult Example If the stocking unit of an item is liters but the item is delivered to the work center in 500 liter barrels set an order multiple of 500 to ensure the item is transferred 500 liters at a time You can transfer inventory even if a picklist has not been created or printed Use the Alloc and Picked fields to set the default for your transfers You can also directly specify inventory to issue After issuing inventory the system records an ISS TR transaction and a RCT TR transaction in transaction history Advanced Repetitive 181 Managing Cumulative Orders The system keeps a running total for each combination of items sites production lines product structures and routings using a cumulative order The cumulative order tracks work in process WIP costs and quantities for repetitive production A cumulative order is created for a profile that defines the site item number production line routing code BOM formula code for the order and start and end effective dates Cumulative orders can be created three ways Automatically by the system when you execute a repetitive transaction 18 22 13 18 22 21 Oneata time with Cumulative Order Maintenance 18 22 6 na batch with Cumulative Order Create 18 22 11 When a cumulative order is created a cost rollup establishes the cumulative order cost Cumulative orders have an assigned ID number but no order number Repetitive transactions create a cumulative ord
364. r Purchase Order Receipts The quantity you enter cannot exceed the subcontract shipper quantity b Enter a positive number in the Receipt Quantity field to indicate returned quantities if the Subcontract Shippers frame displays in Purchase Order Returns The quantity you enter cannot exceed the subcontract shipper quantity 3 To return an item on a purchase order that is linked to a previously closed subcontract shipper set Close Sub Shipper to No The system reopens the subcontract shipper and updates the received quantities to reflect the portion of the item quantity that you return Once you update the quantity the system opens the subcontract shipper for that quantity b See Defining Subcontract Shipping Control Options on page 208 FAQAD 220 User Guide QAD Manufacturing Fig 8 25 Subcontract Shippers Frame AQAD 4 Add comments about why you are returning items or reopening the subcontract shipper in the Comments field Purchase Order Returiis XI DB NY USD 5 13 7 Purchase Order Returns 03 12 07 GoTo ACTIONS Purchase Order BCPOA Supp ier SUPO Status RTY Nor Subcontract Shippers Shipper Number Lot Serial Reference Open Qty Receipt Qty SHN1 RANN n nn Shipper Number SHO1 Lot Serial Reference Receipt Quantity 0 0 Scrap Quanrity 1 3 Cose Sub Shippe 7 Corrments M Enter a positive quantity in a return program or a negative quantity in a receipt program Use Subcontract Item Sta
365. r fairly constant The routing does not include subcontract operations The Advanced Repetitive module supports manufacturing environments where the following apply Manufacturing lead times are long Continuous processing is in use lines are dedicated to one item for days weeks or months WIP costs are variable or high FAQAD Advanced Repetitive 155 Subcontracting operations are managed in a release management just in time environment Batches can overlap and visibility of and control over WIP are necessary Note The WIP Lot Trace WLT module affects some features of the gt For details see Advanced Repetitive and Repetitive modules WIP Lot Trace is available E eos as menu option 3 22 13 When activated additional frames display in on page 251 some programs The discussion in this chapter assumes that WLT features are not active Distinctive Features of Advanced Repetitive Advanced Repetitive provides features that are not available in the basic Repetitive module Cumulative Work Order Processing Ability to post usage variances without having to close a cumulative order Ability to close a cumulative order and transfer work in process WIP balances to a new cumulative order for easy phase in of product structure or routing changes This also supports accounting period cutoffs Automatic start and end effective date assignment for cumulative order expiration dates Expanded WIP inventor
366. r manufacturing environment you should list these restrictions organized by routing operation and work center It is very important to note any lot size restrictions that differ at operations within the same routing The lot size information you collect facilitates configuring the WIP Lot Trace module You use it to create records in Routing Registration Maintenance 3 22 13 1 that limit the size of lots processed by a routing or routing operation Inventory Lot Quantity Issuing Restrictions Some manufacturing environments allow WIP inventory quantities to be driven negative by overissuing of material others do not WIP inventory is the amount of WIP material that resides at an operation If these types of restrictions apply in your manufacturing environment sort them by routing Then sort any restrictions within each routing by operation Example You have WIP lot 5A with 50 items at operation 30 of routing 101 At operation 40 you issue WIP lot 5A with 100 items This issue would result in an overissue of 50 items giving you a negative WIP QOH of 50 items at operation 30 You note that for routing 101 overissuing of WIP is allowed Use the information you collect regarding issuing restrictions to create records in Routing Registration Maintenance 3 22 13 1 that prevent or allow WIP lot overissuing based on the routing or routing operation QAD 262 User Guide QAD Manufacturing AQAD Inventory References In addition
367. r of days specified in the Consume Back field from the reporting transaction effective date It then searches for exploded schedules with due dates that are between this day and the effective date Schedules with due dates that are before the day specified in the Start of Week field are not considered Starting with the schedule that has the earliest due date the system consumes open scheduled quantities until all available quantities are consumed or all excess completions have been recorded against a schedule Note When Start of Week is set to Today the system does not consider the Consume Back value when searching for open schedule quantities to consume Only the Consume Forward setting is used If excess quantities still remain after the system has consumed open quantities on past schedules the system adds the number of days in the Consume Forward field to the reporting transaction effective date It then searches for exploded schedules with due dates that are between this day and the effective date Starting with the schedule that has a due date closest to the transaction effective date the system consumes open scheduled quantities until all available quantities are consumed or all excess completions have been recorded against a schedule Repetitive 235 When Consume Back and Consume Forward are both 0 zero the system simply transfers excess completed quantities to inventory and does not report them against a repetitive schedule
368. r receipt quantity Scrap Qty Enter the quantity you want to scrap To enter a quantity you must set Scrap Unreturned Material to Yes in Subcontract Shipping Control 18 22 5 24 If you enter a scrap quantity that equals the open quantity the system closes the subcontract shipper Note You cannot enter a scrap quantity in PO Shipper Maintenance 5 5 5 5 and 5 13 14 Close Sub Shipper This field lets you indicate whether the entire subcontract shipper is complete or not You can specify the subcontract shipper as fully received even when the quantity received does not match the original quantity shipped If you reopen a previously closed subcontract shipper and the cumulative ID has expired the system uses the ID from the scheduled order No The subcontract shipper is not complete and remains open Yes The entire subcontract shipper is complete If there are several lines for the same subcontract shipper setting this field to Yes on just one line updates all lines for that subcontract shipper as closed For example for a subcontract shipper that includes four lines if you set this field to Yes because you received the entire shipment of line 1 then the system sets the Close Sub Shipper field to Yes for the remaining three lines too Comments Enter comments about the receipt Use Subcontract Item Status Inquiry 18 22 5 17 to view the shipment status of subcontract items Set Show Shipped Complete to Yes to display the c
369. r these requirements at the Work center consisting of the material already there Actual OH and the material to be transferred Untransferred Picked minus the existing requirements The existing requirements consist of the Qty Req by Other Scheds and the quantity allocated at that work center to work orders or sales orders Qty Alloc Note When Use Work Center Inventory is No on hand inventory and quantities from untransferred picklists are not considered in the calculation As the equation shows the picklist supplies material for the work center not individual schedules You can ensure that picklists supply individual schedules by running the picklist calculation immediately after exploding each new schedule The picklist calculation already considers all existing picklists so the new picklist will only meet the new requirements FAQAD 178 User Guide QAD Manufacturing Choosing Options Repetitive Picklist Calculation offers several options to control the picklist calculation Use Work Center Inventory When Yes the system counts inventory in a work center as well as quantities from untransferred picklists as inventory Use Order Multiple When Yes the system determines the number of items to be transferred quantity required and then rounds that number up based on the order multiple defined in Item Master Maintenance 1 4 1 Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 When No t
370. rable material usage variance for the order Fig 6 9 Prior Scrap Cycle Work Center Good Quantity Receive into inventory through labor reporting Reject through reject reporting Rejects Scrap bad quantity reworked Report hours put into rework FAQAD 132 User Guide QAD Manufacturing Product Loss When products are lost during manufacturing you can record the loss for the work order when it is received For an operation you can record the loss using Shop Floor Control but this is for reporting only Shop Floor Control creates WO SCRAP operation history records but does not update the general ledger Only units recorded as rejects during work order receipt affect the general ledger debiting scrap and crediting WIP You can use Work Order Receipt Work Order Receipt Backflush or Work Order Operation Backflush to update the general ledger Note Another way to scrap items is by using an unplanned issue and changing the default account debit account to the Scrap account Scrap Quantities by Order To view scrap quantities by order regardless of costing method use Work Order by Order Report 16 3 1 Generating Reports Many of the Work Order Reports 16 3 reflect activities supported by the Repetitive module Table 6 10 Work Order Menu Report Reports Description Report 16 3 1 Work Order by Order Designed for managers who need th
371. race component lot numbers to base processes and to co products and by products Joint Work Order Sets When you enter a work order for a base process or co product the system creates a joint order set comprised of a work order for the base process and one for each of its co products and by products All work orders in the joint set called joint orders share the same work order number site and status but have different work order IDs Note While Rework and Expense work orders may retain the work order number shared by the joint order set they have a different status and are not considered part of the joint order set A joint order set consists of the following A work order for the base process A work order for each co product and by product A work order bill for the base process A work order routing for the base process FAQAD 82 User Guide QAD Manufacturing Table 5 4 Effect of Work Order Status Codes FAQAD Accessing and Modifying Joint Order Sets Joint orders for co products and by products can be added or deleted from a joint set when the status of the set is Exploded Allocated or Released Status codes determine when and how joint work orders can be modified relative to each other Status codes are always the same for all orders in a joint set The processing and restrictions applied are similar to those applied to work order bills Table 5 4 describes how work order status codes affect j
372. ract information frame to optionally specify the work order ID and operation where the subcontract services are required c Optionally specify the WIP lot serial of that material This lot serial prints on reports generated by Purchase Order Print 5 10 2 Use Work Order Component Issue 16 10 to issue the components for the operation For example many manufacturers send component item kits and WIP to their subcontractors or subcontract assemblers In these situations you issue the components and WIP a Use the WLT Current Work Center and Machine frame to specify the subcontract work center and machine to which components will be issued for this subcontract operation b Use the WIP Lot Input Queue Issue Data frame to specify the lot serials sent to the subcontractor WIP Lot Trace 291 c Use the Issued to WIP Lots frame to specify the lot serials processed and returned by the subcontractor 3 Report completed subcontract labor using Labor Feedback by Work Order 16 20 1 a Operation Complete should be No b Move Next Op should be Yes c Use the WIP Lot Output Queue Data frame to specify the WIP lot serials produced Lot serials default from the lot serials entered in the Issued To WIP Lots Data frame 4 Register the subcontract processing performed when you receive the subcontract material using Purchase Order Receipt 5 13 1 The work order operation is automatically closed Processing Subcontract Operations for Multip
373. rapped consumed and produced for each lot processed at every traced operation Table 10 7 Menu Description Program Programs That 3 13 1 Purchase Order Receipts poporc p OOH Inventory 5 13 7 Purchase Order Returns porvis p maae 16 10 Work Order Component Issue wowois p FAQAD 258 User Guide QAD Manufacturing Table 10 8 WIP Lot Trace Programs FAQAD Menu Description Program 16 11 Work Order Receipt WOWOIrC p 16 19 Work Order Operation Backflush wobkfl p 16 20 1 Labor Feedback By Work Order sfoptr01 p 16 20 2 Labor Feedback By Employee sfoptr02 p 16 20 3 Labor Feedback By Work Center sfoptr03 p 16 20 6 Operation Move Transaction sfoptr06 p 16 20 7 Operation Scrap Transaction sfscrap p 18 14 Repetitive Labor Transaction reoptr10 p 18 16 Repetitive Rework Transaction reoptr13 p 18 17 Repetitive Reject Transaction reoptr11 p 18 18 Repetitive Scrap Transaction reoptr4 p 18 22 13 Backflush Transaction rebkflmt p 18 22 14 Run Labor Transaction relbr p 18 22 15 Setup Labor Transaction reset p 18 22 16 Reject Transaction reject p 18 22 17 Rework Transaction rework p 18 22 18 Scrap Transaction rescrap p 18 22 19 Move Transaction remove p 18 22 21 WIP Adjust Transaction rewadj p WIP Lot Trace Programs WIP Lot Trace programs are located on the 3 22 13 menu This module includes the following menu level programs Menu Description Program 3 22 13 1 Routing Registration Maintenance wlrmmt p 3 22 13 2 Routing Registration Inquiry
374. ration is identified by a routing code and an operation number B Routing Maintenance Go To Actions Routing Code 20005 FG20005 Operation 10 Start Date 02 22 2007 End Date Standard Operation Work Center ROUT WC1 Routing Work Center 1 Machine Description Machines per Operation 1 Milestone Operation v Overlap Units 0 Subcontract LT 0 Queue Time 0 0 Setup Crew 0 00 Wait Time 0 0 Run Crew 1 00 Setup Time 0 0 Tool Code 2 Run Time 0 0 Supplier P Move Time 0 0 Inventory Value 0 00 Start Date 02 22 2007 Subcontract Cost 0 00 End Date M Comments Yield Percent 100 0096 Many of the fields in Routing Maintenance are the same as in Standard Operation Maintenance 14 9 Additional fields are described below Routing Code This is typically the same as the item number but routing codes and item numbers are entirely independent This allows the same routing to be used for multiple items One item can also be made using one of several routings A matching item number and routing code are automatically linked to each other When an item s routing code is blank in the item or item site planning data the system uses the item number as the routing code If they are different specify the routing code in Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 Operation Each routing consists of a series of steps Enter a number to identify this step within this sp
375. rations and work centers to existing routings Use Standard Operation Maintenance 14 9 to set up standard operations x Standard Operation Maintenance Go To Actions Standard Operation INSP Fe Description Inspection Work Center 200 02 Machine 2000 Setup Time 2 0 Run Time 0 001 Move Time 0 5 Yield Percent 98 0096 Tool Code Supplier Milestone Operation I Inventory Value 0 00 Subcontract Cost 0 00 Subcontract LT 0 Overlap Units 0 Comments I Work Center and Machine Enter codes for the work center and machine that normally perform this operation Setup Run and Move Time Enter the normal times in decimal hours to process items during this operation Run time is per unit setup and move time are independent of order size Routings and Work Centers 33 Yield Enter the order percentage expected to be in usable condition See Yield on after this operation page 41 Tool Code Optionally enter the code for a tool normally used during this operation This is for reference only To standardize tool codes set them up in Generalized Codes Maintenance 36 2 13 for field ro_tool Supplier If this is a subcontract operation enter the code of the supplier doing the work Milestone Operation Enter Yes to define this as a repetitive labor See Chapter 9 reporting operation and to backflush all previous operations since the Repetitive on a page 227 last milestone operation Th
376. rder is like an allocated order except that detail allocations are made for its components and its operations are scheduled Depending on which program is used a picklist or routing can be printed when an order is released The picklist uses detail allocations to indicate the specific inventory detail records to pick for the order You can record inventory transactions or labor feedback against work orders with status Released Closed Work orders are typically closed when the items are received This status is useful for reporting For most purposes this ends the life cycle You cannot process inventory transactions for closed orders However additional labor can be reported until either The operations are closed in Shop Floor Control Work Order Accounting Close 16 21 is executed FAQAD 114 User Guide QAD Manufacturing See Routings and Work Centers on page 25 gt See Chapter 7 Shop Floor Control on page 139 b See Yield on page 41 gt See Material Requirements Planning on page 355 FAQAD Routing Code Work order routings identified by routing codes specify the operations or steps required to manufacture an item Set up routings and operations using the Routings Work Centers module Link routings to items using Item Master Maintenance 1 4 1 or Item Data Maintenance 1 4 3 When a work order is created the standard routing is copied into it As work progresses req
377. re Supplies pop up frame These items are consumed during testing or inspection and are issued from inventory They are not issued to WIP but are treated as floor stock and expensed to cost of production when quality orders are processed Defining Sampling Patterns Define sampling patterns for items in inventory in Sampling Pattern P See Inventory Maintenance 19 3 1 Patterns can be defined so that an audit selects e 1 Ci inventory based on expiration dates or lot interval more details Days to Expire Specify the number of days prior to expiration an item is to be sampled FAQAD 310 User Guide QAD Manufacturing FAQAD You can specify different sampling criteria for each item either on a regular interval or prior to expiration Sample by Lot Interval Inquiry 19 3 14 reviews items based on the first criteria and Sample by Expire Days Inquiry 19 3 13 reviews items based on the second Both print in sequence by item number When sampling by days to expire the system reviews all of the inventory details for this item and selects any that are due to expire within this number of days Sampling by Days to Expire is only useful for items with limited shelf life as defined in Item Site Inventory Data Maintenance 1 4 16 or Item Master Maintenance 1 4 1 Lot Interval Use this method for sampling items that are stored at more than one site or location and that are stored with lot serial or lot reference numbers Enter a val
378. re received if the components are linked to the last operation Note For each change in the quantity complete at a milestone operation the quantity complete at all of the previous non milestone operations is changed to reflect the fact that the later operation was completed If completions are recorded on nonscheduled dates the reporting of quantities on these dates causes entries to be automatically added to the repetitive schedule If you are using shipping groups and inventory movement codes you can See the Shipping enter shipment information and generate shippers when items are os DAD backflushed The system looks for a shipping group with matching Sales for details addresses for the issuing and work order sites and with inventory movement codes that include ISS WO If you report completions for today s date using Repetitive Labor Transaction the report has the following effects Inventory is incremented by the completion amount A backflush occurs Component inventory is shown as issued to the repetitive order The requirements for components at all previous non milestone operations are decremented Floor stock items are accounted for If there is a scheduled amount for today the quantity completed is incremented and the quantity open decremented until the scheduled quantity is reached These quantities can be reviewed in Operation Schedule Report 18 2 5 f there are previous non milestone operations the quantity
379. recalculated automatically or maintained manually depending on the work order status Adjust Co By Order Dates Enter Yes or No This prompt does not appear on base process work orders If the order release or due date changes entering Yes resynchronizes the dates for all orders in the joint order set The work order status must be E A R or C to optionally adjust dates Firm status orders always resynchronize the dates for all orders in the set Default due dates for orders in a joint set are calculated using the manufacturing lead time for the base process FAQAD 84 User Guide QAD Manufacturing P See Setting Up Mix Variance Accounts on page 59 FAQAD Mix Variance Acct Sub Account and Cost Center Enter the account number for Mix Variance Account defaults from the product line of the item and may be different for work orders within a joint order set If this field is blank you should define a default account in Product Line Maintenance 1 2 1 Creating a Joint Order Set from an Alternate Base Process To create a joint order set using an alternate base process use Work Order Maintenance 16 1 Enter a work order using the item number for the alternate base process Enter a work order for a co product and specify an alternate base process as its BOM Formula code Define valid alternate base processes using Alternate Structure Maintenance 13 15 Enter the co product item as the item number and the b
380. rements These planned orders are imploded creating planned orders for each of the co products and by products Material Requirements Planning 369 Routable Assemblies For routable assemblies MRP generates a separate routable work order when an order for the parent item is released Usually you should not approve these orders or change their status to firm planned Improving MRP DRP Performance Because of the number of calculations required in an MRP or DRP run it can be a time consuming resource intensive process MRP DRP is typically executed as a batch process for example at night when the load on the system is usually much lower To enhance MRP DRP performance in an environment that includes Symmetric Multiple Processor SMP computers your system can be configured in two optional ways which are described in more detail in the DRP discussion Running synchronized simultaneous MRP DRP calculations by defining synchronization codes Using a Progress application server AppServer to perform multi threaded processing which allows MRP DRP tasks to be spread out among more computing resources These methods can result in a significant improvement in the time required to run MRP particularly with scenarios such as running regenerative MRP for a large database that includes multiple sites MRP Scheduling When MRP runs it compares each item s demand with existing supply orders for each period It automatically re
381. ring FAQAD If you see It means indented command line A long command that you enter as one line although it appears in the text as two lines Note Alerts the reader to exceptions or special conditions Important Alerts the reader to critical information Warning Used in situations where you can overwrite or corrupt data unless you follow the instructions Work Orders Shop Floor C Flow Sche anban 6 User Guide QAD Manufacturing Manufacturing modules handle internal supply and demand material is moved out of inventory into production or finished goods or components are moved from production into inventory These modules are used by make to stock assemble to order process batch process flow kanban and repetitive operations Figure 1 1 illustrates the manufacturing modules Fig 1 1 Manufacturing Product Structures Capacity Requirements Routings Planning CRP Work Centers Material Requirements Formula Planning MRP Process Forecast 5 Co products Master Plan Hir Rig By products Quality Work Management Orders Shop Floor R am Control Flow epetitive Scheduling and Kanban Advanced Repetitive P See Product Once items such as products components and materials are identified in er em your system the Product Structures module adds and maintains the bills of material for each product ass
382. ring drawings and bills define transient product items that exist independently for a relatively short time and are not stocked Instead they are immediately consumed by higher level products These are called phantom structures Example Frames for sunglasses are assembled or purchased but before final assembly the company name is printed on the side An engineering drawing specifies the exact location The product structure now has one FAQAD 16 User Guide QAD Manufacturing FAQAD more level a labeled frame In practice when the sunglasses are being manufactured the labeling and final assembly processes may be so close together that the labeled frames without lenses exist only briefly A product that starts out as a normal subassembly that is kitted manufactured and stocked can later evolve into a phantom If manufacturing engineering can support changes to the manufacturing flow you can use phantoms to reduce inventory movement shorten lead times and effectively reduce the levels in a bill of material Using phantoms may require changes in manufacturing technology or something as simple as introducing kanban to control the movement of components and phantoms Use Item Planning Maintenance 1 4 7 to identify an item as a phantom for all sites When an item is a phantom at one site but not at another indicate exceptions in Item Site Planning Maintenance 1 4 17 Items that are marked as phantoms using either of these
383. rk F Move to Next Operation I Previous Ops Complete I Start Setup Elapsed Stop Setup Elapsed Setup 0 000 Start Run Elapsed Stop Run Elapsed Run 0 000 Comment Down Time Down Time Reason Employee Some companies summarize the hours worked by all employees for an operation and record them in a single transaction Others record the hours worked by each employee Use the second method if you want to report on employee efficiency or examine labor rate variances You can calculate employee efficiency when you report labor by P See Utilization employee provided that only one employee works on any given DIS UE operation more information The system calculates labor rate variances by comparing the labor rate defined for an employee in Actual Pay Rate Maintenance 14 13 21 to the standard labor rate for the operation s work center defined in Work Center Maintenance 14 5 Note The employee code specified for a transaction does not need to correspond to an actual person You can set up an employee code in Employee Create 36 1 7 1 to be used for reporting purposes only FAQAD 142 User Guide QAD Manufacturing FAQAD Department The department code defaults from the work order routing The system creates GL transactions using the accounts associated with this department code Changing the department code changes the accounts used for the GL transactions created by these programs Work Center The work center code
384. rmine requirements at the top level first then continue down through the item structure one level at a time Regenerative MRP Regenerate Materials Plan 23 2 recalculates demand and plans supply for all items in the site The outputs of net change and regenerative MRP are the same However net change MRP generally runs faster than regenerative since it only plans for items that changed since MRP was last run You should always schedule periodic regenerative MRP runs even if you primarily use net change MRP since net change MRP does not consider demand or forecast for items entering the MRP horizon over time Note The first time you run MRP it should be regenerative Selective Materials Plan Selective Materials Plan 23 3 plans only for items and sites you select It can be run in net change mode by setting the Required Items Only field to Yes or in regenerative mode by setting Required Items Only to No You can use Selective Materials Plan to plan master schedule items separately from other items or to plan small groups of items by using buyer planner product line group type supplier or any combination of these as selection criteria Set MRP Items to Yes to generate planned orders for items at the specified sites and gross requirements for DRP items Set DRP items to Yes to generate intersite requests for DRP items Material Requirements Planning 373 Selective MRP recalculates demand and plans supply only for select
385. rocess is a manufacturing operation that creates more than one product These products are called co products or by products For this discussion a co product is an intended result of a base process and generally has significant value In contrast a by product is an incidental result of a base process Figure 5 1 illustrates a typical base process that produces two co products Fig 5 1 A Base Process menoy o Produces Multiple i Products Co product 1 Co product 2 Base Process 1 Component 1 Component 2 Raw Materials Example A sheet metal stamping process yields a piece of sheet metal used to make school bus window casings The stamping process also yields two other products Pieces of metal that are removed from the window hole and used to make seat brackets in another process Metal shavings that are swept up and disposed of at a cost The pieces cut from the window hole have value and are considered a co product The metal shavings have little value and an associated disposal cost and are considered a by product If the shavings can be sold as scrap the manufacturer may decide to define them as a co product instead See Figure 5 2 FAQAD 56 User Guide QAD Manufacturing Fig 5 2 Defining Co products and By products miraia School Bus Window Casing Factory Inc o Base Process Co pro
386. rogram Settings llleleleeeess 158 Setting Up Production Lines 0 0 eee eee eee 161 Setting Up Line Allocations 2 0 0 ce eee eee eee 163 Setting Up Shifts iiis us ceded ede dee ee ad 163 Setting Up Changeover Times 0 0 0 0 cece eee eee ee 165 Setting Up Routings and Operations 00 005 166 Setting Up Locations 0 0 eee eee eee 168 Simulating Schedules in the Workbench 0 0 00 c eee eee 169 Determining Order Multiples 0 00 00 0 ee eee eee 170 Sequence Numbers and Due Dates 00000004 171 Production Quantities 0 0 0 0 ce eens 171 Scheduling and Lead Times 20 0 0 0c eee eee ee eee 172 Deleting Sequence Records 0 0 c cece eee eee 172 FAQAD Contents ix Reviewing Line Schedules 0 0 00 cece eee eee eee 172 Creating Repetitive Schedules 0 0 0 eee eee eee eee 173 Updating a Repetitive Schedule from a Line Schedule 173 Schedule Maintenance 0 0 0 174 Reviewing Repetitive Schedules 0000000000 eee 174 Exploding Repetitive Schedules l l 175 Using Repetitive Picklists 0 0 0 keene eee 175 Calculate the Picklist ocsi 0 2 eee eee 176 Print the Picklist 2 2 Gaia eoh nel oe INR ek es 179 Transfer the Inventory 00 cece eee eee 179 Managing Cumulative Orders 0 0 0 cece eee 181 Cumulative Order Crea
387. rol transactions update the WIP account for the base process work order Table 5 5 shows the origins of account sub account and cost center information for work order transactions Table 5 5 Co product Origins of Account Account Sub Account Cost Center Base Process By product Component Sub Account and Inventory Product Line Product Line seer Scrap Product Line WIP Work Order Material Usage Variance Work Order Material Rate Variance Work Order Subcontract Usage Variance Work Order Mix Variance Work Order Floor Stock Work Order Calculating Mix Variances for Joint Orders Mix or yield variance is the costed difference between the actual b Also see Setting quantities received and scrapped for a co product or by product and the ee expected receipt quantity for that product page 59 For a co product or by product the expected receipt quantity is not always the same as the quantity planned when the joint order set was created For example you may receive more or fewer co product or by product items than ordered because you issued fewer components than originally planned In this case you will probably want the system to consider actual product receipt quantities as part of the mix variance calculation FAQAD 90 User Guide QAD Manufacturing P See Setting Up a Co By product Structure on page 62 FAQAD Mix variance calculation methods for co products and by products can accommodate a wide range of base pro
388. rs have material shortages related to them Identify the components causing the shortage related to a repetitive order Locate and determine the cause of material shortages View in transit supply in the form of ASN receipts FAQAD 244 User Guide QAD Manufacturing Fig 9 6 Component Check pomum UNE by Work Order Baie iei poten jette aee bora Production Line i Jem 2 x Eie Ge 10 a Membe 2 Component States Component Stats Quanti Ondered Quartty Compiled Quantty Open Renae Date Ove Oe wok OrderStans Prodictonine PwayUne Ste woo at Ves Complete 2 10 T 10 T1AX 207 11077007 R 10000 1065 620540 No Component 30 19 20 MAS T5200 a an T0000 104 4 No Component 1 30 oo 30 nana 1172072007 w 4 10000 Wwe ats Prnced Shotage w00 06 WOO NAE 1106007 e PN Mob ow Projected Shortage 7 100 ao o0 11 06 2007 11052007 pace deb Y citt Shotage 10 06 300 AIA 1100 007 A mer WO Component laiabity Schedule Mantenenca Net Change Matenals Plan Batons Pret oly Chan BB Cree Oovigner Verrg 15265 Records pes page 100 YYY Dem Number a V Component Sune OY Prorced Net Avalable Y OyFleqeed OY Quantiy Alocated SY Quanti Pid SY Oumiyined SY Quantity Open Y Desopion IDO F mor Ld 50 100 00 00 00 100 SA20101 LJ WO Como Availabilty Supeh Demand Summary WO Compenert Avadabiay Calculston Details twentory Detad ty Ste e D Aem t S Pho le IB an Denger New J tae Veng 1 1 oft Racot per page
389. ry short Total item costs consist mostly of material and overhead and the labor component is relatively small Capacity can be easily managed Repetitive module is not used Figure 3 1 summarizes the steps required to set up routings Fig 3 1 Routing Setup Workflow Set up shop calendar Define standard operations Define departments Set up routings Define work centers Important Work centers and operations work in conjunction with the P See User Guide shop calendar which determines the work days and hours for the plant oy i os Use Calendar Maintenance 36 2 5 to add work center specific calendars for more Before you begin defining the elements needed to create routings make information on calendars sure you set up the shop calendar FAQAD 28 User Guide QAD Manufacturing b See Chapter 14 Capacity Requirements Planning on page 379 Table 3 1 Department GL Accounts FAQAD Departments A department groups similar work centers Departments are like product lines because they are used to organize information on planning reports and to determine the GL accounts on transactions Each department is set up with a fixed daily labor capacity and a set of GL accounts Example A manufacturer of sunglasses has a department for lens fabrication with several work centers for lens grinding and lens polishing A separate department does lens coating The depar
390. s This includes additional WLT frames that display when you process a subcontract order Figure 8 21 depicts the tasks involved when processing a subcontract shipment that is not WLT controlled Advanced Repetitive 211 Create a repetitive schedule release Record receipt of items from subcontractor Optionally backflush materials i up to the subcontractor operation i Optionally move received items into finished goods if last subcontract operation Create subcontract shipper Report on items sent to and received from subcontractor Issue shipper to record items sent to subcontractor Creating Repetitive Schedule Releases Use Schedule Explosion 18 22 2 4 to explode the subcontract schedule When you explode a repetitive schedule the system creates the scheduled work orders generating component demands for each item and day Note The generated work orders are identified as a type S The S indicates a scheduled work order not a subcontract work order Next create the subcontract schedule release by running Schedule Update from MRP 5 5 3 1 Schedule Update from MRP uses the percentages you defined to allocate MRP planned orders for the item among subcontractors Transmit the schedules to subcontractors using Schedule Print 5 5 3 8 Schedule Print in Fax Format 5 5 3 9 or Supplier Shipping Schedule 35 4 8 if you are using EDI eCommerce to e
391. s and Work Centers on page 25 b See Formulas and Processes on page 45 P See Co products and By products on page 53 gt See Work Orders on page 99 See Shop Floor Control on page 139 FAQAD 8 User Guide QAD Manufacturing b See User Guide QAD Lean Manufacturing b See User Guide QAD Lean Manufacturing b See Advanced Repetitive on page 153 P See Repetitive on page 227 gt See WIP Lot Trace on page 251 FAQAD Flow Scheduling The Flow Scheduling module lets you create and manage the life cycle of time phased production schedules for use in a flow driven lean manufacturing environment Optionally you can link flow scheduled orders with existing demand orders and work orders Kanban The Kanban module lets you identify items that are kanban controlled maintain kanban related data for these items print kanban cards on demand and use kanban transactions to track and manage the movement of kanban controlled items in and out of the production process Advanced Repetitive The Advanced Repetitive module supports high volume manufacturing where lead times are more than a day and up to a month or more where work is continuous and lines are dedicated to one item for days weeks or months and where work in process WIP costs are either variable or high enough to track closely Repetitive The Repetitive module supports high volume manufa
392. s bills of material or routings Planning for more information Approving a planned work order with Planned Work Order Approval i planned orders 23 10 changes its status to firm planned Note Work orders with statuses other than Planned have fixed quantities and due dates and are therefore not replanned by MRP QAD 112 User Guide QAD Manufacturing AQAD Firm Planned A firm planned order has been approved This is the default status for an order you create in Work Order Maintenance MRP does not replan these orders but instead generates action messages as needed A firm planned order has a work order bill and a routing with scheduled operations These are not fixed Bills are re exploded by MRP while routings are re exploded by CRP Both are re exploded when the status is changed to Exploded Allocated or Released This allows entry of a work order for a fixed quantity and date while reflecting future engineering changes in the bill or routing as the order advances toward release You cannot record inventory transactions or labor feedback against firm planned orders Batch A batch status indicates that this is a firm planned order entered in batch This method speeds up processing for large numbers of orders The system does not create and explode bills or routings for these orders until their status changes As a result MRP does not recognize any component demand Enter batch work orders manually as needed or
393. s are rounded to the nearest ten thousandth Summarize If Quantity Complete Method is set to SUM in the co by product structure the following equation is used to determine the base process quantity complete Base Process Quantity Complete Co prod1 Quantity Complete Scrap Base Process UM Conversion Factor Co prod2 Quantity Complete Scrap By prod1 Quantity Complete Scrap Base Process Quantity Complete 55 1 1 2 25 3 15 0 56 1 2 28 15 67 2 284 15 110 2 In this case expected co product and by product order receipt quantities are calculated as shown in Table 5 9 Co products and By products 93 Table 5 9 Order ID Product Expected Receipt Calculation Sample Expected 1001 Orange Juice 110 2 50 100 110 2 0 5 55 1 Ce nator 1002 Pulp 110 2 30 100 110 2 0 3 33 06 SUM Method 1003 Seeds 110 2 10 100 110 2 0 1 11 02 Based on these expected quantities mix variance calculations are as shown in Table 5 10 Table 5 10 Order ID Product Mix Variance Calculation Sample Mix 1001 Orange Juice 55 1 56 1 50 0 9 1 50 1 35 buo MTM 1002 Pulp 33 06 28 0 50 5 06 0 50 2 53 SUM Method 1003 Seeds 11 02 15 0 60 3 98 0 60 2 39 The Summarize method may be appropriate for base processes in which the sum of the co product and by product output quantities is always close to or equal to the base process quantity E
394. s as sources of supply To recalculate total requirements at a work center delete all untransferred picklists A picklist remains open until deleted or inventory is transferred even if the schedule changes The picklist calculation blows through phantoms There is no phantom use up logic The picklist does not calculate requirements by shift Since the calculation is based on requirements from an exploded repetitive schedule it is not affected by changes in structures or routings You can further control the quantities on a picklist using the item site planning parameters Minimum Order and Maximum Order Print the Picklist Print the picklist in Repetitive Picklist Print 18 22 3 5 Printing changes the status of the detail allocated inventory to picked The picking logic is the same logic used elsewhere in the system set in Inventory Control 3 24 You can reprint the picklist without affecting inventory status Use Repetitive Picklist Undo 18 22 3 8 to cancel a picklist and reprint it later It changes the inventory status back to detail allocated When a picklist exists it is considered supply by later picklist calculations If you want to start over you must delete the outstanding picklists with Repetitive Picklist Delete 18 22 3 9 Deleting reverses all effects of running any picklist function If the inventory is picked or allocated it is returned to unallocated status Transfer the Inventory Use Repetitive Pickli
395. s available as option 3 22 13 When activated additional frames display in some work order programs The discussion in this chapter assumes that WLT features are not active Defining Control Settings Use two programs to specify control and default values for work order processing Work Order Control 16 24 includes several settings that mainly affect numbering and comment defaults An additional field affects the work order release process Fig 6 2 x Work Order Work Order Control Go To Actions Control 16 24 Auto W O Numbers v Next W O Nbr 400033 Work Order Comments v Routing Comments v Move First Operation v FAQAD 104 User Guide QAD Manufacturing Fig 6 3 Work Order Accounting Control 36 9 11 b See Calculating Mix Variances for Joint Orders on page 89 FAQAD Move First Operation This field determines whether the work order release function sets the status of the first operation to Queue If No the operation status is left blank and must be changed manually This field is typically set to Yes The released order then appears on the dispatch list for the specified work center and the Queue status indicates it is waiting to be started If a lengthy picking effort is required the work order may not be ready as soon as it is released In this case set this field to No Use Operation Move to change the status later Work Order Accounting Control
396. s for that item Computer Assisted Master Scheduling By defining time fences for master scheduled items you can let MRP control orders outside of a specified time period and allow the master scheduler to control orders within that time period To use this approach to master scheduling specify a planning horizon in calendar days for each master scheduled item in the Time Fence field in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 When MRP plans orders for these items it will not schedule order due dates within this time fence Forecasting Master Schedule Planning 345 Note The time fence for an item should generally be equal to the cumulative lead time for that item To use the computer assisted approach for master scheduling set the following values for each master scheduled item in Item Master Maintenance 1 4 1 or Item Planning Maintenance 1 4 7 Master Schedule Yes Plan Orders No Order Policy Any option other than blank Time Fence The cumulative item lead time Selective Materials Plan Selective Materials Plan 23 3 lets you plan master scheduled items separately from MRP items If you use the computer assisted approach to master scheduling you may want to run Selective Materials Plan as follows 1 Run Selective Materials Plan for master schedule items only 2 Adjust the master schedule and rerun Selective Materials Plan as needed 3 Run Selective Materials Plan for MRP scheduled
397. s frame 287 tracing WIP 286 Work Order Control 103 Work Order Cost Report 133 co products by products 85 Work Order Delete Archive 137 co products by products 88 Work Order Dispatch Report 127 134 Work Order History Report 134 135 co products by products 85 work order ID specifying in an order 205 Work Order Maintenance 105 closing orders 134 co products by products 80 83 deleting orders 137 master production scheduling MPS 344 master schedule orders 350 releasing orders 120 Work Order Operation Backflush 100 tracing WIP 286 Work Order Receipt 127 289 co products by products 72 85 87 FAQAD WIP Lot Output Queue Issue Data frame 288 WIP lot serial tracing 288 Work Order Receipt Backflush 123 128 co products by products 66 72 85 86 Work Order Release Print 109 120 123 co products by products 84 Work Order Reports 132 Work Order Routing Maintenance 120 operation status 144 Work Order Split 122 work order status 240 Work Order Status Change 111 Work Order Status Report 132 135 Work Order WIP Cost Report 133 co products by products 85 period end procedures 136 work orders 99 137 bill 114 119 BOM Formula 114 close and receipt date 135 co products by products 81 deleting 137 dispatching 134 due dates 115 forward vs backward scheduling 117 issuing components 123 multiple sites 125 joint order sets 81 key items 121 lead times 117 life cycle 100 manufacturing lead time 115 modifying 119 MRP planned 375
398. s substitutes A new order with a quantity of zero is added to the joint set Regulatory Attributes Control 1 22 24 setting for Modify Co By Product Receipts determines what items can be received by Work Order Receipt 16 11 Work Order Receipt Backflush 16 12 Work Order Operation Backflush 16 19 When an item does not have a joint order in the joint order set being processed Yes enables a receipt to be processed for any item number even if it is not defined as a co product or by product of the base process Noenables you to receive only the expected items or valid substitute items Valid substitute items are defined in Item Substitution Maintenance 13 19 P See Setting Up Definitions for Valid Substitute Items on page 68 QAD 88 User Guide QAD Manufacturing FAQAD When a substitute item is received instead of an expected one change the status of the joint set to Closed shortly after recording the receipt The order and open quantities for the expected item remain unchanged when another item is received as an unplanned receipt Closing the joint order set effectively changes the open or expected quantities for all items to Zero Receiving Unplanned Items Use Unplanned Receipts 3 9 to receive an item that has no work order Related items in the co product by product structure cannot be received with the item Processing Shop Floor Control Transactions Shop floor control transactions are
399. s that the item is now included in ATP calculations and is considered a source of supply by MRP Note Since MRP sums nets multiple seasonal build records within an order period ensure that the seasonal build forecast for zero is in an order period 48 following the period 47 with the forecast for the final quantity of 600 If the forecasts for 600 and zero are in the same order period MRP does not create orders for the final 200 units and only the 400 previously built are released to ATP FAQAD Forecasting Master Schedule Planning 353 Generating Master Schedule Reports The Master Schedule Summary Inquiry and Report 22 18 and 22 19 and Master Schedule Detail Inquiry and Report 22 21 and 22 22 functions display the following information Production Forecast System calculated forecast used in multilevel master scheduling Forecast Forecast quantity for an item either loaded into forecast summary records using Simulation to Summarized Forecast 22 7 13 or manually entered using Forecast Maintenance 22 1 or Forecast Worksheet Maintenance 22 2 Sales Orders Demand derived from confirmed sales orders and required ship schedules Gross Requirements Manufacturing requirements from a parent work order On a multilevel bill gross requirements can include both master scheduled family items type P and components of any type In a DRP environment gross requirements may also indicate intersite demand Master Scheduled
400. s useful if you plan orders in single units and schedule in multiples Or you can set Multiple to any meaningful decimal quantity such as 0 5 Then you can enter schedule quantities in units of 0 5 A negative value is not allowed Advanced Repetitive 171 You cannot change the value of Multiple on existing schedules if non divisible quantities would result Sequence Numbers and Due Dates The workbench uses sequence numbers and due dates to resolve scheduling conflicts When two production runs are scheduled for the same due date but there is only enough capacity for one the system gives priority to the one with the lower sequence number After planning the first production run and making adjustments for changeover time it plans output for the second production run Because the system uses finite loading the first scheduled due date for the second production run may be later than the date originally entered Whenever you create or modify a sequence record the system automatically reschedules the production quantities and dates and reassigns new sequence numbers To insert a new production quantity between two existing quantities enter a sequence number with a value between the two and a due date equal to the earlier of the two dates Production Quantities Add production quantities to the workbench directly or select from MRP planned orders The system converts the quantities on the planned orders to schedule quantities and delet
401. schedules planned orders to reflect changes in the plan and generates an action message for each rescheduled order Some orders MRP cannot change because they are firm planned or within the time fence specified in the item planning data For these it generates action messages suggesting that these orders be rescheduled to balance supply with demand b See the DRP chapter in User Guide QAD Supply Chain Planning for information b See User Guide QAD System Administration for information on AppServers QAD 370 User Guide QAD Manufacturing FAQAD When MRP reschedules planned orders for higher level end items lower level components dependent on the rescheduled demand remain associated with the original supply order date They are not automatically rescheduled based on where action messages say parent orders should be moved To adjust for this 1 Runselective MRP for master scheduled items and review and handle action messages 2 Run selective MRP again at this level to ensure that all action messages have been dealt with 3 Then run regenerative or net change MRP for all dependent demand items MRP Pegged Requirements MRP source to requirement pegging makes it possible to review each of the sources of demand for gross requirements Use MRP Detail Inquiry 23 16 or MRP Detail Report 23 17 to Trace the requirement for a particular end item to the forecast or sales order creating the demand dentify the
402. ser Guide QAD Manufacturing See the Shipping chapter in User Guide QAD Sales for details b See Subcontract Operations on page 40 for more setup details AQAD example if the part master site and location are Site 3 and Location 99 you would need to create Location 99 at the order site Site 1 before you could execute the issue or receipt transaction Note You can specify the item s default location for all sites in Item Master Maintenance 1 4 1 however since locations often vary by site you can set up site specific values in Item Site Inventory Data Maintenance 1 4 16 If you are using shipping groups and inventory movement codes you can enter shipment information and generate shippers during work order issues The system looks for a shipping group with matching addresses for the issuing and receiving sites and with inventory movement codes that include ISS WO Subcontract Operations Work orders with subcontract operations can be used in conjunction with special subcontract purchase orders When units are returned from a supplier with a subcontract purchase order the system recognizes the value added to the work order completes units for that operation and debits the WIP account Separate departments and possibly work centers should be set up for outside processing to distinguish them from internal operations For example if all subcontract work center codes begin with a common character such as
403. ser Guide QAD Manufacturing FAQAD Overview of WIP Lot Trace The WIP Lot Trace WLT module lets you monitor and trace work in process WIP inventory at each operation in the manufacturing process easily and accurately It facilitates tracking of WIP material lot serials processed by multiple subcontractors and supports serial tracking of WIP material as needed This module maintains detailed historical records including which components produced a finished item and which finished items went to a customer WLT can be used in manufacturing environments supported by the Repetitive Advanced Repetitive or Work Orders modules It adds WIP lot and serial tracing and reporting functions to manufacturing operations Tracing records are created at the operation level whenever registered resources are consumed or produced Data recorded includes the lot numbers and optionally the serial numbers and references of Component material consumed e WIP material consumed WIP material scrapped e WIP material produced Finished material produced Cumulative WIP quantity on hand QOH balances are maintained for all traced lots and serials at each operation queue at the site work center machine location where the lot serial resides While you can use this module to trace specific items throughout the manufacturing process it can be used most efficiently to trace the component and WIP material consumed in the manufacturing of parent items
404. set the Primary Line field to No and use Line Allocation Maintenance 18 22 1 11 to set the percent of an item s production for each line The production rate for an item on a production line is equal to that of the operation with the lowest production rate A production line is no faster than its slowest operation The Allow Zero Run Rate field in Advanced Repetitive Control lets you set up a global record for each production line that applies to all or most items on the line You can then specify item specific run rates by exception Production rates can vary by shift or day You can adjust the basic production rate for an item by changing the rate factor in the Productivity field in Shift Maintenance 18 22 1 22 Use the effective date associated with the production rate to indicate changes in a line when items are phased in or out of production or when rates increase or decrease at a certain date Run sequence fields can be used to control the sequence in which planned orders for line manufactured items are added to a production line schedule When Sort by Run Sequence is Yes in Planned Repetitive Sched Approve 23 8 approved orders are sorted and sequenced in production line schedules using the following hierarchy Due date Primary run sequence Secondary run sequence Item number Advanced Repetitive 163 Setting Up Line Allocations Within a supply site items can be produced on one or more production lines
405. similar to Double Moving Average except that it uses Smoothing the alpha factor to weigh the most recent sales data more heavily than the older sales data This method produces a forecast that lags behind trends effects 04 Winter s Linear Produces results similar to Double Exponential Exponential Smoothing but incorporates a seasonal trend Smoothing adjustment factor This method can be used to forecast based on sales history containing both trends and seasonal patterns Uses the trend and alpha factors Requires two years of history 05 Classic Recognizes three separate elements of demand Decomposition patterns in sales history trend seasonal and cyclical factors See Table 12 1 on page 324 for information about demand patterns Classic Decomposition is usually the preferred method for forecasting seasonal high cost items It requires at least two years of history 06 Simple Also called the least squared method this method Regression analyzes the relationship between sales and time span to ensure that the forecast quantity is equally likely to be higher or lower than the actual quantity sold Useful for products with a stable history or horizontal demand pattern Table 12 4 shows each of the predefined forecast methods and indicates the sales patterns they are typically used to quantify the number of years of shipment history required for calculation and whether they use alpha and trend factors AQAD Forecasting Master Schedul
406. site item number routing and operation with different effective dates You must set the subcontract order MRP 6 allocation record effective date within the scheduled order effective date range Enter the MRP 96 effective date in the Effective field in the header then select orders with Advanced Repetitive 207 Start effective dates that are after the MRP effective date End effective dates that are before the MRP effective date Note Orders with a 0 allocation do not have to fall within this date range The system displays the line end effective date in the End Effective field in the Purchase Order Percents frame This date indicates when the scheduled order line is no longer active You can modify the percentage or remove a record if the end effective date is earlier than the system date and the order is closed as long as remaining records equal 100 for each item or are 0 Fig 8 18 X Subcontract Order Subcontract Order MRP 9o Maint Go To Actions MRP Maint 5 5 1 21 Site 12000 Item Number EUB A Effective 06 18 2007 Routing EUB Op 10 Purchase Order Percents Order Percent Line End Effective P1131 9 Specifying Subcontractors for Discrete Purchase Orders In Subcontract Routing Op PO Maint enter the site item effective date routing and subcontract operation in the header then enter either the supplier or the PO number and line number You cannot enter the line number without entering
407. specific parent item creating the need for a component item Pegging is made possible by low level codes which maintain a numeric value for each item relative to its parent item including items planned across sites using DRP The lowest level components of product structures in the database are assigned low level codes of 0 zero Items at the next level are assigned a low level code of 1 and so on Example At a particular site a purchased component has a low level code of 0 That component is then built into an assembly which is assigned a low level code of 1 The assembly item is built into an end item that is assigned a low level code of 2 The end item is then packaged and assigned a low level code of 3 Material Requirements Planning 371 When MRP is run across multiple sites in the same database it processes lower level items first regardless of site Purchase orders and intersite requests are generated after all site and intersite demand has been calculated Because item planning product structure MRP and DRP transactions can alter low level codes net change and regenerative MRP automatically update low level codes before performing calculations Selective MRP updates low level codes only if you set Resolve Low Level Codes to Yes You can also use Low Level Code Update 23 22 to resolve codes as a separate MRP Detail Inquiry 23 16 and MRP Detail Report 23 17 display each source of demand for an item wit
408. ss Set Modify Co By Product Receipts in Regulatory Attributes Control 1 22 24 to Yes to allow any item to be received on a joint work order Set to No to have only valid substitutes received on a joint work order Note This feature is provided as a means of complying with FDA and other agency regulations You can use co products by products without setting this field 1 In Item Substitution Maintenance 13 19 do the following Parent Base Process Item Enter the base process item number or leave blank Item Number Enter the co product or by product item number Substitute Item Enter the item number of valid substitutes for the standard co product or by product For users who have the Regulatory Attributes module go to Regulatory Attributes Control 1 22 24 Modify Co By Product Receipts The default is Yes This allows receipt of any item from a base process work order Enter No to restrict receipts to either items defined as part of the structure of the base process or to valid substitute items defined in Item Substitution Maintenance 13 19 Co products and By products 69 Calculating Costs and Lead Times Co product costs and lead times are calculated by the same programs that calculate regular costs Figure 5 7 outlines some typical steps for calculating and allocating co product costs and lead times Each step is discussed in more detail in the sections that follow Fig 5 7 Typical Cost Calculation Workflow
409. ss order and at least one co product order If you delete the base process order or the only co product order the entire set is deleted Co products and By products 83 To access and modify a joint order set use Work Order Maintenance 16 1 Item Number Enter the item number for a base process or a co product Type Leave blank Routing Code Optionally enter an alternate routing code set up for the base process in Alternate Routing Maintenance 14 15 1 BOM Formula Optionally enter an alternate base process item number To enter this field the work order must be for a co product and the base process must be set up as an alternate product structure in Alternate Structure Maintenance 13 15 Adjust Co By Order Quantities Enter Yes or No This field does not appear on base process work orders If the order quantity changes entering Yes automatically rescales all order quantities in the joint order set The work order status must be E A R or C to optionally rescale quantities Joint order quantities are recalculated automatically when Order quantity changes on a joint order whose status is Firm Status of a work order changes from any status to Firm e Status of a work order changes from Batch Planned or Firm to Exploded Allocated or Released The system calculates the quantities for joint orders from quantities entered in Co By Product Maintenance 15 12 1 Order quantities for a joint order set can be
410. st Transfer 18 22 3 6 to transfer inventory from the stocking location to the work center Inventory is transferred not issued The new location must exist and must have the same name as the work center After transferring the inventory the system deletes the picklist b See User Guide QAD Master Data for information on picking logic FAQAD 180 User Guide QAD Manufacturing Fig 8 12 Repetitive Picklist Transfer 18 22 3 6 FAQAD Specify the date of the transfer in a pop up frame after clicking Next on the header The default is the system date x Repetitive Picklist Transfer Go To Actions Site 12000 Picklist PL1 2 Sequence 2 Alloc Iv Picked Iv Work Ctr Item Number Qty Open Qty Alloc Qty Picked Qty to Iss Work Center Quantity UM Item Number Site Loc Description Lot Serial Reference Multi Entry F Use the Sequence code to transfer only part of the total if space at the work center is limited Example If a work center holds 1 000 of an item but the total requirements are 5 000 one picklist is created allocating 5 000 while the material is picked and transferred in sequences of 1 000 sequence 1 for 1 000 sequence 2 for 1 000 and so on Set the maximum order quantity for an item in the Order Multiple field Ord Mult in Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 To transfer specified quantities other than the order maximum set the amount in Orde
411. sting for an item at a site It overrides the routing code set up in Item Planning Maintenance If the routing should be available as an alternate for an item at any site but not used as the default use Alternate Routing Maintenance 14 15 1 to link it with an item This allows the routing code on a work order to be changed to this alternate routing If the routing should be available as an alternate for an item at a specific site use Alternate Routing Maintenance to link a routing code to an item site This allows the routing code on a work order to be changed to this alternate routing Work Center Routing Standards Sometimes work is actually performed at a different work center than appears on a routing operation If the work center where the work was completed has different equipment it may not be meaningful to compare actual hours with standard hours calculated using the normal work center When alternate work centers can be used for specific operations you can use Work Center Routing Standards Maintenance 14 17 1 to record the expected run times for the alternate work centers This cross reference is used for reporting actual run times on efficiency reports in the Repetitive module Routings and Work Centers 37 Routing Cost Roll Up Use Routing Cost Roll Up 14 13 13 to update the costs for items based on their routing process operations This function can also update the Yield field in the item planning data based o
412. sts recorded on the cumulative order The component costs recorded in a cumulative order are based on the GL standards in effect when the order was created Labor burden and subcontract costs in the cumulative order are based on the routing and work center data in effect when the order was created For component material rate variance is calculated as the difference between the GL standard cost currently in effect and the GL standard cost captured in the cumulative order This type of variance is rare and typically occurs when the GL standard cost of the component material changes during the life of the cumulative order Labor and burden rate variance is calculated in a similar way When a cumulative order is created standard labor and burden rates are captured from the routing and work center data in effect When labor is reported at a cumulative order operation work center rate variance is calculated as the difference between the actual employee pay rate and the standard rate recorded on the cumulative order Subcontract rate variance is the difference between the PO price per unit and the subcontract cost per unit as captured in the cumulative order This is posted when subcontract items are received from a shipper or PO Rate variances are posted only if GL standard costing is in effect for the finished item They are not posted if GL average costing is in effect QAD 190 User Guide QAD Manufacturing gt See Cumulative
413. t Co products and By products 71 The cost calculations related to base processes by products and co products are shown in the equations below Batch size Base proc unit cost Base proc batch cost Batch size By prod unit cost By prod batch cost Base proc batch cost By prod batch cost Net base proc batch cost Net base proc batch cost Allocation Co prod batch cost Co prod batch cost Quantity per batch Co prod unit cost Entering By product Costs By product costs are calculated separately from the base process cost roll up You can enter by product costs manually or have the system calculate them from regular product structures or formulas Since by product costs are to be deducted from base process gross cost on an element by element basis there must be sufficient cost in each cost element of the base process to cover the amounts established in corresponding cost elements of the by product If by product costs are to be entered manually use Item Master Maintenance 1 4 1 Item Cost Maintenance 1 4 9 or Item Site Cost Maintenance 1 4 18 Enter costs for by products of a base process using the same cost elements as the base process item Note As an alternative to entering by product costs manually roll up by product costs from normal product structures using Routing Cost Roll Up 14 13 13 Freezing By product Costs Freeze by product costs using Roll Up Freeze Unfreeze 13 12 1 Site
414. t or higher level items and component items For formulas these are the relationships between products and ingredients Product structures are modular Separate structures are entered for finished goods and lower level assemblies or intermediate products So a component in a higher level structure might be a parent in a lower level structure Looking in the other direction a parent in a lower level structure can be a component in a higher level structure The system can display product structures as either indented multilevel bills of material or as single level bills This chapter uses an example of a manufactured product with both a product structure and a formula sports sunglasses with specially coated lenses Viewed from the top three components make up the parent product a frame assembly a left lens and a right lens Each component has its own structure The frame assembly includes a lens frame left and right sides and so on Table 2 1 illustrates this two level product structure Frame Assembly Left Lens Right Lens Lens frame Lens blank Lens blank Left temple Tint Tint Left hinge kit Coating Coating Right temple Right hinge kit Screws 2 Adhesive Product Structures If a single company manufactures the whole product each structure has its own specific manufacturing steps Assemble frames Grind lenses to size polish tint and coat Assemble sunglasses from frames and lenses Or the company migh
415. t these requirements by routing code and note any requirements that differ within each routing by operation Example Routing 101 has five operations Operation 30 can only process lots of 50 items The lots produced by operation 20 consist of 100 items This requires that lots of 100 be split into two new lots of 50 items each All operations after operation 30 continue to process 50 item lots You note in routing 101 that lot splitting is allowed for operation 30 WIP Lot Trace 263 Allowing lots to be combined should be carefully considered As lots are combined through the manufacturing process quality control risks become greater and more expensive For example if you combine lots at an early operation and later determine that the material from one of those lots is defective you may need to rework or scrap all WIP material and finished material that was manufactured with the defective material The more lot combining that occurs the more material is affected in this manner When you complete your analysis use this information to create records in Routing Registration Maintenance 3 22 13 1 and BOM Registration Maintenance 3 22 13 4 The system uses these records to allow or restrict splitting and combining of WIP and component material lots Custom Lot Serial Number Formats If you have specific lot serial number format requirements create Number Range Management NRM sequence IDs using Number Range Maintenance 36 2 21 1 You
416. t buy the frames only doing lens grinding coating and final assembly Because it might be necessary to ensure a supply of spare screws the frame can have its own product structure so the product structure reports show which frames require these screws You can enter product structures for purchased products without affecting planning or product costing programs This way you can use all the product structure reporting tools for component and parent items regardless of the source of the items 13 The system also uses product structure records to store alternate bills of P See BOM material planning bills and configuration bills Separate these from ep Pu standard bills by using a structure code l Figure 2 1 shows data records associated with product structures and formulas that are discussed in this chapter Not every system uses all of these Fig 2 1 Product BOMS Structure Formula Formula FI Codes Ow Product Structures Formulas Y Y Alternate Substitute Structures Items FAQAD 14 User Guide QAD Manufacturing FAQAD BOM Codes Sometimes a single product structure or formula can produce more than one kind of product Example A company uses the same formula for a beverage or a cheese but depending on how it is processed and aged different products result In this case it does not make sense to define the formula with respect to one specific pr
417. t the effective date for the new registration to a date immediately following the effective end date of the registration being changed When a change needs to be expedited change the effective end date of the registration being changed to correspond with the new registration s start effective date In addition to control records you should also create maintain and adhere to a delete archive schedule for all WLT historical information Set up procedures that let you maintain correct and accurate historical tracing records that have been deleted from your system and archived elsewhere Consider setting up procedures that let you easily locate and extract tracing records from archived tracing records Setting Up WIP Lot Trace Setting up WLT involves the same process whether you are using the Repetitive Advanced Repetitive or Work Orders module Fig 10 1 WIP Lot Trace Setup Workflow Determine your manufacturing environment s tracing requirements Create routing registration operation detail records for routing record exceptions Create BOM registration records for control program exceptions Define control program options Create BOM registration component detail records for BOM record exceptions Create routing registration records for control program exceptions FAQAD WIP Lot Trace 265 Defining Control Program Settings To begin setting up WIP Lot Trace activate it by setting
418. tail record created for a product group you must also specify an item number Forecast detail records display in three columns Month Original Forecast Adjusted Forecast The quantities in the Orig Fcst column are the original forecast quantities either the result of the system forecast calculation or the original quantity you manually entered or loaded You can modify the forecast as needed by changing the quantities in the Adjusted Forecast column Warning All changes to forecast detail records are permanent To reproduce original forecasts you must rerun the forecast calculation Before modifying forecast detail records you should archive the original forecast or copy it to another forecast ID FAQAD 332 User Guide QAD Manufacturing Fig 12 6 Simulation to Simulation Copy Q2 7 11 b See Modifying Forecast Results on page 330 AQAD Copying and Combining Forecasts To create new forecasts by copying or combining existing detail records use Simulation to Simulation Copy 22 7 11 or Single Item Simulation Copy 22 7 12 E Simulation To Simulation Copy Go To Actions Source Forecast ID 2007 Forecast Year 2007 Item Number 2 BB 2 To 3 BB P Line 2 To 2 Group P To P Type D Ta DB Target Forecast ID P Forecast Year 2008 Replace Combine Replace x Base Increase Decrease 0 00 Scale 0 00 Trend 0 0096 These functions let you copy replace or combine forecast d
419. te 0 0 ee eee 182 Cumulative Order Close 0 2 0 0 eee eee 183 Cumulative Order Maintenance 0 eee eee ee ee 186 Executing Repetitive Transactions 0 0 0 cee eee eee ee 186 Shipping Documents 0 ee eens 186 Common Transaction Data 0 eee eee 187 Warning Messages 00 eee eee eee 189 Rate Variances oe emearen dows he ele woe ea b tae ane sade 189 Method Change Variances 0 00 eee cece eee eee 190 Repetitive Transaction Programs 0 0 02 cee ee eee 190 Generating Repetitive Reports 0 eee eee eee 199 Managing Subcontracting 2 2 eee eee eee 200 OVERVIEW su cid iow ean bree aaa eagle ue Boo ue ae 201 Setting Up Preliminary Subcontract Data 0 4 202 Setting Up Advanced Repetitive for Subcontract Operations 208 Processing Subcontract Shipments 02 000 0005 210 Viewing Subcontracted WIP Materials 005 224 Deleting Archiving Subcontract Purchase Orders 225 Subcontract Shipping Limitations in API Mode 226 Chapter9 Repetitive 00 cece eee 227 Introduction 41e ce tals eo ea va ae ee OR a wee 228 Setting Up Repetitive lsslseleeeeeeeee I eee 228 x User Guide QAD Manufacturing Defining Control Program Settings 00 0 0005 229 Simulating Schedules in the Workbench 0 0 0 00 00s eae 230 Creating an
420. te summary forecast records for one item a subset of items or all items in the detail record Forecast detail records are copied to summary forecasts only in terms of units Note You can combine multiple detail records into one summary forecast but this is not recommended since the combined result is not a valid forecast Updates to the summary forecasts are permanent and cannot be undone You should run Simulation to Summarized Forecast in report mode before performing the update You can manually modify summary forecast quantities as needed using Forecast Maintenance 22 1 or Forecast Worksheet Maintenance 22 2 Loading Methods When loading forecast detail records into summary forecasts you can specify one of three loading methods that the system uses to break the monthly forecast quantities into the weekly quantities used by MRP Go To Actions Autospread Output Batch ID Fig 12 7 Simulation to Summarized Forecast 22 7 13 P See Creating Criteria Templates on page 322 b See page 338 FAQAD 338 User Guide QAD Manufacturing Fig 12 8 Forecast Worksheet Maintenance 22 2 FAQAD The three loading methods are Autospread 1 Monthly forecasts are broken into daily averages and summed into weekly buckets starting on Monday Unless the day that you are loading forecast is a Monday the loaded forecast begins on the following Monday This is the default loading method
421. tems When Trace Components is Yes in WIP Lot Trace Control but this field is No tracing does not occur when this component is consumed under this BOM code This value defaults from the first frame of this program Changes you make here override the value set in the first frame for this component item in this BOM code only Trace Heference Enter Yes to trace references assigned to lots of this component item To trace references you must also trace corresponding component and parent items Example Lot 3A of steel wire comes in three spools Each spool is separately identified in inventory using the Reference field as Spl Sp2 and Sp3 When steel wire is consumed you must enter the spool number in the Reference field during backflush If Trace Reference is Yes the spool numbers are recorded in tracing history and display in the Lot Where Used and Lot Actual Bill reports They also display in transaction detail reports and inquiries QAD 274 User Guide QAD Manufacturing AQAD This value defaults from the first frame of this program Changes you make here override the value set in the first frame for this component item in this BOM code only Combine Component Lots Enter Yes if multiple lots of this component can be consumed into a single WIP lot serial Combine Component Lots is No for steel Two lots of steel lot A and lot B are in the storeroom Lot A is processed at the first operation becoming WIP lot W1 and is
422. terial requirements planning MRP Forecasts and master schedules can be created for any item but are usually created for end items critical subassemblies and service parts Creating Forecasts You can create shipment forecasts using one of the following methods Use the forecasting simulation functions to calculate item forecasts using sales history data and the forecast method you specify e Use the CIM interface to load externally generated forecasts into forecast detail records in your database Use Forecast Maintenance 22 1 or Forecast Worksheet Maintenance 22 2 to manually enter forecasts Use Simulation to Simulation Copy 22 7 11 or Single Item Simulation Copy 22 7 12 to create new forecasts based on existing forecasts Forecast Creation Workflow 1 Create a criteria template 2 Doone of the following to create a forecast detail record e Run the simulated forecast calculation Manually enter a forecast generated outside of the system 3 Manually modify forecast detail records as needed 4 Optionally copy or combine detail forecast records 5 Generate reports to review the cost price and profit margin for monthly forecast quantities Forecasting Master Schedule Planning 321 6 Load the detail forecast records into summary forecasts to become a source of demand for MRP 7 Ifrequired manually create forecasts or adjust quantities for forecasts generated by forecast simulation functions using F
423. ters in the General Ledger GL setup functions 25 3 2 Verify that Mix Variance account numbers appear in the variances frame of Domain Account Control 36 9 24 3 Setup Mix Variance accounts for specific product lines in Product Line Maintenance 1 2 1 4 Setup Mix Variance accounts for product lines at specific sites in Work Order Accounts Maintenance 1 2 9 5 Associate product lines with co products and by products in Item Master Maintenance 1 4 1 or Item Data Maintenance 1 4 3 Mix variances are generated when co product and by product work orders are processed by Work Order Accounting Close 16 21 Variance amounts are posted to the Mix Variance account on the applicable co product or by product work order and subtracted from the work in process WIP amount of the base process work order The work order close procedure can be performed more than once for a work order and the variance amounts are cumulative Setting Up Sites and Locations for the Base Process Establish sites for the base process in Site Maintenance 1 1 13 A location is an area within a site A site can have an unlimited number of locations You can use the same location code for different sites Use Location Maintenance 1 1 18 to set up locations for the base process FAQAD 60 User Guide QAD Manufacturing FAQAD Setting Up Work Centers A work center is a production facility capable of performing a certain task A work center might b
424. the PO number The system then connects subcontract purchase orders to a routing and operation based on the supplier You cannot allocate percentages for orders with this program Fig 8 19 Ae z Subcontract Subcontract Routing Op PO Maint Go To Actions Routing Op PO Maint 5 11 Site 12000 Item Number EUB A Effective 06 18 2007 Routing EUB Op 10 Purchase Orders Supplier Order Line EDSsup01 P1126 2 1 FAQAD 208 User Guide QAD Manufacturing b See Schedule Maintenance on page 174 Fig 8 20 Subcontract Shipping Control 18 22 5 24 b See Specifying Subcontractors for a Routing Operation on page 206 FAQAD Setting Up Advanced Repetitive for Subcontract Operations For subcontract operations in Advanced Repetitive set up schedules and subcontract shipping control options Setting Up Schedules Use Schedule Maintenance 18 22 2 1 to set up repetitive schedule requirements for a subcontracted item The repetitive schedule defines how much of an item can be manufactured per day and provides visibility to the quantity per day that requires subcontracted services Defining Subcontract Shipping Control Options You set subcontract shipping options in Subcontract Shipping Control 18 22 5 24 The options let you ship items to alternate subcontractors manually track subcontract shipper numbers sent to and received back from a subcontractor and scrap items that the subcontractor does not return
425. the day specified in the Start of Week field are not considered This process stops when all available schedule quantities are consumed or all excess completions have been recorded against a schedule For schedules with due dates in the past the Consume Back value also determines which open quantities planning functions such as Material Requirements Planning MRP consider as sources of supply Start of Week Enter the day of the week for the system to use in coordination with the Consume Back value e When searching for exploded schedules with past due dates on which to record excess item completions FAQAD 230 User Guide QAD Manufacturing See Simulating Schedules in the Workbench on page 169 FAQAD To determine which open quantities on past schedules to consider as sources of supply in planning functions such as MRP Valid values are Sunday Saturday Today and None To ensure that all completions are recorded only against scheduled orders for the current week you can define control program settings as follows Set Start of Week to the first day of your company s business week typically Monday e Set Consume Back to 7 Set Consume Forward to 0 zero Allow Zero Run Rate Specify whether item level records defined in Production Line Maintenance can include a 0 zero value in the Units Hour field No default The item Units Hour defaults from the production line run rate The system al
426. the defaults however you can add other browse and maintenance programs that help you resolve shortage problems Once you make the change you refresh the data in Work Order Browse to determine if the shortage no longer exists for the component Component Check by Work Order Item Example As a materials expediter you want to ensure that you have enough components for all orders of an item You want to start at the work order component level accessing data by component item number To do this FAQAD 248 User Guide QAD Manufacturing Fig 9 9 Unconfirmed Receipt FAQAD you set search criteria for buyer planner ID to see items assigned to you You add secondary search criteria to find items that contain a specific work order release date then click Search The system displays the component base on your selection criteria Note To view only items with shortages you can filter on a specific item status such as Shortage or you can include this as part of your browse selection criteria To get a summary of the issue you then look at Supply Demand Summary to determine the total source of the supply demand for this component You then drill down into the details using the Supply Demand Detail Browse viewing projected QOH based on supply and demand by date You have several options to resolve the shortage You can contact your company s sales planner or production planner to reschedule either supply or demand For example to r
427. the number of units completed for a specific work order operation This information is used to track the status of work order operations monitor performance of work centers and update the general ledger GL for manufacturing costs The Repetitive and Advanced Repetitive modules contain reports and transactions similar to those in Shop Floor Control Review Chapter 8 and Chapter 9 for information on these modules The WIP Lot Trace WLT module affects some features of the Shop Floor Control module WIP Lot Trace is available as menu option 3 22 13 When activated additional frames display in some programs The discussion in this chapter assumes that WLT features are not active Reporting Labor by Operation You can report labor in Shop Floor Control by work order employee or work center using Labor Feedback by Work Order 16 20 1 Labor Feedback by Employee 16 20 2 Labor Feedback by Work Center 16 20 3 For each feedback transaction you must specify an employee code a department code and a work center or production line code Shop Floor Control 141 Fig 7 1 zx Labor Feedback by Labor Feedback by Work Order Go To Actions Work Order 16 20 1 work Order 400033 2 ID 42 D Operation 10 Op Status Employee 8001 Susan Pay Cade Department 100 Work Center 100 01 Time Ind Decimal Hours Shift 1 Machine Project Quantity Completed 2 000 0 Effective Date 02 22 2007 Rejects Operation Complete I Rewo
428. the output queue of the current operation is WLT controlled and is not the last routing operation The programs listed in Table 10 11 if the previous two conditions are true and only one lot serial was entered If the current input queue is WLT controlled the WIP lot serial entered in the Input Queue WIP Lot Issue Data frame defaults to this frame Assign this lot serial or assign a new one to the WIP material being produced FAQAD 278 User Guide QAD Manufacturing Fig 10 9 WIP Lot Output WIP Lot Output Queue Receipt Data Qty Processed 15 EA Queue Receipt Data Lot Serial Ref f Quantity Li 15 0 Lot Serial Ref Quantity L1 15 0 For Advanced Repetitive the total processed is the number entered in Qty Processed This total includes the reject and scrap quantities For Repetitive the quantity processed is the number entered in Qty Completed This quantity does not include scrap or reject quantities Table 10 11 Programs Menu Program Displaying WIP Lot Output Queue 5 13 1 Purchase Order Receipts Receipt Data Frame 16 19 Work Order Operation Backflush 16 20 1 Labor Feedback by Work Order 16 20 2 Labor Feedback by Employee 16 20 3 Labor Feedback by Work Center 18 14 Repetitive Labor Transaction 18 22 13 Backflush Transaction Reporting Reject Data Use the WIP Lot Reject Data frame to report the WIP lot serial numbers references reject codes and quantities of rejected material The quantity is mov
429. the product line Scrap account Note To do this you must set Inspect to No in Item Planning Quality Order Order 51 Item 101 Batch 506 Site 1000 Procedure 400 Qty Accepted Qty Rejected Maintenance 1 4 7 Operation 10 20 30 Item Procedure 400 Physical Electrical Mechanical Specification 101 Procedure 400 Operation 10 No Specification Results Height Weight Length Accepted Rejected Quality Management Fig 11 6 Quality Orders 311 FAQAD 312 User Guide QAD Manufacturing Fig 11 7 Quality Order Maintenance 19 7 FAQAD Creating Quality Orders Create quality orders in Quality Order Maintenance 19 7 Quality Order Maintenance vx Quality Order Maintenance Go To Actions Quality Order 1003 Batch 5 Item Number WLT18 P1 WIP Lot Std Rep Unit of Measure EA Parent 1 Type I Site 10000 Auto Issue V Quantity Pending 100 0 Start Date 02 27 2007 Quantity Accepted 0 0 Release Date 02 27 2007 v Quantity Rejected 0 0 Due Date 02 27 2007 Effective Date 02 27 2007 v Status c Procedure test P PO Job Project Remarks Type Specify the type of testing to be done I Inspection The quantity to inspect is transferred to the inspection location specified in Quality Management Control Any quantity rejected is issued from this location and expensed to the Scrap account Quantity accepted is transferred ba
430. tion In the Order Line Item Data frame set the following Type Enter S to specify that the line item is for a subcontract operation The Type field defaults from the Memo Order Type in Item Master Maintenance 1 4 1 and determines the effect of inventory planning and cost accounting when the item is received When you set the field to S a work order number lot ID and operation are specified on the order and on the receipt When the receipt is processed work order operation status is updated and a GL transaction debits the WIP account from the work order Work Order ID Enter the work order ID or cumulative order ID associated with the subcontract item When you use Advanced Repetitive features you can leave this field blank The system validates this field when the order type is S and automatically updates the ID when it creates a cumulative ID in Advanced Repetitive transactions Operation Specify the operation code for the operation that the subcontractor performs When you use Advanced Repetitive features you can leave this field blank The system validates this field when the order type is S and automatically updates the operation field when it creates a cumulative ID in Advanced Repetitive transactions FAQAD 206 User Guide QAD Manufacturing FAQAD When you execute Schedule Update from MRP 5 5 3 1 the system creates the subcontract lines on the scheduled purchase order to produce schedules for subcontracted serv
431. tion The system creates an individual transaction history record for each transaction line The total of all lines is used to update the inventory balance Comments Enter comments about the shipment Issuing Subcontract Shippers Confirm the subcontract shipper using Sub Shipper Issue 18 22 5 11 For the quantities identified on the subcontract shipper the equivalent of a move transaction is performed from the output queue of the operation preceding the subcontract operation If the preceding operation is a non milestone then non milestone backflushing takes place for that operation and any other preceding non milestone until the quantity requirement is either satisfied or another milestone operation is encountered For component material requirements of the subcontract operation the system performs the equivalent of an inventory location transfer Inventory is transferred from the site and location entered on the subcontract shipper to the cumulative order site and operation work center location if there is a corresponding record in the location master Otherwise the inventory is transferred to the item default location Receiving Completed Subcontract Items You receive shipments from the subcontractor using Purchase Order Receipts 5 13 1 or PO Shipper Maintenance 5 5 5 5 and 5 13 14 If you use Purchase Order Receipts the receipt of subcontract items Moves goods out of subcontract operations Creates GL transactions
432. tity transferred Method change variances are posted only if GL standard costing is in effect for the finished item They are not posted if GL average costing is in effect Repetitive Transaction Programs The following sections describe the use and application of various transaction programs on the Advanced Repetitive menu Advanced Repetitive 191 Backflush Transaction Backflush Transaction 18 22 13 is the primary tool for reporting production line activity and the only transaction that automatically backflushes component inventory You can report the number of gross units processed scrapped units rejected units and labor hours Backflush Transaction can be used at both milestone and non milestone operations If the transaction is reported at the last operation you can receive completed items into inventory You can backflush components of the current operation and any preceding non milestone operations You can also backflush standard labor and burden if the routing record of the reporting operation or any preceding non milestone operation has Auto Labor Report set to Yes When you report that you have completed and moved items at the final operation the quantity is posted as complete at the operation and is also posted to the repetitive schedule and the related work order If there are multiple schedules for an item the system determines the earliest open schedule date and posts the completed quantities from that point forw
433. tive lead time 22 Cumulative Lead Time Roll Up 23 co products by products 76 Cumulative Order Browse 182 Cumulative Order Close 183 transferring WIP 184 Cumulative Order Cost Report 199 Cumulative Order Create 182 Cumulative Order Maintenance 186 changing effective dates 186 closing orders 183 Cumulative Order Report 182 cumulative orders 181 closing 183 component costs 189 creating in batch 182 labor and burden rate variance 189 subcontract rate variance 189 Work Order module 109 cumulative work order ID in shipper 213 Current Work Center and Machine frame 284 customizing forecasting methods 327 cyclical pattern 324 D date work order 116 delete archive forecast detail 338 quality orders 314 transactions 152 work orders 137 demand patterns sales history 324 demand row 242 Demand Supply Detail Browse PQOH column 241 Demand Supply Summary Browse 242 Department Maintenance 29 departments account codes 28 accounts 28 capacity 380 labor capacity 28 labor feedback by 142 work center 28 Destination Work Center and Machine frame 275 destructive testing 317 Detail Forecast Delete Archive 338 Detail Forecast Maintenance 329 modifying results 330 discrete work orders 244 dispatch lists work order 127 134 dispatching work orders 134 Down Time by Reason Report shop floor control 145 Down Time Report 145 Down Time Transaction 193 downtime 143 due dates work order 116 E EDI eCommerce 211 effective dates
434. tment load reports in the Capacity Requirements Planning CRP module use the department labor capacity when calculating the total department capacity for a period of time The labor capacity should correspond to the sum of the total capacities of all work centers in the department Department account codes are similar to the GL account codes for product lines They are used When reporting labor and downtime in the Shop Floor Control and Repetitive modules When backflushing inventory and closing the accounting for completed work orders A department code is independent of the GL accounts sub accounts and cost centers defined for it In the General Ledger module cost center codes are often used to organize transactions by department However you do not have to use the same code for the cost center and department Table 3 1 lists the accounts for a department the account type and the transactions where the account is used All department accounts must be of GL type Standard Account Type Use Cost of Production Expense Non Prod Labor SFC Transfer Labor Absorbed Expense SFC Repetitive WO Close Burden Absorbed Expense SFC Repetitive WO Close Labor Usage Variance Expense SFC Repetitive Labor Rate Variance Expense SFC Repetitive WO Receipt Routings and Work Centers 29 Account Type Use Burden Usage Variance Expense SFC Repetitive Burden Rate Variance Expense SFC Repetitive WO Receipt Use Department Ma
435. to tracing component and WIP lot serials use this module to trace component lot inventory references Example Lot 3A of steel wire comes in three spools Each spool is separately identified in inventory using the Reference field as Sp1 Sp2 and Sp3 When consuming steel wire in manufacturing enter the spool number in the Reference field during backflush The inventory references are recorded in tracing history records WLT reports that display references show the spool reference consumed into each finished item If inventory reference tracing is required in your manufacturing environment you should first set up naming and usage standards for references References are not validated within the system but a clearly defined system facilitates data entry and reporting during and after manufacturing processes Note You must trace component material in order to trace references Lot Splitting and Combining WIP Lot Trace manages lot splitting and combining Lot splitting occurs when processing a single material lot at an operation results in two or more output lots Lot combining occurs when two or more input lots are combined at an operation resulting in one output lot If lot splitting or combining is an issue in your environment clearly define your requirements Consider whether you have a single requirement you can or cannot split or combine lots or multiple requirements you can split or combine some lots but not others Lis
436. ts Shift Start Time Hours Pattern Productivity 08 00 8 0 100 0096 00 00 0 0 100 0096 00 00 0 0 100 0096 00 00 0 0 100 0096 The system rates shift capacity as Shift Capacity Production Rate Hours Productivity The hours per shift is the number of hours the shift is capable of producing rather than the total number of working hours for the shift Shifts can overlap so the total number of hours for all shifts can exceed 24 hours When a shift is more or less productive than a normal shift enter an adjustment factor in Productivity Note This Productivity field has no connection to productivity measures elsewhere in the system Example A production line has three shifts and the third shift has only 20 of the employees of the first two shifts Enter a shift adjustment factor of 20 for that shift If the production rate is 100 units per hour a shift is capable of production for seven hours and the productivity factor is 100 00 then its capacity is 700 units per shift If a second shift has a productivity factor of 50 then its capacity is 350 units Advanced Repetitive 165 The hours worked by a particular shift can change because of holidays planned shutdowns or periods with planned overtime Manage exceptions by adding reference hours to shifts by effective date in the same way you modify the shop calendar Example A shutdown is planned for shifts 2 and 3 which normally work seven hours a day Add 7 hours to
437. ts For example if this item has a requirement for one each of four components each with a product structure quantity per of 1 MRP determines that 151 units are required for each component item based on this calculation 100 1 66 Operation Based Yield The system also supports yield calculation for component requirements based on individual operations within a parent item s routing To use this method you must Set Op Based Yield to Yes in Item Planning Maintenance 1 4 1 or 1 4 7 or Item Site Planning Maintenance 1 4 17 Set Enable Op Based Yield to Yes in MRP Control 23 24 When operation based yield is in effect the Yield field associated with the item is not used to determine component requirements Operation based yield affects the explosion of bills of material in work orders repetitive advanced repetitive and configured products as well as MRP Using this method typically results in more accurate calculations and prevents overplanning of components This is especially true in a mature process where yield percentages are highly predictable Example When subassemblies are scrapped at earlier operations operation based yield lessens component quantities required for later operations Consider the following example An order for 100 ITEM A is entered in the system ITEM A has four components COMP 1 COMP 2 COMP 3 and COMP 4 The quantity required for each component is one unit per c
438. ts and inquiries you can use to view or track subcontractor data Report Inquiry Menu Number Description Subcontract 5 12 Displays the supplier PO number and PO line for Routing Op PO each discrete purchase order allocation detail record Browse WIP Status 18 22 12 Displays where WIP material resides within the Inquiry manufacturing process Sub 18 22 5 6 Displays subcontract shipper information This Shipper Contain program is the same as the subcontract shipper and er Inquiry container inquiries in Customer Schedules except that Work Order ID and Operation replace PO Order and Line Advanced Repetitive 225 Report Inquiry Menu Number Description Subcontract Item Status Report 18 22 5 16 Displays status and history of items sent to and received from subcontractors View either summary or detailed reports Summary reports show a subset of data related to material in transit to and from a subcontractor Detailed reports show subcontract shipper data for material in transit to and from a subcontractor You can sort by e Work Center and Location The work center represents the subcontractor Location and Work Center The location is the location where subcontractors ship their completed subcontracted material Subcontract Item Status Inquiry 18 22 5 17 Displays a subset of data related to material in transit to and from a subcontractor Deleting Archiv
439. turing b See Distinctive Features of Advanced Repetitive on page 155 gt For details Chapter 10 WIP Lot Trace on page 251 P See Setting Up Production Lines on page 161 AQAD Introduction The Repetitive module provides many of the basic features of Advanced Repetitive but differs in some significant respects e You can only post usage variances when you close a cumulative order e You do not have the same control over the assignment of start and end effective dates You do not have as many options for reporting and tracking WIP throughout the life of the cumulative order In addition you cannot transfer WIP from an order that is being closed to a new order e You cannot report detailed information about scrap reject and rework quantities or enter multiple reason codes e Repetitive does not have the integrated support for managing subcontracting operations from shipping to receiving You can only report against milestone operations e Repetitive uses a consume forward or backward logic when completions exceed scheduled quantities Advanced Repetitive always uses the earliest open schedule e Advanced Repetitive has additional utility programs that let you modify the quantity completed on a repetitive schedule and delete schedules as needed Note The WIP Lot Trace WLT module affects some features of the Advanced Repetitive and Repetitive modules WIP Lot Trace is available
440. tus Report 18 22 5 16 to display total quantities returned to the subcontractor Scrapping Subcontract Items If the quantity you receive from the subcontractor is less than the quantity indicated on the subcontract shipper you can optionally scrap the items that you did not receive from the subcontractor There are two ways to register scrap items from subcontractors and update the subcontract shipper associated with the order Scrap when receiving or returning items against a purchase order using the Subcontract Shippers frame Scrap through Subcontract Scrap Maintenance 18 22 5 13 Both methods let you adjust the scrap quantity on subcontract shippers and register a scrap transaction with Advanced Repetitive Note You can also scrap items not returned from the subcontractor through Scrap Transaction 18 22 18 however this method does not update subcontract shippers Scraping Items Using the Subcontract Shippers Frame When you scrap items using purchase order receipts or returns you can Advanced Repetitive 221 Complete the receipt as short and scrap the short Do not complete the receipt as short and manually adjust WIP quantities using the scrap transaction of your choice Follow these steps to scrap the quantity at the subcontract shipper level 1 InSubcontract Shipping Control 18 22 5 24 set Manual Shipper P See Defining Subcontract Update to Yes Shipping Control This causes the Subcontract Sh
441. uantity adjusted for input WIP Adjust Transaction 18 22 21 queue WIPADJ O Quantity adjusted for output WIP Adjust Transaction 18 22 21 queue WIPADJ R Quantity adjusted for reject WIP Adjust Transaction 18 22 21 queue WO CLOSE Work order accounting close Work Order Accounting Close post 16 21 Table 7 1 Operation History Transaction Types Page 2 of 2 Use either of the following reports to review operation history records Operation Transaction Browse 17 13 8 Operation Transaction Detail Inquiry 16 20 13 9 Use Operations Numbering Report 16 20 13 22 to review operation transaction history by number or date range Transaction sequence numbers apply to the database as a whole as a result transactions within a domain may appear to have gaps This report lets you see transactions created in all domains and verify that numbering is sequential Shop Floor Control 151 Downtime Review recorded downtime by work center or reason code using the P See Recording F Nonproductive following reports bU Down Time Report 16 20 13 16 page 145 Down Time by Reason Report 16 20 13 17 Input and Output Use Input Output Report 16 20 13 12 to review the load at work centers You can use this function to compare planned input and output with actual input and output for a given period The planned input and output data are based on work order operation start dates standard setup and r
442. ue of the previous milestone reported operation into the input queue of the subcontract operation Creating Subcontract Orders You can use either supplier scheduled orders or purchase orders to handle the purchasing side of a subcontract operation You create supplier scheduled orders using Supplier Scheduled Order Maintenance 5 5 1 13 You create discrete subcontract purchase orders using Purchase Order Maintenance 5 7 Fields in Supplier Scheduled Order Maintenance or Purchase Order Maintenance play an important role in subcontract operations In the line item frame specify the item being sent to the subcontractor and the site that receives the item when the subcontractor finishes the service Supplier Scheduled Order Ma Supplier Scheduled Order Maint Go To Purchase Order P1131 Wholesale Supply Co Item Number 100C 7 Ship To Site 10000 Order Line Item Data Discount Tbl Unit Cost 0 00 Pur Acct 5100 Taxable v Type s Consignment Item Revision Item Rev Date Advanced Repetitive 205 Fig 8 17 x Supplier Scheduled Order Maintenance 5 5 1 13 Actions Supplier 5010 Finished Good C Line 1 Update Current Cost v Location 100 0100 Fixed Price Iv Unit of Measure EA UM Conversion 1 0000 Work Order ID D Operation 0 Subcontract Type P Set these fields for subcontract operations Optional fields supplied by Advanced Repetitive transac
443. ue n to pick every nth lot from inventory For example if there are 16 unique inventory records for an item and Lot Interval is 2 Sample by Lot Interval Inquiry 19 3 14 selects every second record for a total of eight records Inventory selection based on a sampling is not automatically entered into a quality order You must run Sample by Expire Days Inquiry or Sample by Lot Interval Inquiry to see which items are to be sampled Executing Stand Alone Tests Use quality orders to conduct stand alone inspections of incoming material or material already in inventory A quality order authorizes a test or inspection and specifies how much to test where when and how After testing enter results in Quality Order Results Entry 19 11 The immediate effect of a quality order is to transfer material from its current inventory location to an inspection location at the same site This is where the procedure designated on the quality order is run and test results recorded Quality orders link The quantity of an item A set of testing procedures and A set of test specifications for those procedures You can use quality orders to manage inspection of incoming materials When material arrives at a receiving location create a quality order to transfer the material to an inspection location After inspection the accepted material is transferred to inventory Rejected material is issued from the inspection location and expensed using
444. uired changes can be made to this copy using Work Order Routing Maintenance 16 13 13 This way what actually happens can be compared to the standard Monitor work order operations using the Shop Floor Control module Once the work order status is Exploded Allocated or Released no more changes can be made to the routing If the operation based yield calculation method is used for the item on the work order any manual changes to the Yield field in the work order header have no effect on component requirements When the work order is exploded the system always uses the yield percentages from operations in the item s routing to determine component quantities BOM Formula The work order BOM is derived from the item s product structure defined in Product Structure Maintenance 13 5 or Formula Maintenance 15 5 and the quantity ordered Inventory allocations and issues are based on the bill MRP uses the bill of material to calculate component demand As work progresses you can make any required changes to the work order BOM This way you can compare what you actually use with the standard Item quantities allocated issued or picked are also maintained in the BOM Once the work order status is Exploded Allocated or Released no more changes can be made to the BOM However you can reassign the picking location for items on the bill even if the work order status is Allocated or Released Use Work Order Bill Maintenance 16 13
445. umulative order to Closed so that Cumulative Order Accounting Close 18 9 can be used Cumulative orders should remain open for the periods used by accounting to monitor WIP costs Procedures should be in place to ensure they are closed at the end of each fiscal month or period Executing Repetitive Transactions Repetitive transactions provide feedback for repetitive operations Like those in the Shop Floor Control module they require use of an employee code However Repetitive Labor Transaction differs significantly from shop floor control transactions because it triggers inventory transactions to backflush components and receive completed units Operation Reporting The reporting of setup hours labor hours downtime reject quantities rework quantities and scrap quantities works much the same in Repetitive as in the Shop Floor Control module but with the following differences Repetitive 231 P See Creating Repetitive Schedules on page 173 b See Using Repetitive Picklists on page 175 b See Managing Cumulative Orders on page 181 b See Chapter 7 Shop Floor Control on page 139 FAQAD 232 User Guide QAD Manufacturing FAQAD The reason codes for nonproductive labor should use DOWNTIME instead of DOWN Operation scrap can be reported in Repetitive but not in Shop Floor Control Like the reporting of reject and rework quantities scrap quantities have no impact on the general ledg
446. un times and the work center or shop calendar Actual input is based on the quantities moved to a work center while actual output is based on the quantities completed at a work center Utilization and Efficiency Two key measures of performance are utilization and efficiency Utilization is the ratio of the total number of hours worked to the total number of hours available to be worked as defined in the shop calendar Utilization Actual Hours Worked Clock Time Scheduled 100 Use Work Center Utilization Report 16 20 13 18 to review this information Efficiency is the ratio of the total number of standard hours earned by completing units at operations to the total number of hours worked Efficiency Standard Hours Earned Actual Hours Worked 100 Productivity is the ratio of standard hours earned divided by the number of available hours It is not reported but can be manually calculated by multiplying utilization by efficiency Productivity Standard Hours Earned Clock Time Scheduled 100 Use any of the following reports to review efficiency data Efficiency by Work Center Report 16 20 13 19 Efficiency by Work Order Report 16 20 13 20 FAQAD 152 User Guide QAD Manufacturing FAQAD Efficiency by Employee Report 16 20 13 21 Deleting and Archiving Transactions Depending on the volume of transactions you may only want to maintain one to three months of history online Use Operations History Del
447. unting for 89 97 archiving 88 deleting 88 from alternate base processes 84 printing 84 releasing 84 reviewing 84 lead times rolling up 76 lots 88 material requirements planning MRP 61 77 action messages 79 multiple base processes 77 planned order reports 80 planned work orders 80 summary reports 80 mix variances accounts 59 84 calculating 59 89 97 Planned Order Reports 80 product line 60 quantity complete method 63 90 97 MAX 94 QAD 392 User Guide QAD Manufacturing MIN 95 ORD 96 SUM 92 SUMC 93 receiving 85 recyclable by products 64 routings 56 scrap 85 setting up an operation 58 shop floor control transactions 88 sites 59 structures 56 types of 55 unexpected items receiving 87 unit of measure conversion factors 66 unplanned items receiving 88 WO status codes 82 work centers 60 work orders 81 accounting close 59 88 allocated status 82 batch status 82 closed status 82 exploded status 82 firm status 82 mix variance accounts 59 planned status 82 released status 82 routable 84 work in process amounts 59 copying forecasts 332 formulas 49 processes 50 costs allocating to co products 63 69 allocation methods co products by products 73 average co products by products 72 freezing by products 70 rolling up co products by products 72 creating subcontract orders 204 criteria templates 329 creating 322 modifying 322 Cumulative Completed Maintenance 157 FAQAD cumulative ID expired 217 cumula
448. ve Than Zero Beginning Available Less The quantity on hand less safety stock is negative Than Zero FAQAD 374 User Guide QAD Manufacturing Message Meaning Create De Expedite Expedite Cancel Release Due For Release Past Due For Quantity Less than Minimum Quantity Exceeds Maximum Past Due Time Fence Conflict Shipment Due Shipment Past Due A supply order should be created to satisfy a negative projected on hand balance This message is only generated if Plan Orders is No or if a new requirement appears within the time fence A scheduled supply order is due before it is needed and should be delayed or demand rescheduled to an earlier date A scheduled supply order is due after it is needed and should be rescheduled to an earlier date or demand rescheduled to a later date A scheduled supply order is no longer needed and should be deleted A supply order should be released You can release both planned and firm planned orders Approving the order changes its status to firm planned Use the Order Release Horizon field in MRP Control 23 24 to specify the number of days prior to the order release date for this action message to display A supply order was not released when it was due It now needs to be released and expedited or the demand must be rescheduled for a later date A supply order was created for a quantity less than the minimum quantity set in the item planning data
449. ve dates are not set Advanced Repetitive 159 1 Start and end effective dates match the dates of the GL period in effect during the transaction 2 Start and end effective dates match the calendar start and end effective dates of the month of the transaction 3 Start and end effective dates cover a number of days so the transaction effective date falls in that interval The setting determines effective date calculation for orders created in the background by repetitive transactions or in batch using Cumulative Order Create 18 22 11 End Eff Days If End Eff Default Method is 3 specify the number of days that the start and end effective dates cover Figure 8 2 shows how the system uses the End Eff Days field to set the start and end effective dates on cumulative orders In this example an End Eff Days value of 10 days is entered as indicated by the diagonally shaded boxes Fig 8 2 Example of End Eff November 2000 Days Use Start effective date of cumulative order End effective date of last cumulative order End effective date of cumulative order Start effective date of next cumulative order Date of transaction Include Yield Set this to Yes to have the system include the yield percent established in Routing Maintenance 14 13 1 in the cumulative order standard cost It should match the setting for Include Yield used normally when running other cost rollup functions
450. ve menu entries and therefore can be secured Component Check Calculations The system calculates component availability for a work order component record by calculating projected quantity on hand PQOH using MRP supply and demand detail information The calculation results display in two columns within the Work Order and Work Order Component Browses Component Status Status ID Fig 9 3 System calculated shortage Work Order severity displays here Browse Viewing 1 100 of 1971 WOID C Parertitem WO Component tus StsuriD Quai Scheduled Quanity Comgeted Guantty Open Hewe ae DueDue WO Sise Prdutonlme Prmayine Sie 9 ET 73 mo Pur Shertoge 8 100 00 100 MES Praected Shortage 7 100 00 1000 1108 aS Pinete Shore 7 1000 tr 1000 n ASME Shertape 8 100 oo 100 rrente pacel db pace thb vaD ny ag Propctad hoe 7 10 00 1 00 t tab 1e Gun Propcted Shotage 1000 400 eno pace 0000 FAQAD 240 User Guide QAD Manufacturing The Component Status column displays a textual description of the status while the Status ID column displays the numeric value of the severity Status IDs can range from 1 to 8 with 8 being the highest severity The following lists the possible Status IDs and associated Component Status 1 No components The work order does not have any components 2 Issued complete All materials have been issued for the work order component 3 Available Sufficient inventory is projected to be
451. ways uses the item run rate when calculating schedules for the item Although you can change the default you cannot set it to 0 Yes The item Units Hour defaults to 0 Unless you change it the system uses the production line run rate when scheduling the item Otherwise it uses the specified non zero item level value Set the field to Yes to define a global run rate for all items on each production line In Production Line Maintenance you can then specify a Units Hour value at the production line level and leave all or most item level fields set to O If individual items are exceptions you can define item specific run rates just for them Simulating Schedules in the Workbench Line Schedule Workbench 18 1 10 is exactly the same as the workbench 18 22 1 10 in Advanced Repetitive Creating and Exploding Repetitive Schedules These functions are almost identical in the two modules Internally the system processes additional information for Advanced Repetitive schedules but the interface and input values are the same Using Repetitive Picklists Picklist Menu 18 3 functions are identical in both the Repetitive and Advanced Repetitive modules Managing Cumulative Orders Cumulative orders track repetitive activities in much the same way as in Advanced Repetitive Cumulative orders can be added manually using Cumulative Order Maintenance 18 6 However this function s primary purpose is to change the status of an existing c
452. wing The rejecting operation s output queue The input queue of the operation following the rejecting operation Note This method requires an additional Move Transaction 18 22 19 You can enter rework hours and issue additional components However no automatic backflushing takes place Enter up to 10 reject quantities and reason codes at a time Advanced Repetitive 195 Scrap Transaction Use Backflush Transaction 18 22 13 for most of your scrap reporting It backflushes the scrapped units and records all costs at the operation Use Scrap Transaction 18 22 18 to scrap or remove quantities from any queue of an operation without backflushing This transaction is often used to scrap previously rejected units Enter up to 10 scrap quantities and reason codes at a time When scrapping from an operation s input queue the scrap quantity is first moved back to the prior operation s output queue and then posted as scrap at that operation This ensures a proper balance in the queues and cumulative quantities as seen in the WIP Status Report and Browse You cannot report hours and no backflushing takes place with this transaction WIP Adjust Transaction You can reconcile actual WIP quantities with those recorded in your database by using the WIP Status Inquiry 18 22 12 or WIP Status Report 18 22 4 11 Labor hours cannot be entered and no backflushing takes place When quantities do not match use WIP Adjust Transact
453. wlrmiq p 3 22 13 4 BOM Registration Maintenance wlbmmt p 3 22 13 5 BOM Registration Inquiry wlbmiq p 3 22 13 13 WIP Lot Inventory Status Report wlrp01 p 3 22 13 14 Item Lot Ship Transaction Report wlrp04 p 3 22 13 15 WIP Lot Convert Transaction Report wlrp06 p 3 22 13 16 WIP Lot Non Convert Transaction Report wlrp07 p WIP Lot Trace 259 Menu Description Program 3 22 13 17 WIP Lot Inquiry wliq01 p 3 22 13 18 Supplier Lot Transaction Report wlrp08 p 3 22 13 19 WIP Lot Where Used Report wlrp02 p 3 22 13 20 WIP Lot Actual Bill Report wlrp03 p 3 22 13 23 WIP Lot Delete Archive wldel p 3 22 13 24 WIP Lot Trace Control wlpm p Planning for WIP Lot Trace Setup of the WIP Lot Trace WLT module depends greatly on how much tracing your manufacturing environment requires Having clearly defined tracing requirements simplifies the setup process This section discusses the issues you should resolve and the types of information that you should collect before you set up WLT This information about your manufacturing environment will facilitate the setup and use of this module Deciding Which Material to Trace This module traces material based on parent item routing Routings define where component items to be traced are consumed and where the WIP material to trace is produced WLT also traces material based on parent item BOM codes when the component item is part of the BOM Tracing does not occur on an item per item basis You should begin setu
454. xamples of this type of base process include processes that involve sorting and separation of co products and by products such as a process that sorts fruit by size and weight Summarize Co products If Quantity Complete Method is set to SUMC in the co by product structure the following equation is used to determine base process quantity complete Base Process Quantity Complete Co prod1 Quantity Complete Scrap Base Process UM Conversion Factor Co prod2 Quantity Complete Scrap Base Process Quantity Complete 55 1 1 2 25 3 56 1 2 28 67 2 28 95 2 In this case expected co product and by product order receipt quantities are calculated as shown in Table 5 11 Table 5 11 Order ID Product Expected Receipt Calculation Sample Expected 1001 Orange Juice 95 2 50 100 95 2 0 5 47 6 Pu dimi 1002 Pulp 95 2 30 100 95 2 0 3 28 56 SUMC Method 1003 Seeds 95 2 10 100 95 2 0 1 2 9 52 FAQAD 94 User Guide QAD Manufacturing Table 5 12 Sample Mix Variance Calculations for SUMC Method FAQAD Based on these expected quantities mix variance calculations are as shown in Table 5 12 Order ID Product Mix Variance Calculation 1001 Orange Juice 47 6 56 1 50 8 4 1 50 12 60 1002 Pulp 28 56 28 0 50 0 56 0 50 0 28 1003 Seeds 9 52 15 0 60 5 48 0 60 3 29 Because it does not consider by product quantities
455. xclude base process planned orders Include exclude by product planned orders Sort the report output by item number or BOM Formula code Creating MRP Summary Reports To create MRP summary reports use MRP Summary Report 23 14 To support features related to base processes you can Select planned orders by BOM Formula code Include exclude base process planned orders Sort the report output by item number or BOM Formula code Identifying the Source of Demand for a Co product To get detailed MRP information for co products by products and base processes use MRP Detail Report 23 17 This feature provides pegging which enables you to identify the source of demand for co products Indicate co products by item number You can also Co products and By products 81 Select planned orders by BOM Formula code Include exclude base process orders Sort the report by item number or BOM Formula code within site Managing Joint Work Order Sets Figure 5 9 outlines some typical steps for managing joint work order sets Fig 5 9 Typical Workflow for Joint Work Order Sets Access modify review and or print orders in a joint order set Process shop floor control transactions Receive scrap co products by products and unplanned items Process joint orders at work order accounting close Or receive co products and by products and backflush base process components T
456. xecuting Repetitive Transactions As work is performed labor and movement of WIP units are reported You can report these activities using various types of transactions including downtime scrap rework move and rejects There are nine transaction types and several purchase order functions for subcontract activities Repetitive transactions affect other areas of the system As quantities are moved through repetitive operations inventory transactions are recorded and posted as backflushing occurs Labor and burden costs are recorded by manual entry or as a result of backflushing Transactions generate cost variances and create GL entries Most transactions generate quantity and cost posting to the cumulative order and associated operation and bill of material BOM records Transactions affect any one of the three quantity queues associated with routing operations The input queue which holds quantities from the previous operation The output queue which holds quantities from the current operation that have not been moved to the next operation The reject queue which holds quantities rejected by the current or a subsequent operation Shipping Documents Many countries require that formal shipping documents accompany any movement of goods If you are using shipping groups you can record shipping information and generate shipping documents from some repetitive transactions Advanced Repetitive 187 When a backflush occurs at
457. xpected output from a line But if the system encounters a scheduling conflict and reschedules due dates these dates will not take into account the new lead time There are two ways to avoid this Assign due dates manually and then monitor the line schedule to see if any due dates following a changeover have been automatically rescheduled Increase the changeover time to reflect the increased lead time between two products This way the changeover time reflects the total time a line is disrupted between model changes Deleting Sequence Records Delete records from the workbench in two ways Select one or more records for deletion and choose Delete Reverse the original production quantity by entering a negative value For example enter a quantity of 2000 for a production quantity of 2000 The system deletes all of the scheduled quantities and dates created by that entry Reviewing Line Schedules Use Line Utilization Report 18 22 1 15 to review the results generated by the workbench This report provides information for evaluating the load placed by a line schedule on a production line if it replaced the existing repetitive schedule It also shows the changeover load between shifts when appropriate Advanced Repetitive 173 Creating Repetitive Schedules A repetitive schedule is a statement of planned output for a production line for one day It consists of a list of scheduled quantities and due dates A repetitive s
458. xport schedules in electronic data interchange EDI format Fig 8 21 Subcontract Shipping Process b See Specifying Subcontractors for a Routing Operation on page 206 b See User Guide QAD EDI eCommerce FAQAD 212 User Guide QAD Manufacturing Fig 8 22 Backflush Transaction 18 22 13 FAQAD Backflushing Subcontract Materials You can use Backflush Transaction 18 22 13 to optionally backflush components up to the subcontractor operation and create a cumulative work order and its ID to track subcontractor activity When the system creates the cumulative work order it assigns a work order ID The system automatically updates blank work order ID fields on subcontract order lines with the new ID if you connected a subcontract Discrete purchase order to the subcontract routing and operation through Subcontract Routing Op PO Maint 5 11 Scheduled order to the subcontract routing and operation in Subcontract Order MRP Maint 5 5 1 21 Also the system automatically populates the subcontract operation on subcontract purchase order lines Therefore you do not have to return to purchase order maintenance programs to enter the work order ID and subcontract operation In Backflush Transaction set Move Next Op to No for subcontractor operations Since the backflush operation is prior to the subcontract operation you set Move Next Op to No because subcontract shipping functionality moves WIP materia
459. y Ordered 100 0 Quantity Completed 100 0 Backflush Qty 100 0 Backflush Loc Issue Alloc These fields Issue Picked M Cancel Backorders control Quantity Calculation Method Component Required Quantity issue Backflush Method Standard Backflush quantity defaults Quantity Calculation Method Sets the calculation method used to determine the quantity to issue for all components The default is Component Required Quantity Other valid choices are Work Order Bill Qty Per and Phantoms First You can still adjust each issue quantity on a line by line basis in the detail screen Backflush Method Defines whether to use the backflush quantity you entered the default standard backflush or to include prior issues and receipts against this order The two fields work in conjunction with each other In most cases you should accept the default However in three instances you obtain more accurate issue quantities by resetting these values The first instance occurs when you issued components to the order or made a partial receipt without issuing all components In this instance set the backflush method to Net of Prior Issues and Receipts This setting factors in prior receipts and issues to derive the Quantity to Issue value Example If you issue all of a component or more than you need the quantity to issue is 0 If however you receive and backflush 50 out of 100 parents and then receive the remain
460. y if Quantity Type is P Use Formula Code Maintenance 15 1 to set up a BOM Formula that is not an item number Site specific formulas Set up a BOM Formula for each required site For simplicity use the item number followed by site code Then use Formula Maintenance to attach the ingredients list Finally use Item Site Planning Maintenance to assign the normal BOM Formula to each item site This designates the formula used for planning and manufacturing at that site Formulas and Processes 49 Common formulas Several products can use exactly the same ingredients the only difference being processing or aging Set up a BOM Formula and attach the formula to it Then assign that BOM Formula to each of the items in Item Planning Maintenance as the default formula Alternate formulas One item can have several formulas common for different batch sizes Set up a BOM Formula for each batch size and attach the formula to that BOM Formula Associate these with each BOM Formula as an alternate using Alternate Structure Maintenance or link them to items and processes using Alternate Routing Maintenance Designate one formula in Item Planning Maintenance as the default for planning Co product by product formulas The BOM Formula code or base P See Chapter 5 process for a co product by product structure is actually a component p em of the co products and by products that it produces The unit of page 53 measure UM for the BOM Formu
461. y transfer 179 printing 179 repetitive production schedules 243 Repetitive Reject Transaction WIP Lot Trace frames 299 Repetitive Schedule Explosion co products by products 98 Repetitive Schedule Maintenance co products by products 98 Repetitive Schedule Update 173 repetitive schedules master production scheduling MPS 350 Repetitive Scrap Transaction 235 WIP Lot Trace frames 299 Repetitive Trans Detail Inquiry 299 repetitive See also advanced repetitive reports labor 148 reprinting picklists 123 returning subcontract items 219 Rework Analysis Report 199 Rework Transaction 194 tracing WIP 292 rework work orders 107 rolling forecasts 321 routable work orders 109 Routing Cost Roll Up 37 product structure Op field 20 yield percentage 364 Routing Maintenance 203 co products by products 64 overlap units 118 quality operations 314 run time 37 Routing Maintenance Rate Based run time 37 Routing Registration Maintenance 268 Routing Update applying changes 32 routing connection to subcontract POs 207 routings 34 37 advanced repetitive requirements 166 alternate 36 co products by products 84 defaults 36 defining 34 lead times and 27 quality management 314 site specific defaults 36 uses of 26 work orders 114 Run Labor Transaction 193 Labor WIP Lots frame 292 run sequences 361 runtime 143 S safety stock 363 safety time MRP use of 365 sales history demand patterns cyclical 324 horizontal 324 seasonal 324 trend 324 f
462. y visibility and control Addition of WIP accumulators to track cumulative work moved rejected reworked scrapped and adjusted Scrap Reject Rework and Adjustments Reporting Scrap or adjust from either the input output or reject queue Record multiple scrap reject and rework quantities with reason codes Generate analysis reports scrap and adjustments usage variance reports and scrap and adjustments valuation reports FAQAD 156 User Guide QAD Manufacturing b See Managing Subcontracting on page 200 FAQAD Subcontract Processing Integration of supplier scheduled orders with Advanced Repetitive supports repetitive purchasing of subcontract services For example use Backflush Transaction 18 22 13 to optionally backflush components up to the subcontractor operation and create a cumulative work order to track subcontractor activity When the system creates the cumulative work order it assigns a work order ID and automatically updates blank work order ID fields on subcontract order lines with the new ID Also the system automatically populates the subcontract operation on subcontract purchase order lines Therefore you do not have to return to Purchase Order Maintenance programs to enter the work order ID and subcontract operation Subcontract shippers let you create shipment paperwork register the physical shipment of materials to the subcontractor and track subcontract activities Usi
463. you are scrapping Depending on which queue you are scrapping material from these WLT frames can appear WIP Lot Input Queue Scrap Data See page 280 WIP Lot Output Queue Scrap Data See page 281 WIP Lot Reject Queue Scrap Data See page 280 The WIP QOH at each queue is reduced by the quantity scrapped at the indicated work center and machine Additionally the quantity scrapped is added to the cumulative scrapped quantity for the indicated lot serials Adjusting WIP Quantities for WLT Controlled Queues Use WIP Adjust Transaction 18 22 21 to adjust quantities at an operation s input output or reject queues The current queue balances display when you run the program When adjusting quantities for WLT controlled operations Reason Code and the three queue quantity fields are not editable Use the WLT frames to specify adjustments to QOH balances for the WIP lot serials in each queue You can create entries for new lot serials and optionally enter reason codes as needed One WLT frame is used for each queue The three WLT frames appear in this order WIP Lot Input Queue Adjust Data WIP Lot Output Queue Adjust Data WIP Lot Reject Queue Adjust Data FAQAD 294 User Guide QAD Manufacturing Fig 10 22 Purchase Order Maintenance WLT Lot Serial Field FAQAD Using WLT with Purchasing Various purchasing programs used to support subcontracting let you trace subcontract WIP material only when using the Adva

QAD 2008 Enterprise Edition User Guide: Manufacturing

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